Downhole Axial Hydro-Clone Separation for Filter-Free Debris Collection

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Solution Overview

Problem

Conventional debris collection tools in wellbores face limitations due to filter clogging, requiring multiple trips to the surface for debris removal, leading to significant time and resource expenditure.

Innovation Solution

A debris collection tool equipped with a swirl generator that separates debris and fluid using centrifugal forces, allowing efficient collection and storage of debris without filter clogging, enabling larger volumes to be removed in a single operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional filter-based debris collection is used, then debris can be collected, but filters clog quickly requiring frequent trips to surface

Engineering Contradiction:

Improvefilter performanceVSAvoidtime for multiple trips

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent extracts the harmful filtering function that causes clogging and replaces it with a centrifugal separation system. The hydro-clone separator removes debris from fluid without using filters, eliminating the root cause of repeated trips to surface while maintaining debris collection capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical filter system with a centrifugal separation system using a hydro-clone. This substitution eliminates filter clogging by using rotational force to separate debris from fluid based on density differences, allowing continuous operation without frequent interruptions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If multiple trips to surface are made for debris removal, then debris is eventually removed, but significant time and resources are expended

Engineering Contradiction:

Improvedebris removal efficiencyVSAvoidtime and resources for repeated operations

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent enables continuous debris collection operation by eliminating the interruptive filter replacement process. The centrifugal separator maintains continuous fluid flow and debris separation, allowing the wellbore treatment to proceed without repeated interruptions for debris removal trips.

Inventive Principle:

Principle #20Continuity of useful action

3Quantity of substance

If filter-based collection is used, then debris is captured, but flow paths are obstructed requiring pressure increases

Engineering Contradiction:

Improvedebris collection volumeVSAvoidpumping pressure

Core Design Contradiction:

Quantity of substanceVSStress or pressure

Solution Approach 1:

The patent extracts the obstruction-causing filtering mechanism and replaces it with open-channel centrifugal separation. This allows large volumes of debris-collecting fluid to flow continuously without pressure buildup from blocked flow paths.

Inventive Principle:

Principle #2Taking out (Extraction)

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 system enhances debris removal efficiency by allowing greater volumes of debris to be collected before needing to be retrieved, reducing the number of trips required and saving time and resources.

Implementation Method 1

A debris collection tool may include a swirl generator which causes fluid and debris to experience centrifugal forces. In turn, the centrifugal forces cause the liquid and debris to separate

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

Downhole debris collection device with an axial hydro-clone design

Methodology Applied

Scientific EffectCyclone separation: Cyclone Separation

Data Source

PatentUS12442277B1Downhole debris collection device with an axial hydro-clone design

Publication Date: 2025.10.14 HALLIBURTON ENERGY SERVICES INC

AI summary

A debris collection tool that includes a swirl generator that includes a first opening disposed on an exterior of the debris collection tool, and a second opening disposed inside the debris collection tool, where the first opening and the second opening are disposed at opposite axial ends of the swirl generator.