Membrane Separator for Drilling Fluid Solids Removal
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Solution Overview
Problem
Current systems for separating solids from drilling fluids often fail to effectively remove colloidal and low-gravity solids, leading to increased viscosity and potential damage to formations and downhole equipment, requiring costly dilution and altering chemical balances.
Innovation Solution
A system incorporating a membrane separator, which further processes the effluent from centrifuges to produce a permeate with low solids content, reducing the need for additional drilling fluids and minimizing equipment damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional separation devices (shakers, centrifuges, hydrocyclones) are used to separate solids from drilling fluids, then large and medium solids can be removed, but colloidal and low-gravity solids remain in the fluid
Solution Approach 1:
The patent employs a membrane separator with porous structure that has specific pore size and distribution designed to capture colloidal and low-gravity solids. The membrane's porous material allows it to retain particles that conventional separation devices cannot remove, achieving complete solids removal including fine colloidal particles.
Solution Approach 2:
The separation process is divided into multiple stages: conventional separation devices handle large and medium solids first, then the membrane separator handles colloidal and low-gravity solids in a subsequent stage. This segmented approach allows each device to specialize in removing specific size ranges of solids.
2Quantity of substance
If additional drilling fluid is added to dilute solids content, then solids concentration is reduced, but fluid cost increases and chemical balance is altered
Solution Approach 1:
The membrane separator extracts and removes colloidal and low-gravity solids from the drilling fluid, allowing the fluid to be reused without dilution. This extraction process eliminates the need to add additional drilling fluid, maintaining both cost efficiency and chemical balance.
Solution Approach 2:
The system discards removed solids while recovering and reusing the cleaned drilling fluid. The membrane separator enables recovery of fluid with complete solids removal, eliminating the need for costly dilution and maintaining proper fluid chemistry.
3Quantity of substance
If solids are recycled downhole with clean fluid, then fluid volume is maintained, but formation and equipment damage occurs
Solution Approach 1:
The membrane separator converts the potentially harmful recycled solids into a benefit by completely removing colloidal and low-gravity solids that would otherwise damage the formation. The system transforms what was previously a harmful recycling practice into a beneficial closed-loop fluid recovery system.
Solution Approach 2:
The patent replaces the mechanical recycling system (which simply circulated fluid without effective solids removal) with a membrane-based separation system. This substitution enables complete solids removal while maintaining fluid volume, eliminating formation damage risks.
4Manufacturing precision
If multiple separation steps are used to remove solids by size, then separation completeness improves, but system complexity and cost increase
Solution Approach 1:
The membrane separator serves as a universal final-stage separator that handles all remaining colloidal and low-gravity solids in one unit, replacing the need for multiple specialized separation devices. This multi-functional approach achieves complete separation while simplifying the overall system.
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 achieves a significant reduction in solids content, improving fluid stability and reducing the need for costly dilution, while maintaining the desired fluid properties and preventing equipment damage.
Implementation Method 1
a membrane separator configured to receive the effluent and separate the effluent into a permeate and a concentrate
Implementation Method 2
flowing the solid-laden fluid through a centrifuge, removing at least a portion of high gravity solids
Data Source
AI summary
A system for separating solids from fluid including a solid-laden fluid may include a base fluid, a first separator configured to receive the solid-laden fluid and separate the fluid into a solids portion and an effluent, and a membrane separator configured to receive the effluent and separate the effluent into a permeate and a concentrate. A method for separating solids from fluid may include obtaining a solid-laden fluid, wherein the solid-laden fluid comprises a base fluid, feeding the solid-laden fluid through a centrifuge, removing at least a portion of high gravity solids from the solid-laden fluids, flowing the solid-laden fluid through a membrane separator, removing at least a portion of low gravity solids from the solid-laden fluid, and collecting a permeate from the membrane separator.