Magnetic Separation Apparatus for Drilling Mud Swarf Removal
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Solution Overview
Problem
Existing apparatuses for handling oil and gas process liquids or slurries are inadequate in removing both magnetic and non-magnetic swarf particles, with limitations in magnetic field penetration, flow rate, and apparatus size, particularly for offshore use.
Innovation Solution
An apparatus comprising a plurality of magnet assemblies that cyclically move between active and inactive conditions to attract and release magnetic particles, with a drive mechanism and activation means to convey non-magnetic solid particles, and a configuration that enhances magnetic field exposure and flow rate while reducing the apparatus's footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If magnetic bars are used to separate swarf from liquid, then magnetic particles can be removed, but non-magnetic solid particles cannot be separated
Solution Approach 1:
The conveyor chain performs multiple functions: it transports the liquid through the magnetic field for magnetic particle separation, and simultaneously mechanically conveys non-magnetic solid particles to the collection chamber. This multi-functionality resolves the contradiction by making a single device capable of handling both particle types without requiring separate mechanisms.
Solution Approach 2:
The invention combines magnetic separation and mechanical conveyance into a single integrated system. The conveyor chain merges the function of liquid transport with solid particle collection, allowing both magnetic and non-magnetic particles to be removed together through one apparatus.
2Productivity
If magnetic field penetration is increased to improve swarf removal, then separation efficiency improves, but apparatus size increases
Solution Approach 1:
The magnetic field is applied dynamically through the cyclic movement of the conveyor chain, which alternates between exposing the liquid to the magnetic field and collecting particles. This dynamic approach allows effective swarf removal without requiring a continuously large apparatus, as the magnetic field is active only during the transport phase.
Solution Approach 2:
The invention moves the separation process from a static vertical configuration to a dynamic horizontal conveyor system. By utilizing the horizontal movement of the conveyor chain through the liquid, the apparatus achieves effective magnetic field penetration and particle collection without increasing the vertical footprint, thus resolving the size-efficiency contradiction.
3Productivity
If flow rate is increased to improve processing capacity, then productivity improves, but magnetic field exposure time decreases
Solution Approach 1:
The conveyor chain provides continuous magnetic field exposure as it constantly moves through the liquid, ensuring that liquid is continuously processed. This continuous action maintains high productivity while the cyclic nature of the conveyor ensures adequate exposure time for particle attachment during each cycle.
Solution Approach 2:
The conveyor chain operates in periodic cycles, moving through the liquid to expose it to the magnetic field, then returning to collect particles. This periodic action allows the system to maintain high flow rates while ensuring sufficient magnetic field exposure time during each cycle, resolving the contradiction between processing capacity and exposure duration.
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 separates magnetic and non-magnetic swarf particles from drilling mud, improving the efficiency and reliability of the process, allowing for safer recirculation of drilling fluids and reducing the risk of equipment damage.
Implementation Method 1
The ferrous nature of swarf has led to proposals to use magnetic fields to separate the swarf from the fluid
Implementation Method 2
U.S. Pat. No. 3,476,232 describes an apparatus for batch treatment of drilling fluid, which includes a series of magnetic bars on a conveyor inside a casing. The magnetic bars lift the swarf from a vessel
Data Source
AI summary
The invention provides an apparatus (10) for removing magnetic particles (53) from a liquid flowing from an oil or gas operation and method of use. The apparatus (10) comprises a plurality of magnet assemblies (20), each having a first condition in which an operable part is active to attract magnetic particles (53) to the magnet assembly (20), and a second condition in which the operable part is inactive and magnetic particles (53) are not attracted to the magnet assembly (20). A drive mechanism (13) moves the magnet assemblies (20) between exposure to a flow path of from a liquid (40) flowing from an oil or gas operation and a collection location (54). An activation means (36) moves the magnet assemblies (20) between the first condition and the second condition.