Ceramic Separator for Sand and Rock Particles in Boreholes
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Solution Overview
Problem
Existing separating devices for sand and rock particles in rock boreholes suffer from low wear and abrasion resistance, tendency to break under bending stress, and rapid clogging, particularly when using porous ceramic materials, which are not suitable for mechanical loads and acidic environments.
Innovation Solution
The use of dense, brittle-hard ceramic materials forming non-porous separating devices with ring-shaped discs or bush-shaped elements, designed with a spherical axial bearing and support structure to withstand mechanical loads, reduce clogging, and maintain high corrosion resistance, allowing for less frequent flushing and effective separation of particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If porous ceramic materials are used for separation devices, then filtration capability is improved, but mechanical strength and fracture toughness deteriorate (flexural strength less than 30% of dense material)
Solution Approach 1:
The patent applies porous ceramic materials for the filter elements to provide effective filtration of sand and rock particles. The porous structure allows liquid or gas to pass through while trapping solid particles, achieving the filtration function required in borehole operations.
Solution Approach 2:
The patent uses composite construction by combining porous ceramic filter elements with a metallic support framework. The metallic framework provides the necessary mechanical strength and structural stability, while the porous ceramic elements provide filtration capability. This composite approach resolves the contradiction between filtration performance and mechanical strength.
2Reliability
If porous ceramic materials are used for separation devices, then filtration capability is improved, but abrasion resistance deteriorates
Solution Approach 1:
The metallic support framework in the composite structure provides superior abrasion resistance to the porous ceramic filter elements. The framework protects the fragile porous material from direct contact with abrasive rock particles, while the porous ceramics maintain their filtration function. This division of functions resolves the abrasion resistance problem.
Solution Approach 2:
The patent applies different material properties to different parts of the separation device: the metallic framework is designed for mechanical strength and abrasion resistance, while the porous ceramic elements are optimized for filtration. This local differentiation of material qualities allows each component to excel at its specific function.
3Reliability
If porous ceramic materials are used for separation devices, then filtration capability is improved, but clogging tendency increases
Solution Approach 1:
The porous ceramic materials provide effective filtration by capturing particles within their pore structure. The three-dimensional porous network offers multiple flow paths, reducing the tendency for surface clogging compared to non-porous filters.
Solution Approach 2:
The patent implements periodic backwashing to reverse the flow direction and flush accumulated particles from the porous filter elements. This periodic cleaning action maintains filtration capability over extended operation periods and prevents permanent clogging.
4Strength
If metallic slotted screens are used for separation, then mechanical strength is maintained, but wear resistance deteriorates
Solution Approach 1:
The patent combines metallic materials (for structural strength) with porous ceramic materials (for filtration). The metallic framework maintains mechanical integrity while the porous ceramics provide wear-resistant filtration surfaces that are less susceptible to abrasive wear from rock particles.
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 solution provides enhanced wear and abrasion resistance, reduced tendency to break, and improved corrosion resistance, allowing for longer intervals between flushes and effective separation of sand and rock particles without rapid clogging, while maintaining a larger free filter area and compatibility with curved boreholes.
Implementation Method 1
separating devices made of dense, brittle materials, particularly ceramic materials... they are not porous, so that the materials used according to the invention do not themselves exhibit a filtering effect
Data Source
Figure 1a~1g
Figure 2a~2d
Figure 3a~3c
AI summary
Provided herein is a separating device for removing sand and rock particles in the extraction of liquids or gases from wells drilled in rock having a plurality of brittle-hard annular discs stacked one on top of another and axially braced by a supporting structure. The annular discs have at least three spacers uniformly distributed over the circumference on their upper side. The discs are stacked on each other such that the spacers lie one over another and a separating gap with a height of 0.05-1 mm, preferably 0.2-0.5 mm, is present between each of the discs. Similarly, another embodiment of the separating device has a plurality of brittle-hard bush-shaped elements with slits formed therein.