Dual-Gradient Drilling and Riserless Mud Recovery Technology: A Review of Principles, Progress, and Challenges

Deepwater drilling operations face critical challenges including narrow pore-fracture pressure windows, wellbore instability, and environmental concerns from drilling discharge. This paper presents a comprehensive systematic review of Riserless Mud Recovery (RMR) technology, tracing its evolution from its conceptual origins to its current applications, critically analyzing its technical limitations, and identifying future research directions. A systematic literature review was conducted covering peer-reviewed journals, SPE/IADC conference proceedings, industry technical reports, and independent academic studies from 1990 to 2025. Databases searched included Web of Science, Scopus, OnePetro, and Google Scholar, supplemented by Derwent Innovation Index for patents. After screening over 100 publications, approximately 60 references were selected following a two-step process excluding vendor-only promotional materials. Key findings reveal the following: (1) RMR technology has evolved through three distinct hardware generations—flexible hose systems, steel-pipe return lines with tandem pumps enabling deepwater breakthrough to 1419 m, and hybrid riser configurations for conceptual designs beyond 3000 m; (2) documented field benefits include 70% drilling fluid reduction, 9 days’ time savings per well, and successful mitigation of shallow geohazards across more than 1000 global well applications; (3) integration with casing-while-drilling and managed pressure cementing has enabled record-breaking performance of 1710 m in a single run; (4) independent academic validation confirms fatigue mechanisms affecting mud return lines; (5) systematic failure mode analysis identifies critical reliability issues in suction hoses, seals, and control systems; (6) quantitative economic analysis shows RMR cost-effectiveness depends on water depth, geological conditions, and environmental regulations. RMR technology has matured into a reliable drilling solution, yet its continued evolution requires addressing hardware limitations, developing dedicated well-control protocols, expanding to ultra-deepwater and emerging applications, and integrating digitalization for real-time optimization.