Filter Press Dewatering Drilling Mud Flocculation RF Heating
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Solution Overview
Problem
Current methods for separating drilling muds and drill cuttings are inefficient, leading to contamination and environmental concerns, as they fail to effectively recover drilling mud from drill cuttings and require costly processing for disposal.
Innovation Solution
A filter press system that includes chemical treatment with dilution and the addition of flocculating agents, followed by radio frequency heating and vacuum processing to separate liquids and insoluble solids, allowing for efficient dewatering and drying of drilling muds and mixtures with drill cuttings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shale shakers are used to separate drill cuttings from drilling mud, then some cuttings are removed, but the mud retains too many fine particulates for reuse and cuttings retain significant mud that needs recovery
Solution Approach 1:
The patent changes the physical and chemical parameters of the drilling mud by adjusting pH levels, adding flocculating agents, and controlling particle size distribution. These parameter changes enable effective separation of fine particulates from the mud, allowing mud recovery while achieving acceptable separation efficiency for cuttings removal
Solution Approach 2:
The patent introduces filter press membranes and flocculating agents as intermediary substances that facilitate the separation process. These intermediaries enable the capture of fine particulates that shale shakers cannot remove, while allowing the recovered mud to be reused and cuttings to be disposed of with minimal mud content
2Object-affected harmful factors
If drilling mud is processed for disposal to meet environmental regulations, then environmental compliance is achieved, but costly processing and hauling are required
Solution Approach 1:
The patent implements a recovery system that separates and recycles drilling mud from cuttings using filter press technology. By recovering and reusing the mud, the system eliminates the need for costly disposal processing while ensuring environmental compliance through effective separation of solids and liquids
Solution Approach 2:
The patent replaces mechanical disposal systems with a chemical-physical treatment process involving flocculation and membrane filtration. This substitution achieves environmental compliance through controlled separation processes that are more cost-effective than traditional mechanical hauling and disposal methods
3Quantity of substance
If filter press is used for dewatering drilling mud, then water content is reduced, but chemical treatment and energy input are required
Solution Approach 1:
The patent applies preliminary chemical treatment to the drilling mud before filtration, including pH adjustment and flocculating agent addition. This preliminary action prepares the mud for more efficient dewatering in the filter press, reducing the energy input required during the actual filtration process by pre-conditioning the slurry
Solution Approach 2:
The patent changes physical parameters such as particle size distribution and chemical parameters such as pH and flocculation characteristics. These parameter changes optimize the dewatering process, achieving effective water removal with reduced energy input by making the slurry more filterable through controlled chemical and physical modifications
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 system achieves significant dewatering, producing a dried filter cake with low water content, facilitating environmentally friendly disposal and reducing the need for costly processing.
Implementation Method 1
adding a flocculating agent to the diluted mixture and stirring to form a chemically processed mixture
Implementation Method 2
pumping the chemically processed mixture into a chamber between two filter plates in the filter press to form a filter cake, wherein the chamber is lined by filter cloths, and wherein, during the pumping, filtrate is forced through the filter cloths and out of the chamber
Implementation Method 3
heating the filter cake in the chamber, wherein, during the heating, filtrate is forced through the filter cloths and out of the chamber
Implementation Method 4
During the heating, the chamber may be vacuum pumped to facilitate removal of filtrate vapor
Implementation Method 5
each of the multiplicity of chambers being lined by filter cloths, wherein the plurality of filter plates, the multiplicity of chambers and the filter cloths are configured to allow filtrate to escape from the chambers while retaining solids from the mixture to form a filter cake
Data Source
AI summary
A method of separating a mixture of liquid and insoluble solids in a filter press may comprise: diluting the mixture; adding a flocculating agent to the diluted mixture and stirring to form a chemically processed mixture; pumping the chemically processed mixture into a chamber between two filter plates in the filter press to form a filter cake, wherein the chamber is lined by filter cloths, and wherein, during the pumping, filtrate is forced through the filter cloths and out of the chamber; heating the filter cake in the chamber, wherein, during the heating, filtrate is forced through the filter cloths and out of the chamber; and releasing dried filter cake from the chamber. Furthermore, before the diluting, additional solids may be added to the mixture. The method may be used to dewater drilling mud, and mixtures of drilling mud with drill cuttings.