Binary Fluid Density Separation for Drilling Mud Recycling
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Solution Overview
Problem
Conventional drilling operations face inefficiencies in recovering and recycling loss circulation materials (LCM) and weighting agents from drilling fluids due to their similar size or mass to drill cuttings, leading to incomplete separation and increased logistical costs, especially in remote or offshore locations.
Innovation Solution
A system and process utilizing a primary separation device to create two streams, followed by a binary separation device with a distinct binary fluid of selected density to separate target recycle materials from drill cuttings, and additional solid/liquid separation devices to recover and rejuvenate the binary fluid for continuous recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional screening operations are used to remove drill cuttings, then drill cuttings can be removed from drilling fluid, but LCM and weighting agents are also removed along with the cuttings, preventing their recovery and recycling
Solution Approach 1:
The patent applies parameter changes by introducing a binary fluid with a specific density intermediate between LCM and drill cuttings. This density parameter modification enables selective separation where LCM floats on the binary fluid while cuttings sink, allowing cuttings removal efficiency to be maintained while LCM recovery is achieved.
Solution Approach 2:
The binary fluid serves as an intermediary substance that facilitates separation between LCM and drill cuttings. By having a density between these two materials, the binary fluid acts as a mediator that allows LCM to be recovered while still enabling effective removal of cuttings through the same screening process.
2Reliability
If LCM and weighting agents are retained in drilling fluid for extended periods, then wellbore strengthening and lost circulation control are maintained, but processing to remove drill cuttings and undesirable solids cannot be utilized
Solution Approach 1:
The patent changes the density parameter of the separation system by introducing binary fluid with intermediate density. This allows the processing system to differentiate between LCM (which should be retained) and drill cuttings (which should be removed), enabling both wellbore strengthening maintenance and effective cuttings removal to occur simultaneously.
Solution Approach 2:
The binary fluid acts as an intermediary that enables the processing system to selectively separate LCM from drill cuttings. This intermediary substance allows the processing equipment to remove cuttings while preserving LCM, thus maintaining both reliability of wellbore control and ease of manufacturing through effective processing.
3Reliability
If weighting agents are added to increase drilling mud density for well control, then head pressure is maintained to prevent blowouts, but removal of fine drill solids by processing equipment becomes considerably less efficient
Solution Approach 1:
The patent applies parameter changes by modifying the density distribution in the separation system through binary fluid. This creates distinct density zones that allow weighting agents to remain suspended in the drilling fluid for well control while enabling processing equipment to efficiently separate fine drill solids based on their different density characteristics.
Solution Approach 2:
The binary fluid serves as an intermediary that resolves the conflict between maintaining weighting agents in the drilling fluid and removing fine drill solids. By providing an intermediate density environment, it allows processing equipment to differentiate and remove fine solids while weighting agents remain in the fluid phase for continued well control function.
4Device complexity
If LCM and weighting agents are discarded after single use, then processing complexity is reduced, but logistical costs for shipping and maintaining inventories in remote or offshore locations increase
Solution Approach 1:
The patent applies parameter changes by modifying the separation system to use binary fluid with intermediate density. This enables LCM to be recovered and reused, reducing the need for continuous shipping of new LCM to remote locations while maintaining manageable processing complexity through a straightforward density-based separation process.
Solution Approach 2:
The patent implements recovery of LCM from the drilling fluid using binary fluid separation. Instead of discarding LCM after single use, the system recovers it for reuse, significantly reducing logistical costs associated with shipping and maintaining inventories in remote or offshore locations while keeping processing complexity relatively simple.
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
Effectively recovers and recycles target materials, enhancing the efficiency of drilling fluid processing by enabling the reuse of valuable LCM and weighting agents, reducing waste and logistical costs through improved separation based on density and mass.
Implementation Method 1
a binary separation device with a distinct binary fluid of selected density to separate target recycle materials from drill cuttings
Implementation Method 2
a primary separation device to create two streams
Data Source
AI summary
This invention relates to a system and process for recovering and recycling valuable target recycle materials such lost circulation material and weighting agents from drilling fluid used in hydrocarbon drilling operations. The system and process includes use of a binary fluid that is separate from the drilling fluid and has a designed density that allows separation of the valuable target recycle materials from drill cuttings. The solids are separated from the drilling fluid in a primary separation step and then mixed with the binary fluid in a density separation or enhanced mass separation device. The binary fluid density allows the separation device to distinguish the target recycle material from drilling solids and recycles the target material to the drilling operations for re-use in drilling fluid. The binary fluid is recovered and refreshed to maintain a generally continuous process of targeted recycling.