Reimagining drilling waste management

ANDREW MORRIS, Group Commercial Manager at TWMA 

The oil and gas industry is navigating one of the most demanding transitions in its history. On one side lies the ongoing need to deliver reliable, affordable energy to a world still heavily dependent on hydrocarbons. On the other side sits increasing pressure to reduce emissions and demonstrate alignment with global climate goals.  

The International Energy Agency (IEA) has made it clear that emissions from oil and gas operations must fall nearly 45% by 2030, if the industry is to remain aligned with net zero goals. This stark reality places offshore operators in an especially difficult position, as offshore production remains among the industry’s most energy-intensive segments. 

Offshore drilling programs require vast supply chains, continuous vessel operations and high levels of energy consumption to sustain exploration and production. Much of the public discourse and regulatory attention has, therefore, centered on issues, such as fuel efficiency, electrification and direct rig emissions. Even so, an often-overlooked dimension of offshore operations—drilling waste management—is emerging as a critical component in the push for decarbonization. 

Every offshore well drilled produces substantial volumes of waste in the form of cuttings and slops. These unavoidable byproducts of drilling are generated as formations are penetrated, and drilling fluids circulate to stabilize the wellbore and transport solids to the surface.  

Traditionally, waste was managed through a simple but resource-heavy system: collecting the material, storing it temporarily in skips or tanks and transporting it by vessel to shore for treatment and disposal. While this system was compliant with regulatory requirements, it was logistically intensive and carbon-heavy, and it created exposure to safety concerns. Every skip lifted from deck and vessel journey undertaken to shuttle waste and transfer of contaminated material introduced inefficiencies and risks. 

As environmental performance rises higher on the agenda for regulators, investors and host governments, the perception of drilling waste has shifted. Once treated as an inconvenient byproduct and cost center, it is now recognized as a potential source of value and a key contributor to emissions reduction. Cuttings retain valuable drilling fluids, which can be recovered and reused. Slops contain fractions of oil and water that, when properly treated, can be recycled, rather than discarded.  

More importantly, the single-largest emissions reduction in this sector often comes not from recovering materials but from eliminating the need to transport untreated waste to shore in the first place. Vessel operations remain among the most carbon-intensive aspects of offshore activity, and reducing their frequency is a direct and tangible way to cut emissions. 

This shift in mindset has accelerated the evolution of drilling waste management. No longer an afterthought, it is increasingly viewed as a means for emissions reduction, simplification and operational resilience. Among the companies driving this evolution is TWMA, a company that has spent over 25 years developing technologies and processes to transform the way drilling waste is treated. The company’s approach demonstrates how targeted innovation in a seemingly secondary process can deliver measurable sustainability gains, while simultaneously enhancing operational performance. 

EVOLUTION OF DRILLING WASTE MANAGEMENT 

Historically, operators focused on efficiency in well design, drilling speed, and rig performance, with waste management largely relegated to logistics contractors and onshore disposal facilities. The introduction of ESG metrics and the scrutiny that accompanies them has altered this equation. 

Waste streams from drilling are increasingly seen as an opportunity to improve environmental outcomes, reduce costs and reinforce operational resilience. The offshore waste management market reflects this change, with recent forecasts projecting growth of more than 9% annually over the coming decade, driven both by rising drilling activity and the increasing demand for solutions embedded within sustainable operating models. 

Fig. 1. TWMA’s RotoMill technology.

Managing drilling waste effectively requires solutions that address multiple points across the operational chain. Rather than depending on a single method, modern practices combine technologies, such as thermal desorption, fluid treatment and bulk transfer systems. The right mix depends on location, regulatory frameworks and logistical considerations. 

Thermal desorption, as applied by TWMA’s RotoMill (Fig. 1), has become an increasingly preferred method for sustainable waste management. By creating heat via friction, the technology recovers the three constituent parts of drill cuttings—oil, water and solids—into clean, reusable outputs. Each has a defined reuse or disposal pathway, reducing the need for untreated skip transfers to shore.  

Technologies like RotoMill can process drill cuttings at source, safely disposing of solids and recycling base fluid for reuse, significantly reducing vessel journeys and manual handling, as well as logistics-related emissions (up to 90%). Applied at scale, TWMA treats more than 100,000 metric tons of drill cuttings annually, delivering measurable carbon savings while supporting circular-economy principles. 

Slops management represents another challenge that has traditionally been overlooked. Offshore drilling generates large volumes of contaminated liquids that were historically transferred onshore for treatment. On-site treatment units now have the capability of separating usable fractions offshore, significantly cutting both waste volumes and the reliance on fresh resources.  

TWMA supports operators with these processes, tailoring treatment methods to the characteristics of each fluid stream, enabling operators to recover water suitable for reinjection, as well as oil that can be reincorporated into drilling fluids. This not only reduces haul-off requirements by up to 95%, but it also creates a circular system where materials are continually reused, further reducing environmental impact. 

Fig. 2. TWMA's CST tanks.

In situations where on-site treatment is not feasible, logistics optimization provides an alternative. Instead of relying on skips, which require frequent lifts and limited storage capacity, cuttings storage and transfer (CST) systems, like TWMA’s (Fig. 2), are designed to hold larger volumes—up to 200% more drill cuttings per square meter than traditional skips.  

These systems facilitate direct transfer from rig tanks to vessel tanks, avoiding multiple handling steps and reducing vessel trips. By increasing storage volume and integrating automated pumping systems that are designed to allow simultaneous filling and discharge, these units enable faster drilling rates (up to 400 ft/hr), while minimizing bottlenecks and lifting risks. 

The integration of automation and digitalization has further enhanced waste management efficiency. Manual processes—such as preparing cuttings for transfer through air injection—once relied on significant personnel involvement. Today, remotely operated conditioning systems carry out these tasks automatically, with one example being TWMA’s in-house- developed automated air injection system. Tested with real drill cuttings under simulated offshore conditions, this system performs pre-programmed conditioning cycles, eliminating manual intervention while improving both safety and consistency. 

Cloud-based monitoring platforms, such as TWMA’s XLink, extend the benefits further by providing real-time insights into system performance, emissions reductions and resource recovery. These digital tools support compliance, reduce the need for additional offshore personnel and, most critically, provide operators with verifiable data that can be incorporated into ESG reporting and regulatory submissions. 

The importance of this secondary analysis is critical. As stakeholders increasingly demand proof of environmental claims, operators require transparent, data-driven insight into the performance of their waste management systems. By embedding monitoring and analytics directly into its equipment, technology such as TWMA’s XLink enables operators to demonstrate their environmental performance with tangible evidence, reinforcing trust with regulators and investors alike. 

RETHINKING THE FUTURE OF WASTE MANAGEMENT  

In 2021, TWMA restructured its R&D division, bringing mechanical, electrical and automation expertise in house. This integration enabled the company to redesign its core technology from the ground up. This process combined decades of operational insight with customer feedback, leading to the development of the RX Series: a new generation of RotoMill technology designed specifically to address the sector’s most pressing problems. 

Fig. 3. RX Zero Emissions RotoMill.

The first model, RX1, was launched at Offshore Europe in 2023. It introduced a smaller footprint, remote-control capability and A.I. monitoring, supported by over 110 sensors, for predictive maintenance. Early deployment in the Middle East confirmed its performance benefits and established a foundation for subsequent models. 

Building on this foundation, the RX2 is due to mobilize in late 2025, as a fully electric, zero-emission system, Fig. 3. Developed with sustainability and safety at its core, it addresses long-standing barriers in offshore waste management: 

• Zero emissions: Electric drive eliminates diesel-related CO₂ output. 
• Operational safety: Lifting operations see up to a 95% reduction. 
• Lower GHG impact: Emissions are over 50% lower, compared to offsite treatment. 
• Automation and monitoring: More than 110 digital sensors support condition-based monitoring, remote operation via tablet and predictive maintenance. 
• Processing efficiency: Market-leading processing capacity makes it routinely possible to reach up to 10MT/hr for sustained periods. 
• Space and flexibility: Modular design reduces installation time by 30%, while improving site conditions. 
• Recovery and resilience: Combined storage enables rates of penetration (ROP) above 120 m/hr and recovers valuable fluids. 

The RX2 reflects a wider shift in how offshore waste management is approached; rather than treating emissions, safety and efficiency as separate issues, it integrates them into a single platform, aligned with operators’ long-term sustainability goals. 

To address the needs of onshore facilities, the RX3 and RX4 expand the series further. These static units have been specifically developed for large-scale sites in the UAE. These units maintain the zero-emission, electric-drive foundation but deliver higher throughput for industrial-scale operations. Together, the RX series offers operators the tools to reduce environmental impact, improve safety and maximize recovery across both offshore and onshore projects.  

THE ROAD AHEAD 

As the offshore sector navigates its path toward net zero, drilling waste management stands out as an area where environmental and commercial objectives align. Few disciplines offer the chance to reduce emissions without compromising production, lower costs while improving safety, and strengthen ESG performance with verifiable data. Integrated approaches, like TWMA’s, demonstrate how reimagining secondary processes can transform them into strategic enablers of sustainability. 

The next step in innovation is already taking shape. TWMA is investing in the next generation of waste management technologies, with a breakthrough solution on the horizon that is expected to deliver its most significant environmental impact yet. The trajectory is clear: automation and electrification will continue to redefine operational efficiency, while digitalization will ensure every gain is measurable, reportable and optimizable. 

By 2030 and beyond, the industry’s progress will be dependent on a comprehensive framework of solutions that spans alternative fuels, digital twins, carbon capture and renewable integration. Within this landscape, drilling waste management will be pivotal. By embedding technologies that eliminate waste at source, recover valuable materials, and reduce logistical burdens, operators can simultaneously advance climate goals and unlock safer, leaner and more resilient operations. 

Ultimately, the transformation of drilling waste management reflects the wider offshore industry’s transformation. It represents a willingness to challenge assumptions, apply innovation to long-standing challenges and uncover value in areas once seen purely as costs. Net zero will not be achieved through a single breakthrough, but through gradual improvements across the value chain. In this respect, drilling waste management offers one of the clearest opportunities available to offshore operators today: a chance to demonstrate that sustainability and performance are not opposing forces, but rather, that they can reinforce one another. 

ANDREW MORRIS is Group Commercial Manager at TWMA, a position he has just started to serve in. Previously, he was Group Strategy & Innovation manager at the company, where he has fulfilled a variety of positions of growing responsibility over the last nine years. Before moving to TWMA, Mr. Morris served two tenures at Halliburton, where he was Business Segment manager, West, Central & East Africa (November 2013 to May 2016), and a manager of several areas (June 2009 to March 2013). In-between, he served a stint as Global Products Support Engineer at STEP OILTOOLS from March 2013 to November 2013. Mr. Morris graduated from Edinburgh Napier University with a B.Eng. degree in mechanical engineering.