Advancing Multiphase Flow Technologies for Sustainable Drill Cuttings Transport in the Oil and Gas Industry

Document Type : Review Article

Authors
1 Ph.D. Student, Department of Petroleum and Geoenergy Engineering, Amirkabir University of Technology, Tehran, Iran
2 M.Sc., Department of Petroleum and Geoenergy Engineering, Amirkabir University of Technology, Tehran, Iran
3 Assistant Professor, Department of Petroleum and Geoenergy Engineering, Amirkabir University of Technology, Tehran, Iran
4 Professor, Department of Chemical Engineering, Amirkabir University of Technology, Tehran, Iran
20.1001.1/jgt.2025.2073308.1062
Abstract
Drill cuttings transport is a critical process in oil and gas drilling operations, directly affecting efficiency, safety, and environmental compliance. This review synthesizes recent advances in multiphase flow technologies combining computational fluid dynamics (CFD), artificial intelligence (AI), robotics, and sustainable materials with a focus on their practical field implications. Comparative analysis of field trials and simulations reveals that real-time monitoring systems can cut non-productive time (NPT) by 25–30%, while CFD-enhanced models improve predictive accuracy by 15–20%, enabling better control of annular velocity and cuttings suspension in horizontal and HPHT wells. Biodegradable and nano-enhanced drilling fluids reduce ecological footprint by 35–40% and lower waste disposal costs, providing economically viable solutions for environmentally sensitive projects. Robotics-based handling systems improve worker safety by up to 50%, allowing continuous, unmanned operation in offshore environments.
Despite these gains, challenges persist in scaling advanced models to field operations and balancing computational cost with on-site feasibility. The study recommends integrating AI-driven control systems with CFD–DEM simulations and adopting modular robotic platforms for automated solids management. By linking theoretical modeling with field-validated practices, this review provides a practical roadmap for implementing sustainable, efficient, and data-driven drill cuttings transport systems in the oil and gas industry.
Keywords
Subjects

Article Title Persian

پیشرفت در فناوری‌های جریان چندفازی برای انتقال پایدار خرده‌های حفاری در صنعت نفت و گاز

Authors Persian

یاسین خلیلی 1
محمد قادر ظهیری 2
محمدرضا اکبری 3
مصطفی کشاورز مروجی 4
1 دانشجوی دکترا، دانشکده مهندسی نفت و زمین انرژی، دانشگاه صنعتی امیرکبیر، تهران، ایران
2 کارشناسی ارشد، دانشکده مهندسی نفت و زمین انرژی، دانشگاه صنعتی امیرکبیر، تهران، ایران
3 استادیار، دانشکده مهندسی نفت و زمین انرژی، دانشگاه صنعتی امیرکبیر، تهران، ایران
4 استاد، دانشکده مهندسی شیمی، دانشگاه صنعتی امیرکبیر، تهران، ایران
Abstract Persian

انتقال خرده‌های حفاری یکی از فرآیندهای کلیدی در عملیات حفاری نفت و گاز است که به‌طور مستقیم بر بهره‌وری، ایمنی و انطباق زیست‌محیطی تأثیر می‌گذارد. این مقاله مروری، پیشرفت‌های اخیر در فناوری‌های جریان چندفازی را که دینامیک سیالات محاسباتی، هوش مصنوعی، رباتیک و مواد پایدار را با تمرکز بر کاربردهای عملی در میدان ترکیب می‌کنند، مورد بررسی قرار می‌دهد. تحلیل تطبیقی داده‌های میدانی و شبیه‌سازی‌ها نشان می‌دهد که سیستم‌های پایش لحظه‌ای می‌توانند زمان‌های غیرمولد را بین ۲۵ تا ۳۰ درصد کاهش دهند، در حالی که مدل‌های مبتنی بر دینامیک سیالات محاسباتی، دقت پیش‌بینی را بین ۱۵ تا ۲۰ درصد افزایش می‌دهند و کنترل بهتری بر سرعت چرخشی در حلقه حفاری و تعلیق کاتینگز‌ها در چاه‌های افقی و فشار و دمای بالا فراهم می‌سازند. استفاده از سیالات حفاری زیست‌تخریب‌پذیر و نانو‌افزوده باعث کاهش ۳۵ تا ۴۰ درصدی اثرات زیست‌محیطی و کاهش هزینه‌های دفع پسماند می‌شود و راهکاری اقتصادی برای پروژه‌های حساس ازنظر محیط‌زیست ارائه می‌دهد. همچنین، سیستم‌های رباتیکی حمل و مدیریت خرده‌های حفاری و ایمنی کارکنان را تا ۵۰ درصد افزایش داده و امکان عملیات بدون سرنشین و پیوسته را در محیط‌های دریایی فراهم می‌سازد.
باوجود این دستاوردها، چالش‌هایی همچنان در مقیاس‌پذیری مدل‌های پیشرفته به سطح عملیات میدانی و توازن میان هزینه محاسباتی و قابلیت اجرا در محل باقی‌مانده است. این مطالعه پیشنهاد می‌کند که سیستم‌های کنترل مبتنی بر هوش مصنوعی با شبیه‌سازی‌های CFD–DEM ادغام شده و پلتفرم‌های رباتیکی ماژولار برای مدیریت خودکار مواد جامد به کار گرفته شوند. با پیوند دادن مدل‌سازی نظری با تجربیات میدانی معتبر، این مقاله یک نقشه‌ راه عملی برای پیاده‌سازی سیستم‌های پایدار، کارآمد و داده‌محور انتقال خرده‌های حفاری در صنعت نفت و گاز ارائه می‌کند.

Keywords Persian

انتقال خرده‌های حفاری
جریان چندفازی
دینامیک سیالات محاسباتی
هوش مصنوعی
نانوفناوری
رباتیک
حفاری پایدار
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