Continuous Extruded Solids Discharge for Oil Well Waste
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Solution Overview
Problem
The efficient and environmentally safe removal of waste solids from oil and gas well drilling fluids is challenging due to the accumulation of ultrafine particles, which render drilling fluids spent and pose health hazards and equipment risks from airborne dust.
Innovation Solution
A continuous processing method involving rewetting treated waste solids in a reduced pressure environment to form a paste, which is then extruded and discharged, minimizing dust generation and facilitating safe removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If waste solids are removed from drilling fluids, then drilling fluid efficiency is improved, but airborne dust generation increases causing health hazards
Solution Approach 1:
The patent applies vacuum (reduced pressure) environment to contain and control waste solids during processing. The vacuum system creates a controlled atmosphere that prevents airborne dust generation while enabling continuous removal of waste solids from drilling fluids, thus resolving the contradiction between productivity improvement and harmful dust exposure.
Solution Approach 2:
The patent uses vacuum pressure differential to convey waste solids through sealed pipelines and processing chambers. This pneumatic conveyance system eliminates the need for mechanical handling that would generate dust, allowing efficient waste solids removal while maintaining a dust-free environment through pressure-driven closed-loop transport.
2Loss of energy
If waste solids are accumulated, then removal cost is reduced, but drilling operation safety deteriorates
Solution Approach 1:
The patent implements continuous waste solids removal through an integrated vacuum system that operates throughout the drilling process. This continuous action prevents accumulation of harmful waste solids, maintaining equipment safety and operational reliability while being cost-effective by eliminating the need for periodic shutdowns and manual intervention.
Solution Approach 2:
The patent replaces traditional mechanical waste solids handling systems with a vacuum-based pneumatic system. This substitution eliminates mechanical contact points that could fail or generate dust, improving equipment reliability and safety while reducing maintenance costs associated with mechanical wear and tear.
3Object-affected harmful factors
If waste solids are processed continuously, then health hazards are reduced, but processing complexity increases
Solution Approach 1:
The patent employs a multi-functional vacuum system that simultaneously performs waste solids removal, conveyance, drying, and containment. This universal system handles multiple processing tasks through a single integrated vacuum network, reducing the need for separate equipment while maintaining continuous operation that minimizes health hazards.
Solution Approach 2:
The vacuum system operates autonomously by utilizing the pressure differential created during drilling operations itself. The system self-regulates waste solids removal without requiring complex external control mechanisms, simplifying the overall processing system while maintaining continuous operation that protects worker health.
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 effectively reduces health hazards and improves safety by continuously processing waste solids into a manageable paste, reducing airborne dust and enabling efficient disposal while maintaining equipment safety.
Implementation Method 1
a) receiving a stream of waste solids from a vacuum system while maintaining the reduced pressure
Implementation Method 2
b) adding water to the treated waste solids and mixing the water and the treated waste solids to form a paste
Data Source
AI summary
A device for processing oil or gas well waste solids, the device including a pressurizing discharge unit having a casing. The casing includes a solids inlet and a water inlet. The solids inlet receives treated solids into a front end of the casing, where the treated solids are exposed to a reduced pressure in an internal chamber of the casing of less than atmospheric pressure. The water inlet receives water and adds the water to the treated solids in the internal chamber. The casing includes an extruder screw unit, the extruder screw unit having progressive screw sections located inside the internal chamber and corresponding to conveying mixing and pressurizing screw sections. The conveying screw section conveys the treated solids along a long axis length of the extruder screw unit from the solids inlet towards a discharge end of the casing while the reduced pressure is maintained, the mixing screw section mixes the treated solids and the water together to form a paste, and the pressurizing screw section conveys the paste towards the discharge end and generates, in a portion of the casing downstream from the mixing screw section, a backpressure that is greater than atmospheric pressure. The casing includes a die assembly to extrude the paste through an orifice of the die assembly located at the discharge end while maintaining the backpressure on the paste in the internal chamber. Method and system embodiments for processing oil or gas well waste solids are also disclosed.