Inline Drilling Fluid Blending Without Settling Tanks

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Solution Overview

Problem

Existing drilling-fluid additive systems require intermediate storage and settling tanks to eliminate turbulence after blending, leading to inefficiencies and potential issues like overflowing or settling of additives, and lack real-time analysis and direct injection capabilities.

Innovation Solution

An automated drilling-fluid additive system that includes an inline diagnostic unit for real-time analysis, controlled additive delivery, and a blending process that eliminates turbulence, allowing direct injection of blended fluid into a well without intermediate storage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If intermediate storage and settling tanks are used to eliminate turbulence after blending, then the drilling fluid can be properly injected into the well, but the system becomes more complex and prone to problems like overflowing, emptying, or additive settling

Engineering Contradiction:

Improvedrilling fluid injection reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the intermediate storage and settling tank from the system entirely. Instead of using a separate holding tank to eliminate turbulence, the system directly delivers blended drilling fluid to the high-pressure injection pump through a streamlined configuration that eliminates the problematic intermediate storage step while maintaining injection reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines the blending and delivery functions into a more integrated system. The additive injection system blends additives with drilling fluid and delivers the mixture directly to the injection pump without requiring a separate storage tank, merging what were previously separate operations into a continuous process.

Inventive Principle:

Principle #5Merging (Combining)

2Stability of the object's composition

If intermediate storage tanks are used to hold blended drilling mud, then turbulence is eliminated, but the system requires additional processing and handling steps

Engineering Contradiction:

Improvedrilling fluid composition stabilityVSAvoiddrilling fluid processing efficiency

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The patent establishes a continuous flow system where blended drilling fluid is delivered directly from the additive injection system to the high-pressure injection pump without interruption for storage or settling. This continuous operation eliminates the need for additional processing steps while maintaining composition stability through controlled blending and direct delivery.

Inventive Principle:

Principle #20Continuity of useful action

3Extent of automation

If semi-automated blending processes are used, then some control is achieved, but real-time analysis and adjustment capabilities are still lacking

Engineering Contradiction:

Improveblending automation levelVSAvoidreal-time fluid quality information

Core Design Contradiction:

Extent of automationVSLoss of information

Solution Approach 1:

The patent incorporates sensors and controllers that provide real-time monitoring and feedback on drilling fluid properties. The controller receives information about the drilling fluid conditions and automatically adjusts additive injection rates and blending parameters to maintain optimal fluid quality, enabling closed-loop control rather than open-loop semi-automated operation.

Inventive Principle:

Principle #23Feedback

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

Enables real-time adjustment and thorough blending of drilling fluid, eliminating turbulence and the need for intermediate storage, ensuring consistent quality and efficient delivery to the well.

Implementation Method 1

a series of bent and curved baffle plates which divert, rotate, divide, reverse and otherwise create turbulence in the combined flow

Methodology Applied

Scientific EffectTurbulence: Turbulence

Implementation Method 2

injected into the well by a high-pressure pump

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Data Source

PatentUS20250341140A1Automated Drilling-Fluid Additive System and Method

Publication Date: 2025.11.06 COLLINS KYLE

AI summary

An automated drilling-fluid additive system and method for on-site real-time analysis and additive treatment of drilling fluid to be injected into a well. The drilling fluid includes returned drilling fluid intended to be re-used, which has a variety of viscosity and other qualities resulting from its various preceding use. The target drilling fluid will have a variety of viscosity and other qualities depending upon and changing with various phases of drilling operations and various conditions encountered. The drilling fluid is analyzed in real time as it flows into the automated drilling-fluid additive system, and various additives are added to and thoroughly blended with the drilling fluid as needed to achieve the desired result. The blended drilling fluid is discharged from the automated drilling-fluid additive system in the proper condition for injection into a well.