Air/Water Separator for Drill String Bearing Corrosion
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Solution Overview
Problem
The use of an air/water mixture in drilling operations reduces bearing and bit life, particularly when using recycled water containing corrosive minerals, which exacerbates the issue.
Innovation Solution
A separator apparatus is installed at the distal region of a drill string to separate the air/water mixture into discrete air and water streams, with separation chambers and outlets designed to inhibit water from entering the air outlet, allowing air to lubricate the drill bit and water to be directed away from the drill bit, thereby reducing corrosion and extending component life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an air/water mixture is delivered to the drill bit, then cooling and chip clearance are improved, but bearing life and bit life are reduced due to water corrosion
Solution Approach 1:
The invention segments the air/water mixture delivery system by introducing a separator apparatus that divides the mixed stream into separate air and water streams. The air stream is directed to the drill bit bearings for cooling and lubrication, while the water stream is directed separately to contact the drill bit cutting elements for chip clearance and cooling, preventing water from reaching and corroding the bearings.
Solution Approach 2:
The separator apparatus acts as an intermediary device between the water supply system and the drill bit. It processes the air/water mixture and selectively directs each component to its appropriate destination, mediating the delivery to ensure water does not contact the bearings while still providing cooling and chip clearance functions.
2Quantity of substance
If recycled water containing corrosive minerals is used, then water availability is improved, but corrosion effects on drill bit bearings are amplified
Solution Approach 1:
The separator apparatus extracts and removes water from the air stream that would otherwise be delivered to the drill bit bearings. By separating the water component from the air/water mixture, the system prevents corrosive minerals in the recycled water from contacting and damaging the bearings, while still allowing the use of recycled water for chip clearance and cooling functions.
3Productivity
If air/water mixture is used for chip clearance, then drilling efficiency is improved, but water reaches the drill bit and reduces component life
Solution Approach 1:
The system segments the fluid delivery into separate air and water streams. The air stream carries chips away from the drill bit while the water stream is directed separately to contact the cutting elements. This segmentation maintains the chip clearance function necessary for drilling efficiency while preventing water from reaching and degrading the drill bit components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The separation of air and water streams effectively reduces the corrosive effects on drill bit bearings and extends their lifespan, improving drilling efficiency and reducing maintenance costs by preventing water from entering the air outlet and reaching the drill bit.
Implementation Method 1
a separator apparatus suitable for separating an air/water mixture into discrete air and water streams during drilling of a blast hole
Data Source
AI summary
A drill and a separator apparatus and a method of prolonging bearing life are described, the separator apparatus being suitable for separating an air/water mixture into discrete air and water streams during drilling of a blast hole. The separator apparatus includes a separator body which is adapted to be installed at a distal or lower region of a drill string and when installed at the distal or lower region forms one or more separation chambers or reservoirs, each separation chamber or reservoir comprising an inlet adapted to receive the air/water mixture, a first outlet in fluid communication with a drill bit for releasing air thereto and a second outlet in fluid communication with a wall of the blast hole and disposed in the distal or lower region of the drill string to release water separated from the air/water mixture in a region adjacent the drill bit. The one or more first outlets for releasing air from the or each separation chamber is disposed at an upper region of the or each separation chamber and the one or more second outlets is disposed at a lower region of the or each separation chamber for releasing water from the or each separation chamber so that when in use water is inhibited from egress from the or each separation chamber through the or each first outlet.