Curbing GHG emissions and costs

Oil and gas drilling companies today face a dual challenge: deliver high performance and efficiency while meeting regulatory requirements.¹ Drilling operations, which traditionally rely on diesel engines for power, are under pressure to curb fuel costs and reduce greenhouse gas (GHG) emissions without compromising productivity. As a result, many drilling companies are pursuing new strategies to modernise operations fleetwide.

One approach centres on using high-end rigs equipped with advanced automation systems and real-time data analytics. These technologies enable faster drilling times, improved safety metrics and enhanced operational efficiency. Companies leveraging real- time data for decision-making can optimise drilling parameters on the fly, reducing nonproductive time to maximise asset utilisation.

Eliminating waste and improving overall efficiency across the drilling operation has become essential for today’s drillers. This includes optimising crew rotations, enhancing maintenance schedules, reducing material waste and implementing lean operational principles. Routinely evaluating every aspect of a drilling programme can reveal inefficiencies and identify targeted improvements.

Drillers that also prioritise sustainability-related objectives actively seek technologies that reduce GHG emissions while sustaining operational performance standards. This can encompass electrification to fuel optimisation methods. With a myriad of options available, fuel-flexible dual-fuel engine technology is a reliable approach that is field-proven to reduce rigs’ diesel consumption. By blending diesel with natural gas, next-generation dual-fuel systems enable cost savings and GHG emissions reductions on-site.

The importance of fuel flexibility

To make informed decisions, drilling companies require a comprehensive view of a programme’s total operational costs as the economics of a drilling operation involve many factors, including fuel costs. Diesel prices can fluctuate based on market conditions and geographic location, with remote drilling sites often incurring premium pricing due to transportation costs.

With these complexities in mind, next-generation dual-fuel solutions are especially attractive as these technologies enable drilling companies to better leverage natural gas compositions and determine precise diesel displacement calculations that reflect accurate, real-world savings. Modern natural gas blending improves project economics without compromising performance, offering drilling companies a practical way to achieve operational excellence while reducing GHG emissions.

Dual-fuel technology creates compelling value propositions as a large percentage of sites have access to natural gas that often costs less than diesel. This dramatic cost differential could translate to millions of dollars in savings over the life of a drilling programme. For a typical drilling operation that consumes thousands of gallons of diesel per day, even partial displacement with natural gas can yield substantial economic benefits.

When field gas from a nearby production well can be utilised, fewer on-site fuel deliveries may be required. This could help reduce truck traffic, simplify logistics, and decrease transportation costs.

When strategically implemented, dual-fuel operations can reduce GHG emissions while maintaining the performance characteristics drillers expect from their power generation equipment. Importantly, modern dual-fuel solutions deliver these benefits without compromising engine performance.² The latest technological advancements have mitigated concerns about any potential loss of power or slower engine response due to high-volume natural gas displacement. Today’s systems can maintain full diesel power output and responsiveness, enabling rig performance and drilling productivity to remain high while lowering diesel consumption.

References

1. Cat.com. Caterpillar oil and gas announces launch of Cat^® Dynamic Gas BlendingTM (DGB) Gen 2 Kit. February 2025. https://www.cat.com/en_US/ news/engine-press-releases/caterpillar-oil-and-gas-new-cat-dynamic-gas- blending-gen-2-kit.html
2. Cat.com. DGB by the numbers [Blog post]. https://www.cat.com/en_US/ blog/dgb-by-the-numbers.html

Read the latest issue of Oilfield Technology magazine for upstream news, project stories, industry insight and technical articles.

Oilfield Technology’s November/December 2025 issue

The November/December 2025 issue of Oilfield Technology focuses on how the upstream sector is modernising to stay efficient, competitive, and lower-carbon. It explores decarbonising drilling operations, improving performance through advanced monitoring and drilling technologies, reshoring and strengthening supply chains, enhancing offshore inspections, and tightening cybersecurity. Together, the articles highlight a sector pushing towards greater efficiency, resilience, and sustainability across the full lifecycle of oilfield operations.

Read the article online at: https://www.oilfieldtechnology.com/special-reports/12122025/curbing-ghg-emissions-and-costs/