Screw Geometry for Thermal Extraction of Drilling Waste Fluids
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Solution Overview
Problem
Current methods for disposing of spent drilling fluids are inefficient, as they often require high-energy processes that can degrade the oil, making it difficult to reuse, and mechanical means are ineffective for removing smaller cutting particles, leading to unfit drilling fluids.
Innovation Solution
The use of a thermal extraction chamber with a unique screw geometry that enhances mixing capabilities and reduces energy consumption by achieving higher throughputs with lower RPMs, allowing for the separation and recovery of oil from spent drilling fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If high temperature calcination is used to vaporize and recover oil from spent drilling fluid, then oil recovery is achieved, but energy consumption increases and the oil may be cracked or degraded
Solution Approach 1:
The patent changes the temperature parameter from high temperature calcination to lower temperature thermal extraction, enabling oil recovery without cracking or degradation while reducing energy consumption
Solution Approach 2:
The patent replaces the mechanical/high-thermal process of calcination with a thermal extraction process using a screw extruder that operates at lower temperatures, achieving oil separation through controlled thermal extraction rather than high-temperature vaporization
2Loss of substance
If normal mechanical means are used to remove cuttings from drilling fluid, then larger cuttings are removed, but smaller cutting particles cannot be effectively removed
Solution Approach 1:
The patent replaces mechanical filtration methods with thermal extraction using a screw extruder, which can effectively separate and remove both large and small cutting particles through thermal processing and phase separation
Solution Approach 2:
The patent utilizes phase transitions through thermal extraction to separate cuttings from the drilling fluid, enabling effective removal of fine particles that mechanical means cannot handle
3Productivity
If higher RPMs are used in thermal extraction, then processing speed increases, but energy consumption increases
Solution Approach 1:
The patent employs a screw extruder with optimized geometry that achieves high throughput at lower RPMs through improved mixing and thermal extraction efficiency, reducing energy consumption while maintaining productivity
Solution Approach 2:
The patent changes the operational parameters by using lower RPMs with an optimized screw design, achieving the same or better throughput while consuming less energy
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
This approach effectively recovers usable oil from spent drilling fluids, improving the efficiency of the process and reducing energy costs while effectively managing waste, thereby enhancing the sustainability of drilling operations.
Implementation Method 1
The thermal extraction chamber may comprise a first screw and a second screw disposed within the thermal extraction chamber
Implementation Method 2
The screw geometry of the present disclosure may provide high mixing capabilities
Data Source
AI summary
Provided are systems and methods that relate to separating drilling waste fluids. A method for separating a drilling waste fluid, the method comprising: introducing the drilling waste fluid into a thermal extraction chamber; allowing the drilling waste fluid to flow longitudinally along two screws disposed within the thermal extraction chamber, wherein each screw comprises a shaft, a first flite segment, and a first kneading block sequence; allowing the geometry of the screws to separate drilling waste fluid into evaporated fluid and solids; removing evaporated fluid through a first outlet port; removing solids through a second outlet port. A thermal extraction chamber for separating drilling waste fluids, wherein the thermal extraction chamber comprises: barrel; first screw; second screw, wherein first screw and second screw comprise identical profiles, wherein first screw and second screw comprise shaft, first flight segment, and first kneading block sequence; inlet port; first outlet port; second outlet port.