Electric Field Emulsion Decomposition for Drilling Mud
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Solution Overview
Problem
Existing methods for decomposing drilling mud emulsions are inefficient, requiring high energy input, additives, and result in environmental hazards, particularly when dealing with high viscosity systems like drilling muds, where phase separation is challenging and often incomplete.
Innovation Solution
A method involving the use of an emulsion decomposing apparatus with electrodes applying a predetermined voltage and residence time to separate oil and water phases, followed by thermal desorption and mechanical separation, which reduces the oil content to non-harmful levels, allowing for the mud to be reused or recycled.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical vibration or agitation is used to decompose emulsion, then phase separation is promoted, but high energy input is required and separation is incomplete
Solution Approach 1:
The patent replaces mechanical agitation and vibration systems with an electric field-based decomposition method. Electrodes generate an electric field that directly acts on the emulsion droplets to induce phase separation without requiring high-energy mechanical input, thereby achieving complete separation with lower energy consumption.
Solution Approach 2:
The patent changes the physical parameter of the emulsion system by applying an electric field (electrical parameter) rather than mechanical force. This parameter change enables the decomposition of stabilized emulsions by affecting the interfacial tension and droplet stability through electrical forces, achieving separation that mechanical methods cannot accomplish efficiently.
2Productivity
If additives are used to decompose emulsion, then decomposition efficiency is improved, but environmental load increases and costs increase
Solution Approach 1:
The patent employs a self-service approach where the emulsion decomposes under the influence of an electric field without requiring external chemical additives. The electric field directly disrupts the emulsion structure, allowing the system to separate phases through physical forces alone, thereby eliminating harmful chemical byproducts and reducing environmental load.
Solution Approach 2:
The patent substitutes chemical additive-based decomposition with an electric field-based physical decomposition method. This replacement eliminates the need for chemical agents that would create environmental pollution, achieving efficient decomposition through purely physical electrical forces.
3Reliability
If mechanical decomposition is used, then some phase separation is achieved, but emulsifier molecules continuously coat new surfaces preventing complete separation
Solution Approach 1:
The patent replaces mechanical decomposition with electric field-based decomposition. The electric field acts on the emulsion droplets to directly disrupt the emulsifier coating and induce coalescence, overcoming the continuous re-coating problem that plagues mechanical methods. This enables complete and rapid phase separation without the time-consuming cycle of mechanical agitation and re-emulsification.
4Productivity
If high voltage is applied to electrodes, then emulsion decomposition is accelerated, but energy consumption increases
Solution Approach 1:
The patent optimizes the electrical parameters (voltage, current, frequency) to achieve effective emulsion decomposition at lower energy consumption levels. By carefully controlling these parameters, the system achieves rapid decomposition without requiring excessively high voltages, thereby balancing productivity with energy efficiency.
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 method effectively separates drilling mud into water, oil, and solid components, reducing environmental impact and enabling the mud to be reused or safely deposited, while being more economical and efficient than existing technologies.
Implementation Method 1
decomposing the emulsion between electrodes applied to at least a predetermined limit voltage of stability U h1 of the emulsion
Implementation Method 2
delivering the sediment thus obtained into a thin-film evaporator and concentrating said sediment by evaporation
Implementation Method 3
condensing the oily steam created by said evaporation
Implementation Method 4
removing a remained oil content of said powder-dry rock cuttings by thermal desorption
Data Source
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AI summary
The invention relates to a method and apparatus for handling drilling mud containing oil/water emulsion, comprising the step of decomposing the emulsion content of the mud, separating phases thus obtained, and establishing said decomposition between electrodes powered by at least the limit voltage of stability the emulsion, so that determining experimentally the level of the voltage of stability, type of voltage and residence time, then settling the solid phase of the decomposed emulsion content of the mud into a slurry, and separating the liquid phase containing macroscopic oil and water phase elements created during settling. The apparatus (A) according to the invention contains a mixing and storing unit (A1) for drill-cuttings connected to a homogenizing unit, and an emulsion decomposing unit (3) provided by positive "and negative electrodes alternating in a vertical arrangement; and a gas outlet arranged on the top of the emulsion decomposing unit (3).