Magnetic Particle Removal from Mud Slurry Using Segmented Chain
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Solution Overview
Problem
The oil and gas industry faces challenges in efficiently separating magnetic particles from viscous liquid mud, which is hazardous and time-consuming, with existing technologies being either inefficient or dangerous for handling and disposal.
Innovation Solution
An apparatus featuring an endless chain with magnetic field generation units and non-magnetic units to attract and release magnetic particles, circulated within a pipe to collect the particles, allowing for safe and efficient separation and disposal of magnetic swarf from the mud.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If magnetic separator conveyor apparatus with spaced magnets on an endless chain is used, then magnetic particles are removed from the liquid, but the magnetic field continuity prevents complete particle release and collection efficiency
Solution Approach 1:
The endless chain is divided into alternating magnetic and non-magnetic units, creating segmented magnetic field zones. This segmentation allows particles to be attracted in magnetic zones and released in non-magnetic zones, solving the problem of incomplete particle release that occurs with continuous magnetic fields.
2Ease of manufacture
If manual separation of swarf pieces is performed after water removal, then larger magnetic particles are separated from the mixture, but the process is time-consuming and potentially dangerous
Solution Approach 1:
The manual mechanical separation process is replaced with an automated magnetic field-based separation system. The endless chain with magnetic units automatically attracts and transports magnetic particles, eliminating the need for dangerous manual handling while increasing separation speed and efficiency.
3Productivity
If the magnetic chain is enclosed in a pipe, then the magnetic field is contained and directed outward, but the enclosed structure may interfere with particle attraction from the liquid
Solution Approach 1:
The pipe acts as an intermediary structure that contains the magnetic chain while allowing magnetic field lines to pass through its walls. This enables the magnetic field to reach particles in the liquid outside the pipe, solving the conflict between field containment and particle attraction.
4Ease of manufacture
If permanent magnets are used in the endless chain, then no electricity supply is required, but the magnets are susceptible to wear and field degradation over time
Solution Approach 1:
The magnetic units are designed to be replaceable components on the endless chain. When permanent magnets degrade or wear, they can be easily removed and replaced without replacing the entire system, extending the overall service life of the magnetic separator while maintaining the benefit of no electricity requirement.
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 apparatus effectively separates magnetic particles from the mud, enabling safer handling and easier disposal or reuse, with the ability to process large volumes of mud efficiently and handle varying channel shapes.
Implementation Method 1
a plurality of magnetic field generation units to attract magnetic particles
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~4b
AI summary
An apparatus (10) for removing magnetic particles from a mud slurry is disclosed. The apparatus (10) includes one or more endless belts or chains (12) enclosed almost wholly within a pipe (22a). A motor (28) drives the chain (22) around the pipe (22a). When the pipe (22a) is located within a mud slurry, magnetic particles in the mud slurry are drawn to the pipe (22a) and carried along the outside and away from the slurry until a collar (29) is reached. Once so separated the particles can be collected for disposal. The chain (12) comprises a series of units linked together. Each unit includes a magnet (50) with pole pieces (51a, 51b) at either pole to direct magnetic flux. Wear discs (52a, 52b) prevent the magnets (50) and pole pieces (51a, 51b) from abrasion as they are drawn through the pipe (22a). Units can be included in the chain (12) which units do not include a magnet, thereby providing a break in the field, allowing particles to fall away from the collar region.