Hydrocyclone Barite Recovery System for Drilling Fluids

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Solution Overview

Problem

Current centrifuge systems for recovering high-density solids like barite from drilling fluids are costly, complex, and have low capacity, making them impractical for offshore applications and requiring significant maintenance, while existing methods for barite recovery are inefficient and expensive.

Innovation Solution

A separation system with no moving parts, comprising a body with a distribution chamber, overflow chamber, and multiple separation chambers that use a spiral flow pattern to separate high-gravity solids from drilling fluids, producing a barite slurry and minimizing maintenance and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If centrifuge systems are used to recover high-density solids from drilling fluids, then separation effectiveness is improved, but device complexity and cost increase significantly

Engineering Contradiction:

Improveseparation effectivenessVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces the complex mechanical centrifuge system with a hydrocyclone-based separation system that utilizes fluid dynamics and centrifugal force generated by the fluid flow itself, eliminating the need for mechanical rotating components while achieving effective separation of high-density solids from drilling fluids

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention employs hydraulic principles by using the kinetic energy and pressure of the drilling fluid flow to generate centrifugal force within the hydrocyclone chambers, enabling separation without external mechanical power sources or moving parts

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Manufacturing precision

If centrifuge systems are used for barite recovery, then separation capability is improved, but maintenance requirements and operational costs increase

Engineering Contradiction:

Improvebarite recovery capabilityVSAvoidmaintenance requirements

Core Design Contradiction:

Manufacturing precisionVSEase of repair

Solution Approach 1:

By replacing mechanical centrifuge components with stationary hydrocyclone chambers, the system eliminates wearing parts, bearings, and seals that require maintenance, resulting in a system with minimal operational costs and no moving parts to repair

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The hydrocyclone chambers are designed as simple, replaceable components with no moving parts, allowing for easy replacement if needed while eliminating the need for complex maintenance procedures associated with mechanical centrifuge systems

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Manufacturing precision

If traditional centrifuge systems are used, then solids separation is achieved, but processing capacity remains low

Engineering Contradiction:

Improvesolids separationVSAvoidprocessing capacity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system divides the separation process into multiple parallel hydrocyclone chambers, allowing simultaneous processing of large volumes of drilling fluid while maintaining effective separation of high-density solids, thereby significantly increasing overall processing capacity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention processes fluid flow through three-dimensional spiral motion within the hydrocyclone chambers, utilizing vertical and radial flow components to enhance separation efficiency while maintaining high processing rates through increased throughput capacity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 effectively recovers barite without the need for expensive centrifuges, maintaining efficiency across varying drilling fluid densities and viscosities, reducing maintenance, and producing a barite slurry for easier handling, thus addressing the limitations of existing technologies.

Implementation Method 1

Methodology Applied

Scientific EffectSpiral flow pattern: Cyclone Separation

Implementation Method 2

The separation chamber has a high-gravity solids outlet adjacent a lower end thereof, utilizing the spiral flow pattern to separate high-gravity solids from drilling fluids

Methodology Applied

Scientific EffectGravitational separation: Gravitation

Data Source

PatentUS10557322B2Separation system for use with weighting materials in drilling fluids

Publication Date: 2020.02.11 THE HILTL FAMILY TRUST

AI summary

A separation system for use with weighting materials in drilling fluids, the separation system has a body with an interior, a distribution chamber positioned in the interior of the body, a drilling fluid inlet pipe extending into the body in communicating with the distribution chamber, an overflow chamber positioned in the body, and at least one separation chamber positioned in the body and extending below the distribution chamber. The distribution chamber is configured to allow the drilling fluid to pass to the separation chamber. The separation chamber has a high-gravity solids outlet adjacent a lower end thereof and a fluid outlet adjacent an upper end thereof. The fluid outlet communicates with the overflow chamber. The separation channel has an inner diameter that tapers so as to narrow from the upper end thereof to the lower end thereof.