Drilling Emulsion System with Automated Aggregate Dosing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing drilling emulsion systems rely on manual control and dosing methods, which are prone to errors and require extensive knowledge, making them inefficient and unreliable for adapting to changing soil conditions during drilling operations.
Innovation Solution
A drilling emulsion system comprising a basic emulsion unit, a mixing and dosing unit, and a control unit that automatically selects and doses aggregates based on pre-defined recipes, allowing for precise and adaptive emulsion formulation in response to changing soil conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual control and dosing methods are used for drilling emulsion, then the system is simple to operate, but the reliability and precision of aggregate dosing deteriorate due to operator errors and lack of experience
Solution Approach 1:
The control unit automatically selects and doses aggregates based on pre-defined recipes and soil conditions, eliminating the need for manual operator judgment and dosing decisions. The system serves itself by autonomously adjusting aggregate composition based on real-time or pre-programmed parameters, thereby improving dosing reliability without requiring complex manual intervention systems
Solution Approach 2:
The patent replaces manual mechanical dosing operations with an automated control system that uses sensors, control algorithms, and automated dosing mechanisms. This substitution of manual mechanical control with an automated control system improves dosing precision while managing system complexity through integration
2Manufacturing precision
If aggregates are added directly to the main emulsion stream, then the mixing process is simple, but the manufacturing precision of emulsion formulation deteriorates due to inadequate dispersion
Solution Approach 1:
The patent segments the aggregate dosing and mixing process into distinct stages: aggregate selection, separate dosing, and controlled mixing with the base emulsion. This segmentation allows each stage to be optimized independently, ensuring precise aggregate formulation before integration into the main emulsion stream, thereby improving emulsion formulation precision
Solution Approach 2:
The control unit prepares aggregate formulations in advance based on pre-defined recipes and soil conditions before the actual drilling operation. This preliminary preparation and pre-mixing of aggregates ensures proper dispersion and formulation precision before the emulsion is delivered to the drilling operation
3Adaptability or versatility
If the system responds to changing soil conditions, then the adaptability improves, but the response time increases due to the volume of emulsion that must be consumed before new formulation is available
Solution Approach 1:
The control unit stores multiple pre-defined aggregate recipes that correspond to different soil conditions. When soil conditions change, the system can quickly switch between pre-prepared formulations without needing to mix from scratch, significantly reducing the response time while maintaining high adaptability to varying ground conditions
Solution Approach 2:
The system dynamically adjusts aggregate dosing in real-time or near-real-time based on changing soil conditions detected during drilling. The control unit continuously monitors conditions and modifies the aggregate formulation accordingly, enabling rapid adaptation without the delay associated with consuming large volumes of emulsion
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 enables precise and efficient adaptation of drilling emulsions to changing soil conditions, reducing errors and improving drilling efficiency by decoupling the distribution of aggregate particles from the main emulsion stream, ensuring high-quality emulsions and minimizing waste.
Implementation Method 1
decoupling the distribution of aggregate particles from the main emulsion stream
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a drilling emulsion system comprising a base emulsion unit (10), a mixing and metering unit (20), a control unit (30), and an emulsion main line (50), wherein the base emulsion unit (10) is configured to provide a base emulsion and supply it to the mixing and metering unit (20) via the emulsion main line (50), wherein the mixing and metering unit (20) is connected to the emulsion main line (50) and comprises an additive unit (40) and an emulsion bypass line (51), and is configured to provide a finished emulsion by adding an additive emulsion to the base emulsion, wherein the additive unit (40) comprises an additive storage container (41), a pre-stage actuating element (42), an additive emulsion container (43), and a final actuating element (44), and wherein the emulsion bypass line (51) is connected to the emulsion main line (50) is connected and trained,a bypass actuator (52) is used to meter a sidestream of the base emulsion into the aggregate emulsion container (43), wherein the aggregate emulsion container (43) is designed to provide an aggregate emulsion from the aggregate, wherein the final actuator (44) is connected to and controlled by the control unit (30) and is designed to meter the aggregate emulsion into a main stream of the base emulsion.