Dual-Milling Drilling Fluid Particle Size Reduction
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Solution Overview
Problem
Conventional hammer mills used for reducing particle size in oilfield drilling fluids become inefficient and prone to equipment failure due to high abrasion and energy consumption when grinding particles finer than 300 microns, leading to a build-up of particles in the milling circuit.
Innovation Solution
A dual-milling system comprising a hammer mill and a pearl mill, where the hammer mill initially reduces particle size using impact force, and the pearl mill further reduces it using friction, with controlled operation and maintenance features to prevent abrasion and energy inefficiencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hammer mills are used to reduce particle size below 300 microns, then particle size reduction is achieved, but equipment wear and energy consumption increase significantly
Solution Approach 1:
The milling process is divided into two distinct stages: a hammer mill for initial particle size reduction and a pearl mill for final fine grinding. This segmentation allows each mill to operate within its optimal performance range, preventing the hammer mill from excessive wear while achieving the required fine particle size reduction.
Solution Approach 2:
A classification device acts as an intermediary between the hammer mill and pearl mill, separating particles by size. This intermediary ensures that only particles requiring further grinding are transferred to the pearl mill, optimizing the workflow and preventing unnecessary wear on the hammer mill.
2Productivity
If conventional hammer mills operate continuously to maintain particle size reduction, then productivity is maintained, but energy consumption increases
Solution Approach 1:
The system segments the milling function across two devices with different operational characteristics. The hammer mill handles bulk reduction and can operate continuously, while the pearl mill handles fine grinding with lower energy consumption, optimizing overall energy efficiency while maintaining productivity.
Solution Approach 2:
The classification device continuously separates particles and directs them to the appropriate mill, ensuring continuous productive action. Particles are continuously classified and routed to either the hammer mill or pearl mill based on size, maintaining steady-state operation and efficient energy use.
3Manufacturing precision
If particles build up in the milling circuit due to inefficient grinding, then particle size reduction is achieved, but equipment failure risk increases
Solution Approach 1:
The classification device serves as an intermediary that actively manages particle flow by separating and directing particles to the appropriate processing stage. This prevents particle build-up in the milling circuit by ensuring continuous progression of particles through the optimized routing system.
Solution Approach 2:
By segmenting the milling process into two stages with appropriate classification, the system prevents particle accumulation. Particles are efficiently processed and transferred between stages, eliminating the build-up problem that would otherwise occur in a single-stage system.
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 dual-milling system effectively reduces particle size below 300 microns with reduced energy consumption and minimized equipment wear, maintaining efficiency and extending the lifespan of milling tools.
Implementation Method 1
a hammer mill adapted to grind the particles to a first particle size using impact force
Implementation Method 2
a pearl mill adapted to grind the particles to a second particle size using friction
Data Source
AI summary
This disclosure is drawn to systems, devices, apparatuses, and/or methods, related to milling particles in drilling fluid. Specifically, the disclosed systems, devices, apparatuses, and/or methods relate to milling particles in drilling fluid using multiple milling techniques. Some example apparatuses may include a first mill to grind particles from the original diameter to a first reduced diameter, and a second mill to grind the particles from the first reduced diameter to a second reduced diameter, where the second reduced diameter is less than the first reduced diameter.