Drilling Fluid Cavitation for Ultra-Fine Solid Removal
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Solution Overview
Problem
Current drilling fluid systems struggle to effectively remove ultra-fine particles (low gravity solids) smaller than 20 microns, which remain in the fluid and increase in size with circulation, leading to viscosity issues and inefficiencies in separation processes.
Innovation Solution
The SHURE process employs high-pressure tubing to split and collide emulsion streams within a pressure drop chamber, creating a cavitation effect that relaxes the surface tension of the emulsion, allowing mechanical separation of low gravity solids down to 4 microns using devices like hydro-cyclones and centrifuges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mechanical separation devices (shale shakers, hydro-cyclones, centrifuges) are used to remove drill solids, then larger particles can be effectively separated, but ultra-fine particles (low gravity solids) smaller than 20 microns cannot be effectively removed
Solution Approach 1:
The patent applies parameter changes by subjecting the drilling fluid to extreme pressure conditions (up to 30,000 PSI) and temperature variations, which fundamentally alter the physical state and separation characteristics of the fluid and suspended particles. This enables the separation of ultra-fine LGS that conventional devices cannot handle at normal operating conditions.
Solution Approach 2:
The invention replaces conventional mechanical separation mechanisms with a pressure-driven system that uses extreme pressure differential and phase change to achieve separation. Instead of relying on mechanical screens, centrifugal force, or hydro-cyclonic action, the system uses pressure-induced phase separation and flash evaporation to remove ultra-fine particles.
2Productivity
If drilling fluid circulates in the annulus under downhole conditions, then drill cuttings are transported to surface, but the fluid thickens with increased viscosity and gel strength
Solution Approach 1:
The system applies periodic thermal and pressure cycles to the drilling fluid. The fluid undergoes repeated heating to flash point temperatures followed by rapid pressure reduction, creating cyclic phase changes that continuously break down gel structure and reduce viscosity without affecting the cuttings transport function during normal circulation.
Solution Approach 2:
The invention utilizes phase transitions by heating the drilling fluid to its flash point and then rapidly reducing pressure to cause flash evaporation. This phase change from liquid to vapor and back effectively breaks down the gelatinous structure and reduces viscosity, while the condensed liquid phase maintains the fluid's carrying capacity for cuttings.
3Ease of operation
If oil based drilling fluids are used to increase lubricity in directional and horizontal drilling, then drill solids become entrained in the fluid, but the adhesive bond between oil and suspended solids cannot be effectively broken
Solution Approach 1:
The system changes the physical parameters of the oil-based drilling fluid by subjecting it to extreme pressure (up to 30,000 PSI) and temperature variations. These parameter changes alter the interfacial properties between oil and drill solids, weakening the adhesive bond and enabling effective separation while maintaining lubricity during normal operation.
Solution Approach 2:
The invention replaces mechanical breaking of adhesive bonds (which is insufficient for oil-based fluids) with a pressure-driven phase separation system. The extreme pressure differential and flash evaporation process fundamentally change the separation mechanism from mechanical to thermodynamic, effectively breaking the oil-solids adhesive bond.
4Reliability
If more viscous drilling fluid is used to maintain borehole stability, then flow resistance increases and screen conductance decreases, but fluid loss prevention is improved
Solution Approach 1:
The system applies periodic thermal and pressure cycling to temporarily reduce viscosity and break down gel structure. During normal circulation, the fluid maintains its higher viscosity for borehole stability, but during treatment cycles, the periodic heating and pressure reduction temporarily reduce viscosity to improve flow characteristics and prevent screen blinding.
Solution Approach 2:
The invention uses phase transitions through flash evaporation to fundamentally alter the fluid's rheological properties. The rapid vaporization and condensation cycles break down the gelatinous structure and reduce viscosity, allowing the fluid to maintain stability when needed while improving flow characteristics during treatment.
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
This approach reduces low gravity solids by up to 50% more than existing methods, improving drilling fluid properties, increasing penetration rates, reducing tool erosion, and enhancing equipment longevity by effectively removing ultra-fines.
Implementation Method 1
a cavitation effect is realized from a collision force of the high pressure streams within the pressure drop chamber having enough force to relax the emulsion which holds the fluid and LGS together
Data Source
AI summary
A process and device to create access to low gravity solids (LGS) of about 2 to 20 microns for removal from a fluid material/LGS emulsion having the steps of: flowing the emulsion into high pressure tubing; separating the emulsion into at least two high pressure streams; forcing the emulsion through high pressure nozzles at a terminus of each of the at least two high pressure tubing streams at a speed in the range of about 10 ft/sec to 200 ft/sec or at a force in a range of about 10 to 100 PSI; and colliding the streams of emulsion exiting the high pressure nozzle within a pressure drop chamber, wherein the pressure drop is in a range of about 5% to 50% of the back pressure of the nozzles; wherein a cavitation effect is realized from a collision force of the high pressure streams within the pressure drop chamber.