Drilling Mud Dewatering System with Liquid Polymer Injection
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Solution Overview
Problem
Current dewatering systems for drilling fluids face challenges with hygroscopic polymers having limited shelf life and reduced effectiveness due to temperature variations and moisture exposure, leading to increased costs and resource dependency, especially with non-dispersed, inhibitive water-based drilling fluids.
Innovation Solution
A system and method involving a primary separation tank, polymer injection, a clarifying tank, and a centrifuge, where polymers are injected into drilling mud to facilitate flocculation and separation of particulates, with a closed-loop process for efficient recycling and reuse of drilling fluids, minimizing manual mixing and optimizing polymer usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dry polymers are used for flocculation, then flocculation effectiveness is improved, but shelf life is reduced due to hygroscopic properties and temperature variations
Solution Approach 1:
The patent changes the physical state of the polymer from dry to liquid form, and modifies the chemical structure to be non-hygroscopic. This parameter change resolves the contradiction by maintaining flocculation effectiveness while dramatically extending shelf life through resistance to moisture absorption and temperature variations.
Solution Approach 2:
The invention uses composite polymer structures with specific molecular weight ranges and non-hygroscopic chemical composition. This composite approach combines the effectiveness of traditional dry polymers with the stability of liquid formulations, achieving both flocculation performance and extended shelf life.
2Duration of action of stationary object
If liquid flocculants are used, then shelf life is improved, but high energy is required for emulsion breaking and activation
Solution Approach 1:
The patent changes the emulsion formulation parameters to require lower breaking energy. The liquid flocculant is designed with specific nanoemulsion characteristics that reduce the activation energy needed, resolving the contradiction between extended shelf life and energy consumption during activation.
3Reliability
If batch mixing and aging processes are used, then polymer activation is achieved, but operational costs and resource dependency increase
Solution Approach 1:
The patent designs a self-service system where the continuous injection of pre-formulated liquid polymer eliminates the need for manual batch mixing and aging processes. The polymer is ready-to-use upon injection, automatically activating through the continuous flow process, which resolves the contradiction between reliable activation and operational efficiency.
Solution Approach 2:
The invention transitions from discontinuous batch mixing to continuous injection and activation. The liquid polymer flows continuously through the system, maintaining constant activation without interruption, which improves productivity while ensuring reliable polymer activation throughout the dewatering process.
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 the efficiency and consistency of solid separation, reduces polymer consumption, and decreases operational costs by automating the dewatering process, allowing for precise polymer mixing and increased reuse of drilling fluids, while adhering to environmental regulations.
Implementation Method 1
Coagulation occurs when the electrostatic charge on a solid is reduced, destabilizing the solid and allowing it to be attracted to other solids by van der Waals forces
Implementation Method 2
Flocculation is the binding of individual solid particles into aggregates of multiple particles
Implementation Method 3
a centrifuge in fluid communication with the clarifying tank and a second collection tank, wherein effluent from the centrifuge is discharged into the second collection tank
Data Source
AI summary
A system for processing drilling mud, the system including a primary separation tank having an inlet for receiving drilling waste and an outlet in fluid communication with a feed line, and an injection pump in fluid communication with a polymer tank and the feed line. The system also includes a clarifying tank in fluid communication with the feed line and a first collection tank, wherein effluent from the clarifying tank is discharged into the first collection tank, and a centrifuge in fluid communication with the clarifying tank and a second collection tank, wherein effluent from the centrifuge is discharged into the second collection tank.