Rotating Gas Separator for Drilling Fluid Recycling
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Solution Overview
Problem
Existing gas separators for drilling fluid recycling are inefficient, lack commercial viability, difficult to install in limited well-bore spaces, and fail to protect pumping equipment from corrosive and flammable gases.
Innovation Solution
A rotating cylindrical gas separator with hollow bore and tangentially aligned gas ejection ports that utilize centrifugal force to enhance gas separation, allowing gases to expand and generate rotational torque, separating gases from drilling fluid while maintaining fluid flow for effective equipment protection and efficient recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional gas separators are used, then gas separation is performed, but separation efficiency is insufficient and equipment cannot be protected from corrosive gases
Solution Approach 1:
The patent extracts and removes gases (including corrosive gases like sulfur and nitrogen) from the drilling fluid stream before the fluid reaches pumping equipment. The gas separator isolates the gas removal function, extracting harmful gases from the continuous drilling fluid flow to protect downstream equipment from corrosion and cavitation damage.
Solution Approach 2:
The patent converts the harmful effect of gas presence (which causes corrosion and cavitation) into a useful separation process. By designing the separator to efficiently remove gases that would otherwise harm equipment, the harmful factor becomes the target of a protective separation mechanism, transforming the problem into a solution.
2Reliability
If gas separators are installed in well-bore, then gas separation is achieved, but available installation space is limited
Solution Approach 1:
The gas separator is designed as a modular assembly with distinct functional components: a cylindrical separator body, hollow bore, gas ejection ports, and support structures. This segmentation allows the separator to be compact yet functional, fitting within limited well-bore spaces while maintaining effective gas separation capability through optimized component arrangement.
Solution Approach 2:
The patent utilizes the hollow bore extending through the cylindrical separator along its longitudinal axis, creating a three-dimensional flow path that maximizes separation efficiency within a compact volume. The tangential alignment of gas ejection ports with the hollow bore creates rotational flow patterns that enhance separation without increasing overall separator dimensions.
3Productivity
If drilling fluid is recycled, then fluid reuse is achieved, but trapped gases cause cavitation and gas-lock in pumping equipment
Solution Approach 1:
The gas separator is positioned in the drilling fluid circulation system to remove trapped gases from the drilling fluid before the fluid enters pumping equipment. This preliminary gas removal action prevents cavitation and gas-lock conditions that would otherwise occur during fluid recycling, ensuring reliable pump operation while maintaining continuous drilling fluid reuse.
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 solution effectively removes corrosive gases like sulfur and nitrogen, preventing equipment corrosion and cavitation, maintaining hydrostatic pressure, and ensuring the safe reuse of drilling fluid by enhancing gas separation efficiency and protecting pumping equipment.
Implementation Method 1
The ports include channels having a narrower cross-section towards the hollow bore and a wider cross-section towards exit of the fluid ejection port, to permit gas expansion on exit
Implementation Method 2
the cylindrical separator, which in turn generates momentum (sometimes called 'centrifugal force') on the drilling fluid in the hollow bore, and forces more gas trapped in the drilling fluid towards the fluid ejection ports
Data Source
AI summary
A gas-separator for separating trapped gases from drilling fluids retrieved from a well-bore being drilled is disclosed. The gas-separator includes a cylindrical separator which is capable of rotating on its longitudinal axis when fluid and gases flow out through fluid ejection ports, which access the center bore of the cylindrical separator. The fluid ejection ports have a narrower cross-section towards the center bore and a wider cross-section at the opposite end, and are preferably aligned substantially tangentially with periphery of center bore, such that outflow of drilling fluid (and gases) from the center bore through the ejection ports induces a rotational torque on the cylindrical separator. Spinning of cylindrical separator enhances the gas-separation effect.