Mixing Screw Apparatus for Bentonite Drilling Fluid Lumping
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Solution Overview
Problem
The introduction of bentonite into water for drilling fluids often results in lumping, making batch-wise mixing cumbersome and disposal of unused portions complex and expensive, and existing methods do not effectively address the issue of powdery medium lumping upon contact with fluids.
Innovation Solution
A mixing apparatus with a mixing vessel and rotating mixing screws, such as brushing screws with bristles, that impart a helical motion to the fluid, combined with a metering device and optional static or dynamic mixing elements like injector nozzles or ultrasound, to ensure thorough intermixing of the powdery medium with the fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bentonite is introduced directly into water in the region of a high-pressure pump to take advantage of turbulences for mixing, then mixing capability is improved, but lumping of the powdery medium occurs
Solution Approach 1:
A dedicated mixing vessel with mixing screws is introduced as an intermediary device between the bentonite storage and the high-pressure pump. This intermediary mixing system ensures thorough mixing before the fluid enters the pump, preventing lumping while maintaining mixing capability.
Solution Approach 2:
The mixing process is performed in advance in a dedicated mixing vessel before the fluid reaches the high-pressure pump. The mixing screws pre-mix the bentonite and water thoroughly, so that when the mixture enters the pump, it is already homogeneous and free of lumps.
2Reliability
If batch-wise mixing in large storage vessels is used to prevent lumping, then mixing quality is improved, but operation complexity and waste disposal cost increase
Solution Approach 1:
The system enables continuous mixing of bentonite and water through the mixing vessel and mixing screws, replacing batch-wise mixing. This continuous process eliminates the need for large storage vessels and complex batch operations, while maintaining high mixing quality and reducing waste disposal requirements.
3Productivity
If mixing screws are used to impart helical motion for thorough intermixing, then mixing efficiency is improved, but device complexity increases
Solution Approach 1:
The mixing function is segmented into a dedicated mixing vessel with mixing screws, separate from the pumping and storage functions. This segmentation allows the mixing screws to focus solely on efficient mixing without complicating the overall system, as each component has a specific function.
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 prevents lumping of the powdery medium, enabling continuous and efficient mixing of bentonite with water, improving mixing efficiency and reducing waste disposal costs by allowing for a continuous mixing process.
Implementation Method 1
introduces the powdery medium into the mixing vessel where it is mixed with the likewise introduced fluid by imparting a helical rotation along the longitudinal axis
Implementation Method 2
take advantage of the turbulences produced in the water by the high-pressure pump for mixing the bentonite with the water
Implementation Method 3
the large number of bristles and the (small) spaces formed between the bristles can produce increased swirling of the fluid, which can lead to excellent mixing of the fluid with the powdery medium
Implementation Method 4
a high-pressure pump which enables construction of a continuous mixing plant, because a high-pressure pump is capable of producing a pressure sufficient for transporting the drilling fluid through a (hollow) drill rod
Data Source
AI summary
An apparatus for mixing a powdery medium with a fluid includes a mixing vessel which can be filled with the fluid and which has a feed for the fluid, an inlet for the powdery medium and an outlet for the fluid mixed with the powdery medium, and at least one mixing screw arranged inside the mixing vessel and driven by a rotary drive.