Multi-stage Centrifugation for Oil-based Drilling Fluid Processing
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Solution Overview
Problem
Current methods for processing oil-based drilling fluids are inefficient in reducing the volume of drilling wastes, particularly in separating solid and liquid phases, leading to environmental concerns and increased disposal costs due to the presence of hydrocarbons, solids, and emulsions in reserve pits.
Innovation Solution
A method involving centrifugation and addition of base oil fluid, surfactants, and polymers to separate and treat oil-based drilling fluids, allowing for the reuse of treated fluids and effective disposal of solids, including the use of centrifuges and coalescers to separate phases and polymers to facilitate flocculation and coagulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separation equipment is used to remove drill cuttings from drilling mud, then the drilling mud can be reused, but the volume of drilling waste is not sufficiently reduced and disposal costs increase
Solution Approach 1:
The waste treatment process is divided into multiple centrifugation stages with increasing speeds. The first centrifuge separates heavy solids at lower speed, the second centrifuge separates lighter particles at medium speed, and the third centrifuge separates fine emulsion droplets at high speed. This segmented approach efficiently reduces waste volume while maintaining drilling mud quality for reuse.
Solution Approach 2:
The invention changes the operational parameters of centrifugation by using three different rotational speeds across three separate centrifuges. Each centrifuge operates at an optimized speed range to separate particles of different sizes and densities, maximizing waste reduction while preserving valuable drilling mud components.
2Object-affected harmful factors
If reserve pits are used to store drilling waste, then waste can be contained, but environmental concerns increase and disposal costs escalate
Solution Approach 1:
The invention converts the harmful waste mixture into separable components through multi-stage centrifugation. The separated drilling mud can be reused as a valuable resource, while the concentrated cuttings become a smaller, more manageable waste stream that is easier and less costly to dispose of environmentally.
Solution Approach 2:
The process recovers valuable drilling mud for reuse in subsequent drilling operations, discarding only the concentrated solid cuttings and minimal waste fluid. This selective recovery and discarding approach significantly reduces disposal volume and associated costs compared to treating the entire waste mixture.
3Productivity
If multiple centrifuges operating at different speeds are used, then separation efficiency is improved, but device complexity increases
Solution Approach 1:
The separation process is segmented into three distinct centrifugation units, each handling a specific size range of particles. This segmentation allows each centrifuge to be optimized for its specific function, achieving high overall separation efficiency while maintaining manageable complexity through modular design.
Solution Approach 2:
Each centrifuge in the sequence performs a specialized separation function that complements the others, creating a universal waste treatment system capable of handling multiple particle sizes and densities. The series configuration allows the system to process diverse waste compositions through a standardized multi-stage approach.
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 method enhances the separation of solids and liquids, reduces waste volume, and allows for the reuse of treated drilling fluids, while minimizing the need for costly chemical additives and enabling on-site disposal of solids, thus addressing environmental concerns and disposal costs.
Implementation Method 1
centrifuging the primarily fluids phase at a first speed and separating the primarily fluids phase into a first effluent and a first residual; centrifuging the first effluent at a second speed, the second speed higher than the first speed, and separating the first effluent into a second effluent and a second residual; and centrifuging the second effluent at a third speed, the third speed higher than the second speed
Implementation Method 2
adding a surfactant to the diluted return oil-based drilling fluid; and adding a polymer to the diluted return oil-based drilling fluid
Implementation Method 3
adding a polymer to the diluted return oil-based drilling fluid
Data Source
AI summary
A method of processing a return oil-based drilling fluid includes centrifuging a primarily fluids phase at a first speed and separating the primarily fluids phase into a first effluent and a first residual, centrifuging the first effluent at a second speed and separating the first effluent into a second effluent and a second residual, and centrifuging the second effluent at a third speed and separating the second effluent into a third effluent and a third residual. A surfactant, a polymer, combinations of surfactant(s) and polymer(s) and/or a wash water may be added to one or more of the return oil-based drilling fluid, the primarily fluids phase, the primarily solids phase, the first effluent, the second effluent, and the third effluent.