Two-Stage Crushing Machine for Oil Well Cuttings Size Reduction
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Solution Overview
Problem
The disposal of rock cuttings from oil and gas drilling operations is costly and inefficient due to their large size, which makes them difficult to manage and dispose of effectively with the returning drilling fluid.
Innovation Solution
A two-stage crushing machine with rotating hammers and grate plates is used to reduce the size of rock cuttings to fine particles, allowing them to be easily vacuumed and transported with the waste fluid for treatment or recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rock cuttings are disposed of as-is (large size), then disposal can be done with separate processes, but disposal cost and logistics complexity increase significantly
Solution Approach 1:
The cuttings reduction system is divided into multiple crushing stages (first stage crushing machine, second stage crushing machine) with progressively finer grates, segmenting the size reduction process to achieve effective vacuumability while managing complexity through modular stages
Solution Approach 2:
The system changes the physical parameter of cuttings size from large fragments to fine particles through sequential crushing stages, transforming them from a state requiring separate disposal processes to one that can be efficiently vacuumed and transported with waste fluid
2Device complexity
If a single-stage crushing machine is used, then device complexity is reduced, but cuttings size reduction is insufficient for effective vacuuming
Solution Approach 1:
The crushing process is segmented into two distinct stages: a first stage crushing machine with a first grate plate for initial size reduction, and a second stage crushing machine with a second grate plate for final fine particle production. This segmentation enables sufficient size reduction for vacuuming while keeping each individual stage relatively simple
Solution Approach 2:
The first stage crushing machine performs preliminary size reduction of cuttings before they enter the second stage, preparing the material for final fine particle production. This preliminary action distributes the crushing workload across two stages, achieving effective vacuumability without requiring an overly complex single-stage design
3Use of energy by moving object
If water is not injected during crushing, then energy consumption is reduced, but cuttings movement through the crushing machine is insufficient
Solution Approach 1:
Water is introduced as an intermediary substance that facilitates cuttings movement through the crushing machine. The water acts as a carrier medium that flows with the cuttings through the crushing chambers and grate plates, enabling efficient material transport without requiring excessive mechanical energy input
Solution Approach 2:
The system uses hydraulic principles by introducing water into the crushing machine to aid cuttings movement. The water flow provides hydraulic assistance in moving cuttings through the crushing zones and over the grate plates, reducing the energy burden on the crushing mechanism while maintaining effective operation
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 process effectively reduces the size of rock cuttings to 80-90% fine particles, enabling their efficient disposal and potential re-use, thereby reducing disposal costs and logistics complexity.
Implementation Method 1
a first rotating hammer disposed within the first housing, the first rotating hammer comprising a plurality of blades, wherein the first rotating hammer spins on an axis powered by a motor
Implementation Method 2
crushing the cuttings with the first rotating hammer to form reduced-size cuttings
Implementation Method 3
injecting water into the first housing via the first water injector thereby flowing the reduced-size cuttings through the first grate plate toward the second stage of the crushing machine
Implementation Method 4
draining at least a portion of the drilling fluid from the feed through the mesh and delivering the drained drilling fluid to a mud tank
Data Source
AI summary
A method of reducing the size of cuttings to fine particles includes obtaining a mixture comprising at least cuttings and drilling fluid and providing a crushing machine including an inlet and a first stage. The first stage includes a first housing, a first rotating hammer with a plurality of blades disposed within the first housing that spins on an axis powered by a motor, a first grate plate, a first water injector coupled to the first housing, and a second stage that is substantially similar to the first stage. The method further includes crushing the cuttings with the first rotating hammer to form reduced-size cuttings and injecting water into the first housing via the first water injector, thereby flowing crushed cuttings through toward the second stage. The method is repeated in the second stage such that the reduced size cuttings become fine particles and flow into a waste pit.