Mechanical Attrition Emulsifier Particles for Drilling Fluids
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Solution Overview
Problem
The production of spray dried emulsifier particles for invert emulsion drilling fluids is cost prohibitive due to the large quantities of water required and the high energy needed for water removal, making it inefficient for drilling operations in hostile conditions.
Innovation Solution
Emulsifier particles are produced through a mechanical attrition process, reducing the size of an emulsifier solid made from alkali metal or alkaline earth metal salts of carboxylic acid terminated fatty amine condensates or modified tall oils, resulting in particles with improved chemical reactivity and wettability, and are used to create invert emulsion drilling fluids with lower high temperature high pressure fluid loss and yield point values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spray dried emulsifier particles are produced using conventional methods, then the emulsifier can be used to form invert emulsion drilling fluids, but the production cost becomes prohibitive due to large quantities of water required and high energy needed for water removal
Solution Approach 1:
The patent changes the physical state parameter of the emulsifier from requiring aqueous solution (spray drying method) to using a liquid-free paste form. This parameter change eliminates the need for water addition and subsequent energy-intensive drying, directly resolving the contradiction between manufacturing cost and energy consumption.
2Reliability
If spray dried emulsifier particles are produced, then the emulsifier provides stable dispersion, but relatively large quantities of water are required which increases production cost
Solution Approach 1:
The patent extracts water from the emulsifier formulation by using a liquid-free paste form instead of an aqueous solution. This extraction of the problematic substance (water) eliminates the need for large quantities of water while maintaining emulsifier functionality, resolving the contradiction between dispersion stability and water quantity.
3Productivity
If mechanical attrition process is used to reduce emulsifier solid size, then the specific surface area and pore volume increase improving reactivity and wettability, but the processing time and equipment complexity increase
Solution Approach 1:
The patent performs preliminary action by pre-forming the emulsifier as a liquid-free paste with optimized composition before the mechanical attrition step. This preliminary preparation ensures that the subsequent size reduction process is more efficient and requires less complex equipment, resolving the contradiction between productivity enhancement and device complexity.
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 mechanical attrition process produces emulsifier particles with increased specific surface area and pore volume, leading to improved drilling fluid performance with reduced fluid loss and lower yield point, enhancing drilling operations in challenging conditions.
Implementation Method 1
reducing a size of an emulsifier solid via a mechanical process to produce emulsifier particles
Implementation Method 2
improved drilling fluid performance with reduced fluid loss
Data Source
AI summary
Emulsifier particles and methods for making and using same. The emulsifier particles can include an alkali metal salt or an alkaline earth metal salt of a carboxylic acid terminated fatty amine condensate, an alkali metal salt or an alkaline earth metal salt of a modified tall oil, or a blend of an alkali metal salt or an alkaline earth metal salt of a carboxylic acid terminated fatty amine condensate and an alkali metal salt or an alkaline earth metal salt of a modified tall oil. The emulsifier particles can have a BET specific surface area of about 0.3 m2/g to about 1 m2/g. The method for making the emulsifier particles can include reducing a size of an emulsifier solid via a mechanical attrition process to produce the emulsifier particles.