Shaftless Auger Air Drilling Solids Control System
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Solution Overview
Problem
Current air drilling solids control systems are inadequate in efficiently separating solids and gas from fluids in hydrocarbon wells, leading to incomplete separation and potential operational inefficiencies.
Innovation Solution
The system employs a V-shaped tank with a shaftless auger, hydrocyclone units, a diffuser enclosure with perforated air diffuser baffles, and a linear shaker to process the slurry, effectively separating solids and gas through a series of conduits and baffles, allowing for the dewatering and disposal of solids while recycling clean fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional solids control system is used, then the system structure is simple, but the separation efficiency of solids and gas from fluid is insufficient
Solution Approach 1:
The system is divided into multiple functional segments: a V-shaped compartment for initial separation, hydrocyclone units for centrifugal separation of solids, a diffuser enclosure with perforated baffles for gas-liquid separation, and a linear shaker for dewatering. Each segment performs a specific separation function, collectively achieving high overall separation efficiency while maintaining modular complexity management.
Solution Approach 2:
The system employs nested structural arrangements where the shaftless auger is positioned within the V-shaped compartment, hydrocyclone units are integrated with the linear shaker, and perforated baffles are nested within the diffuser enclosure. This nesting allows multiple separation mechanisms to occupy compact space while maintaining independent functionality.
2Manufacturing precision
If multiple separation devices are added to improve separation efficiency, then the separation performance improves, but the device complexity increases
Solution Approach 1:
Multiple separation functions are merged into integrated assemblies: the shaftless auger combines with the V-shaped compartment for solid-liquid separation, hydrocyclone units are combined with the linear shaker for simultaneous centrifugal separation and dewatering, and perforated baffles are integrated into the diffuser enclosure for combined gas-liquid separation. This merging reduces the number of independent components while maintaining high separation efficiency.
3Productivity
If a shaftless auger is used instead of a conventional auger, then the system can handle slurry more effectively, but the device complexity increases
Solution Approach 1:
The central shaft and bearing assembly are extracted from the conventional auger design, leaving only the helical flight elements mounted directly on the drive mechanism. This shaftless configuration eliminates complex bearing arrangements and seal requirements, simplifying maintenance while improving slurry handling capability by preventing mechanical interference with the slurry flow.
4Productivity
If hydrocyclone units are integrated with a linear shaker, then dewatering efficiency improves, but the device complexity increases
Solution Approach 1:
The hydrocyclone units are directly integrated with the linear shaker assembly, where the underflow from hydrocyclones feeds directly onto the shaker screen. This merging creates a unified solids-liquid separation system that performs centrifugal separation followed by vibrational dewatering in a single integrated unit, improving dewatering efficiency while reducing the number of separate components.
5Manufacturing precision
If perforated air diffuser baffles are added to the diffuser enclosure, then gas separation efficiency improves, but the device complexity increases
Solution Approach 1:
Perforated air diffuser baffles are installed within the diffuser enclosure to create a porous structure that allows gas bubbles to rise through the liquid while preventing liquid carryover. The perforated design provides numerous small pathways for gas separation, significantly improving gas-liquid separation efficiency while maintaining a relatively simple baffle structure that can be fabricated from standard materials.
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 configuration enhances the separation of solids and gas, resulting in efficient dewatering and disposal of solids, while ensuring the clean fluid is recycled, thereby improving operational efficiency and reducing waste.
Implementation Method 1
a shaftless auger operatively positioned on the bottom of the compartment, the shaftless auger configured for rotation to cause a second slurry containing first solids to move to the front section of the compartment
Implementation Method 2
a suction pump in fluid communication with a first conduit, the first conduit having an inlet and an outlet, the inlet of the first conduit being operatively positioned within the compartment at its front section adjacent the shaftless auger, the suction pump configured to pump the second slurry containing the first solids through the first conduit
Implementation Method 3
one or more hydrocyclone units in fluid communication with the outlet of the first conduit, the one or more hydrocyclone units receiving and processing the second slurry to produce an underflow comprising the first solids and an overflow comprising a first clean fluid
Implementation Method 4
a linear shaker operatively positioned underneath the one or more hydrocyclone units, the linear shaker configured to receive the underflow from the one or more hydrocyclone units and third solids from the bar screen causing a dewatering of the first solids and of the third solids
Implementation Method 5
one or more perforated air diffuser baffles, wherein the diffuser enclosure receives on the target plate the third slurry from the fourth conduit, the target plate dispersing the third slurry onto the bar screen passing a fourth slurry through grates in the bar screen leaving third solids from the third slurry on a top surface of the bar screen, wherein a first portion of entrained gas from the fourth slurry passes up through the one or more perforated air diffuser baffles
Data Source
AI summary
A system for separating solids from a first slurry mixture recovered from a hydrocarbon well. The system includes a V-shaped tank and one or more second mixing tanks for accumulating a slurry of fine particles from an overflow from the V-shaped tank. A shaftless auger moves solids to a conduit fluidly connected to hydrocyclones. The overflow of the hydrocyclones is mixed with the first flurry coming from a rig flow line and is discharged over a target plate and bar screen. Air is released from the mixture through one or more perforated baffles. Solids fall from the bar screen onto a shaker, which dewaters these solids as well as solids from an underflow from the hydrocyclones.