Gas-Tight Clarifier for Low Gravity Solids Separation

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Solution Overview

Problem

Current methods are ineffective in efficiently removing low micron solids from oil-based drilling fluids, leading to contamination and reduced drilling efficiency, as they either fail to separate these solids effectively or pose safety hazards due to open designs and incomplete separation processes.

Innovation Solution

A gas-tight clarification device is used to mix the drilling fluid with a diluent, creating a recovered liquids phase and separated low micron solids slurry, with a sealed environment to prevent oxygen introduction and vapor escape, and a conveyor for solids collection, ensuring efficient separation and safety through controlled pressure and inert atmosphere.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If mechanical separating devices (shale shakers, decanter centrifuges) are used to separate drill cuttings from drilling mud, then a substantial portion of drilling mud can be returned to storage tanks for reuse, but residual low gravity solids remain in the recovered mud causing contamination and equipment wear

Engineering Contradiction:

Improvedrilling mud reuse rateVSAvoiddrilling equipment reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent extracts and removes low gravity solids from the drilling mud using a hydrocyclone separator. The hydrocyclone creates a centrifugal force field that separates the low gravity solids from the drilling mud based on density differences, allowing the cleaned mud to be returned to circulation while the solids are disposed of separately.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs hydraulic principles through the use of a hydrocyclone separator. The hydrocyclone uses high-velocity fluid flow to create centrifugal forces that separate particles from the drilling mud without moving mechanical parts, enabling continuous separation of low gravity solids.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Ease of operation

If open design separation devices are used for solids separation, then the device structure is simple and easy to operate, but vapors can escape into the atmosphere and atmospheric oxygen can introduce safety hazards

Engineering Contradiction:

Improveseparation device operation simplicityVSAvoidvapor escape and oxygen introduction

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent creates an inert atmosphere within the hydrocyclone separator by controlling the fluid flow and pressure conditions. The sealed design of the hydrocyclone prevents atmospheric oxygen from entering while the inerting effect of the continuous drilling mud flow prevents vapor ignition, eliminating safety hazards associated with open design devices.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Device complexity

If conventional solids separating devices are used, then the device complexity is low and operation is straightforward, but low micron solids cannot be effectively removed leading to contamination

Engineering Contradiction:

Improveseparation device structure simplicityVSAvoidsolids separation effectiveness

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent uses hydraulic principles in the hydrocyclone separator to achieve effective separation of low micron solids. The hydrocyclone's design creates a vortex flow that generates centrifugal forces sufficient to separate fine low gravity solids from the drilling mud without complex mechanical components, maintaining simplicity while improving separation effectiveness.

Inventive Principle:

Principle #29Pneumatics and hydraulics

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 significantly reduces the presence of low micron solids in the recovered fluid, enhancing drilling fluid quality, reducing wear on equipment, and preventing costly downtime, while ensuring a safe and environmentally friendly process.

Implementation Method 1

calming the mixture in a gas tight clarification device to produce a recovered liquids phase and separated low micron solids slurry

Methodology Applied

Scientific EffectGravitational settling: Gravitation

Implementation Method 2

the clarification device is sealed so as to prevent escape of vapors from the mixture into the atmosphere containing oxygen and the introduction of atmospheric oxygen into the mixture

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS11141683B2Gas-tight low gravity separation device

Publication Date: 2021.10.12 RECOVERY ENERGY SERVICES INC

AI summary

A method and apparatus for removing low micron solids from a mixture of recovered oil based drilling fluid and low micron solids and diluent. A gas tight clarifier device that is designed and constructed for this purpose in a gas-tight manor so to ensure vapour cannot escape the separation process, and foreign oxygen cannot enter the process under normal operating conditions.