Mud-loc FAQ

How does the process design address the variable nature of drilling waste? How does it solidify waste materials containing the typical oil concentrations, and variety of salts found in drilling wastes?

All drilling mud formulas are reviewed and samples of the waste are exposed to a bench formulation at a process lab. This is to determine the best process mix, based on the target criteria, final disposition of the material, and other factors such as location restrictions imposed by Regulators.

Under most regulations a concise description of the physical or chemical interactions for all additives and the waste is required. Also the purpose for the additives and under what conditions they are required must usually be identified.

The only additives are the specific types of pozzolans or zeolites, which we have identified for use as stabilizers, and Normal Portland Cement. I have included MSDS sheets for both. The Lassinite, which we used at Kakwa, was found to be the most effective form of pozzolan for this application. This material, like all pozzolans and zeolites, is a natural mineral composed of diatomaceous Alumino-silica and is chemically inert.

Is pre-treatment a requirement and under what conditions? What are the specific limitations for oil, salt, water, or pH?

The only pre treatment recommended is the mixture of some of the Lassinite at the rig; this acts as a stabilizer and prevents the leaching of oily waste onto ground at the site. This “pre treatment” eliminates the need to add any other drying agents, such as sawdust (a common practice which is environmentally unsound). There appears to be no limitation for volumes of oil, water, or pH, as the process formula changes to accommodate these. We suspect that salt in vast quantities may inhibit the formation of good concrete, but have not encountered quantities to date, which could have affected the process. Should we encounter salt in large quantities there are other additives, which are available to assist in the formation of concrete under high salt conditions. (Incidentally, pozzolans like Lassinite are the most common additives for high salt concrete. Which indicates that the stabilizer has some properties, which assist in this exposure).

Is the process limited by the weather conditions? Will the material set in freezing temperatures? Does rainfall or addition of moisture affect the process design?

During one course of processing, we let the samples freeze and left them frozen for 30 days. We did this to emulate the conditions that the mix was exposed to when processing took place in early November with freezing conditions at night. These samples were placed in the lab at room temperature for a further 30 days to cure and then exposed to the EPA 1311 Leachate test. All tested samples passed this leachate test. Concrete will set under freezing conditions however cure times are slower under these conditions than in non freezing conditions. We recommend that mixing not take place in extreme cold as the process water may freeze prior to obtaining a good mix. Extreme rainfall may affect the process, but only after water is introduced to the mix. This is only critical for about four hours until the concrete reaches the “gel” state when the mix becomes waterproof. Our recommendation is for contractors to be aware of weather forecasts prior to mixing, as they may have to adjust their water based on rainfall.

How are the appropriate mix ratios determined to ensure the waste materials are bound and process is effective?

It is important that all drilling mud formulas are reviewed and samples of the waste are exposed to a bench formulation at a process lab. This is to determine the best process mix, based on the target criteria, final disposition of the material, and other factors such as location, or restrictions imposed by Regulators.

What is the change in both mass and volume from raw material to the mixed material?

Changes in mass fluctuate as the process water is used by the cementacous reaction. The final product will vary according to the specific formula, but in any case should not exceed 25% of the original mass. Volume will be in the order of a 20% increase. Both estimates are based on cured products.

Are there emissions that need to be addressed either from the process or the wastes?

Our observations are that once the pozzolans are introduced into the waste the emissions from the waste are significantly reduced. The stabilizer also renders the oil base unavailable for leaching. Further, once the processing takes place with the remaining pozzolan and cement, there is a further reduction in emission.

What is the minimum cure period required? What conditions are required for successful setting of the material?

Pozzolanic concrete takes longer to cure than normal industrial concrete. (But will continue to cure indefinitely, long past the strength curve of normal Concrete). That being the case the processed material should be allowed to cure for a minimum of 30 days.

Does the company have a field manual/process document to ensure consistency in mixing and handling of the material? What steps are taken to ensure a homogeneous mix?

WSTI has a QA/QC manual which outlines the basics of sampling and analysis of the process. The material in process must be constantly observed by competent supervision to ensure that the mix process is complete. Our standard is currently to mix the material at least 5 times more than the mechanical contact required by normal cement. Proper equipment is also the key. Case in point, we recently changed our process to use a high-speed hydraulic mixer, which replaced the original slower speed pug mill for processing, due to the mechanical contact that the high-speed mixer provides. Proper inspection at the mix phase ensures that all of the additives are placed in contact with the waste and ensure a successful result.

Is storage required to maintain waste in a treatable state or to prevent further contamination from the process itself?

Once the material is mixed, it poses no more danger to the environment than normal industrial concrete, and should require no further special treatment or storage. The waste from the shale shakers once combined with the stabilizer should be stored under prescribed conditions until treated. The process does not further contaminate the waste in any way.

Are there site restrictions for the equipment on-lease? Is movement of waste off-lease required for treatment?

As the process uses only a backhoe, there are no restrictions either in space or by regulation for equipment required. Movement of the waste off lease would only be required in extreme cases. The best place to treat the waste using this method is on the location where it was produced.

Is water required for this process? How will this be accommodated, if required?

Water is required, in ratios for normal manufacture of concrete. Water is normally trucked onto the lease by a contract water hauler. The type of water used does not affect the process; any water (except brine) will assist the required hydration.

What quality assurance/quality control measures are established to ensure the end product is sound?

See the QA/QC manual provided in the PDF documents available on this website, however the short answer is theQA/QC is in the hands of the field supervisor taking samples at all phases of the treatment. Further enhanced by a competent independent lab doing the analysis.

Are there residuals from the process itself and how are they disposed of?

There are no residuals other than the concrete mass created by the process. The final disposition of the concrete could be by use as an aggregate on the lease or the road. As the common mix that has been used renders the material closer to soil cement rather than structural concrete, the fines of the crushed product serve to “tighten” the clays used in the roadbed, and add to the quality of the travel surface.

Does the process successfully encapsulate/incorporate volatile organics and semi-volatile organics? Is the nature of the hydrocarbon a limitation?

We have been successful in encapsulating all types of waste both hazardous and controlled waste using this process. Our non-oilfield activity has encountered all types of hydrocarbons, which have been treated successfully, so there does not seem to be any limitations with respect to volatiles, or semi- volatiles.

How does the encapsulated material meet the criteria for the next intended use (i.e. if the material is to be used for road construction how does this encapsulated material meet roadbed construction criteria)?

We can develop a formulation for any type of concrete the client may require. We use concrete chemistry from many sources including independent cement labs to formulate concrete for any use. This process can provide structural grade concrete if required.

Comment on the results of the leachate analysis and how they relate to soil quality criteria and aquatic criteria?

The EPA 1311 is the most invasive TCLP criteria we could find that could be performed by local labs. It is suggested by the EPA that this test emulates the exposure of the encapsulated material to 100 years in a landfill. Further discussions with the EPA indicate that this would be equal to 1000 years of exposure under normal (non-landfill) conditions. Our criteria target to date was Alberta Tier 1(see PDF documents). However, if legislators are aware of any test or criteria, which they feel, would better serve the environment, we would be pleased to develop a formula to meet those criteria. In other words, the process can meet most criteria it is only a factor of revising the formula to meet the standard.

What is MUD-loc?

MUD-loc is a naturally occuring amorphous alumino-silica.

The formation of this amazing material began millions of years ago as volcanic ash had settled in ancient seas and lakes. Here the ash amalgamated with the diatoms (tiny marine creatures with silica shells) that lived and thrived in the sea.

"MUD-loc is an effective and efficient solution to costly Invert Drilling Waste and eliminates environmental liability completely."