Lost Circulation Material Recovery via Segmented Screening
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Solution Overview
Problem
Existing drilling operations face challenges in separating and recycling lost circulation material from drilling fluids, leading to inefficiencies and equipment clogging due to the mixing of valuable and undesirable particles, which complicates the recirculation process and requires continuous introduction of new materials.
Innovation Solution
A system and method involving a combination of size separation and density/fluid-shear separation using hydrocyclones and sizing apparatuses to isolate and recover lost circulation material from drilling fluids, allowing for its reuse in drilling operations by separating it from drilling fluid and undesirable solids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional screening is used to remove solids from drilling fluid, then drilled solids are removed from the mud, but lost circulation material is also removed requiring continuous introduction of new material
Solution Approach 1:
The patent segments the solids removal process into multiple stages with different screen sizes. The first screen (coarser) allows lost circulation material to pass through while catching larger drilled solids, and the second screen (finer) catches drilled solids that passed the first screen. This segmentation prevents loss of lost circulation material while still removing undesirable solids.
Solution Approach 2:
The patent applies different screening qualities at different locations in the system. The first screen has a coarser mesh suitable for allowing lost circulation material through, while the second screen has a finer mesh for catching remaining drilled solids. This local differentiation of screen qualities enables selective separation.
2Reliability
If lost circulation material is added to drilling mud to seal fractures, then circulation is restored, but the material plugs up separator components like fine screen cloth
Solution Approach 1:
The patent segments the screening process into two stages with progressively finer screens. The first coarser screen prevents lost circulation material from reaching and plugging the second finer screen, thereby protecting separator components while still enabling effective solids removal.
3Manufacturing precision
If two-step screening is used to separate lost circulation material, then separation is achieved, but height restrictions and fine screen problems persist and undesirable solids are circulated back
Solution Approach 1:
The patent inverts the conventional approach by using a coarser screen first followed by a finer screen, rather than the traditional finer-then-coarser arrangement. This inversion allows lost circulation material to pass through the first screen and be caught by the second screen, preventing plugging issues while maintaining separation effectiveness.
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
Effectively recovers and reuses lost circulation material, reducing the need for continuous introduction of new materials and minimizing equipment clogging, thereby enhancing drilling fluid treatment technology and operational efficiency.
Implementation Method 1
density/fluid-shear separation (e.g., by subjecting material to a moving fluid, e.g., air, water, clean drilling fluid, or some other liquid component of a drilling fluid mixture)
Implementation Method 2
density/fluid-shear separation (e.g., by subjecting material to a moving fluid, e.g., air, water, clean drilling fluid, or some other liquid component of a drilling fluid mixture)
Implementation Method 3
size separation (e.g. screening)
Data Source
AI summary
A system for recovering lost circulation material from spent drilling fluid, the spent drilling fluid containing lost circulation material, drilling fluid, and undesirable solids, the system having alternating separation apparatuses, including sizing apparatus, destiny/shear separation apparatus, and sizing apparatus; and methods for using such a system.