Horizontal Drilling Fluid Separator with Thermal Zones
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Solution Overview
Problem
The disposal and reuse of oil-covered cuttings from onshore and offshore drilling operations pose significant environmental and economic challenges, including the need for costly pit disposal and the risk of oil residues in water bodies, with existing methods failing due to thermal distortion and economic viability issues.
Innovation Solution
A method and system for separating particulates from drilling fluid in a horizontal vessel, using baffles and controlled pressure to collect and remove barite, cuttings, and bentonite particulates, allowing for the reuse of drilling fluid and particulates in subsequent operations, thereby reducing the need for pits and brine disposal wells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thermal treatment is applied to oil cuttings in vertically mounted kilns, then the cuttings can be processed, but the opening and closing gates become thermally distorted due to extensive temperature differentials
Solution Approach 1:
The vessel is divided into multiple temperature zones (hot zone, warm zone, cool zone) with baffles separating them, allowing different parts of the system to operate at different temperatures. This segmentation prevents uniform thermal distortion while maintaining effective thermal treatment of the cuttings.
Solution Approach 2:
The patent transitions from vertical kiln configuration to horizontal vessel configuration with longitudinal temperature gradients. This dimensional change allows thermal processing while distributing temperature differentials across the length of the vessel rather than concentrating them at specific mechanical joints.
2Ease of manufacture
If oil-covered cuttings are dumped at sea, then disposal is simplified, but a surface film or sheen is created that is costly to recover or remove
Solution Approach 1:
The patent converts the harmful oil-coated cuttings into a beneficial product by applying thermal treatment that drives off hydrocarbons, leaving clean inert material. The harmful oil component is transformed into removable vapor while the solid residue becomes safe for disposal or reuse.
Solution Approach 2:
The patent changes the temperature parameter of the cuttings from ambient to elevated temperatures (but below ignition point), which alters the physical and chemical state of the hydrocarbons, enabling their separation and removal while leaving the solid matrix intact and stable.
3Quantity of substance
If pits are used for onshore disposal of cuttings, then the cuttings can be contained, but the process is not economically viable and requires continuous pit construction and maintenance
Solution Approach 1:
The patent recovers valuable materials from the cuttings including hydrocarbons (as fuel), metals (for recycling), and inert solid residue (for reuse as drilling material or fill). This recovery process transforms a disposal cost center into a resource recovery operation with multiple revenue streams.
Solution Approach 2:
The thermal treatment process uses the heat generated by burning a portion of the hydrocarbon content to provide the thermal energy needed for processing the remaining cuttings. This self-heating approach reduces external energy requirements and operational costs.
4Productivity
If drilling fluid is continuously circulated, then drilling operations can proceed efficiently, but separation and recovery of drilling fluid components requires complex processing
Solution Approach 1:
The separation vessel is segmented into multiple zones with baffles that create sequential separation stages. Different particulate sizes and densities are separated in different zones, allowing continuous processing while maintaining relatively simple equipment architecture.
Solution Approach 2:
The patent uses gravity-based separation where the vessel orientation and internal baffles create conditions for particulates to settle at different rates based on their properties. This passive gravity separation eliminates the need for complex mechanical separation devices while maintaining continuous operation.
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 approach enables the efficient separation and reuse of drilling fluid and materials, minimizing environmental impact and operational costs, and facilitating compliance with offshore drilling regulations by recycling water and drilling materials.
Implementation Method 1
separating particulates from drilling fluid in a horizontal vessel, using baffles and controlled pressure to collect and remove barite, cuttings, and bentonite particulates
Implementation Method 2
collecting a first particulate within a first portion of the vessel, wherein the first particulate has a first average specific gravity and a first average size, collecting a second particulate within a second portion of the vessel, wherein the second particulate has a second average specific gravity and a second average size
Data Source
AI summary
A method and apparatus for separating the constituents of a drilling fluid into two or more groups based on particulate size and specific gravity in a continuous flow process.