Closed-loop drilling vessel cleaning with solids separation
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Solution Overview
Problem
Current methods for cleaning vessels containing drilling fluid residue are inefficient and lack a systematic approach for complete removal of solids, leading to suboptimal preparation for reintroducing new drilling fluids.
Innovation Solution
A closed-loop system utilizing high-pressure water-based cleaning fluid jets to create a slurry, followed by multiple solids/liquid separation stages using shale shakers and centrifugal devices, with recycling of the substantially solids-free fluid for repeated cleaning until the vessel reaches a predetermined cleanliness level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cleaning methods are used for vessels containing drilling fluid residue, then the cleaning process is simple, but the cleaning efficiency and completeness are insufficient
Solution Approach 1:
The cleaning system is segmented into multiple functional zones: a first solids/liquid separation zone with a shale shaker for coarse separation, and a second solids/liquid separation zone with a centrifugal separation device for fine separation. This segmentation allows each zone to specialize in removing particles of different sizes, thereby improving overall cleaning efficiency while maintaining manageable system complexity through modular design.
Solution Approach 2:
A holding tank serves as an intermediary component between the separation zones and the recycling system. It temporarily stores the cleaning fluid, allows for additive injection (such as dispersants or surfactants), and facilitates the controlled reintroduction of cleaned fluid back into the cleaning cycle. This intermediary element enhances cleaning completeness without significantly increasing system complexity.
2Manufacturing precision
If multiple solids/liquid separation stages are implemented, then the removal of solids is more complete, but the system complexity increases
Solution Approach 1:
The separation process is divided into two distinct stages: first, a shale shaker removes larger drill cuttings and solids through mechanical vibration and screening; second, a centrifugal separation device removes finer suspended particles through centrifugal force. This segmentation of separation functions achieves comprehensive solids removal while keeping each individual separation device relatively simple and well-understood in the industry.
Solution Approach 2:
The system exploits changes in physical parameters across the two separation stages. The shale shaker operates with mechanical vibration parameters optimized for coarse particle removal, while the centrifugal device operates with rotational speed parameters optimized for fine particle separation. This parameter differentiation allows each stage to excel at its specific function, achieving high cleaning completeness without requiring overly complex single-stage systems.
3Loss of substance
If cleaning fluid is recycled through a closed-loop system, then waste reduction and cost savings are achieved, but the system complexity and operational requirements increase
Solution Approach 1:
The cleaning fluid is continuously circulated through a closed-loop system: from the cleaning nozzles through the separation zones, to the holding tank, and back to the nozzles. This continuous circulation maximizes the utilization of the cleaning fluid, allowing it to repeatedly contact and remove drilling residue. The system maintains fluid cleanliness and effectiveness throughout multiple cycles, significantly reducing fluid loss and waste while the modular design keeps operational complexity manageable.
Solution Approach 2:
The system recovers and reuses the cleaning fluid after each separation stage. Instead of discarding used cleaning fluid, it is collected in the holding tank, potentially treated with additives to restore cleaning effectiveness, and reintroduced into the cleaning cycle. This recovery approach minimizes substance loss and reduces the need for frequent fluid replacement, achieving economic and environmental benefits without requiring excessively complex treatment facilities.
4Productivity
If high-pressure water jets are used for cleaning, then the cleaning power and effectiveness are improved, but the energy consumption and fluid requirements increase
Solution Approach 1:
The high-pressure cleaning fluid is continuously recirculated through the closed-loop system, maintaining its high-pressure cleaning capability across multiple cycles. Rather than requiring repeated high-energy input to generate fresh high-pressure fluid for each cleaning pass, the system sustains the pressure and flow through controlled circulation, reducing overall energy consumption while maintaining cleaning effectiveness.
Solution Approach 2:
The cleaning fluid performs dual functions: it cleans the vessel surfaces during its circulation and simultaneously undergoes separation and recovery in the same system. The fluid essentially serves itself by being cleaned and regenerated within the closed-loop system, reducing the need for external energy input and additional processing steps that would increase overall energy consumption.
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 method ensures thorough and efficient cleaning of vessels, allowing for the safe and efficient reuse of cleaning fluid, reducing waste and operational costs by maintaining a closed-loop recycling process.
Implementation Method 1
washing the interior surfaces of one or more vessels containing drilling fluid residue by use of one or more jets of a water- based cleaning fluid
Implementation Method 2
The liquid phase and solids smaller than the wire mesh pass through the screen, while larger particles are retained on the screen
Implementation Method 3
larger particles are retained on the screen, and eventually fall off one end as shown by line 14
Implementation Method 4
The second solids/liquid separation zone comprises a device that performs the separation by use of centrifugal force
Data Source
AI summary
A closed-loop system for cleaning vessels containing drilling fluid residue. High pressure jets of water-based cleaning fluid are used to clean the interior of a vessel. The resulting slurry is sent to one or more solids/liquid separation stages to remove drill cuttings and other drilling fluid solids. The substantially solids-free cleaning fluid discharge is recycled.