Smart Solids Control for Sensor-Based Shaker and Centrifuge Optimization
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Solution Overview
Problem
Existing material separation systems, such as vibratory screening machines and centrifuges, often rely on trial and error for optimizing operating parameters, leading to inefficiencies and suboptimal performance, particularly in the mining and oil and gas industries, where quantifying the effects of parameter changes and comparing drilling rigs across geographic regions is challenging.
Innovation Solution
A control system for a multi-component separation system comprising vibratory shakers and centrifuges that measures and adjusts operating parameters based on sensor data, using machine learning algorithms to optimize performance metrics like power consumption, material costs, and waste removal, and provides real-time feedback and recommendations for improving well performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If trial and error method is used to determine operating parameters, then system operation is simple, but optimization efficiency is poor and time-consuming
Solution Approach 1:
The system implements closed-loop feedback by continuously monitoring operating parameters and separation performance, then automatically adjusting parameters based on the feedback signals. Sensors detect variables like flow rate, pressure, and separation efficiency, feeding this data back to controllers that modify operating conditions in real-time, eliminating the need for time-consuming trial-and-error optimization.
Solution Approach 2:
The control system performs self-optimization by automatically adjusting its own operating parameters based on real-time performance data. The system monitors its separation efficiency and autonomously modifies parameters such as vibratory frequency, screen inclination, and centrifuge speed to maintain optimal operation without external intervention or manual tuning.
2Manufacturing precision
If multiple operating parameters are controlled to optimize separation quality, then separation performance improves, but system complexity increases
Solution Approach 1:
The control system is designed as a multi-functional integrated platform that simultaneously manages multiple operating parameters across different separation devices. A single control system coordinates vibratory shaker parameters (amplitude, frequency, screen angle), centrifuge speed, and flow rates, performing multiple optimization functions through one unified interface rather than requiring separate control systems for each parameter.
Solution Approach 2:
The system merges multiple control functions into a unified control architecture that manages all separation parameters through integrated sensors and actuators. By combining temperature control, pressure regulation, flow rate management, and separation parameter optimization into a single coordinated system, the patent reduces operational complexity while maintaining high separation quality through centralized control.
3Loss of energy
If real-time monitoring and adjustment of operating parameters is implemented, then operational costs are reduced, but measurement and control requirements increase
Solution Approach 1:
The system replaces manual measurement and adjustment mechanisms with automated electronic sensing and control systems. Electronic sensors continuously monitor parameters such as flow rate, pressure, temperature, and separation efficiency, substituting manual gauges and visual inspections with automated electronic detection that provides continuous precise measurement without increasing operational complexity.
Solution Approach 2:
The control system dynamically adjusts operating parameters based on real-time measurements to optimize energy efficiency. By continuously monitoring parameters like vibratory frequency, screen inclination angle, centrifuge rotational speed, and flow rate, the system automatically modifies these parameters to maintain optimal separation performance while minimizing energy consumption and operational costs.
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 system enhances the efficiency and cost-effectiveness of material separation by optimizing operating parameters, reducing waste, and providing data-driven insights for improved drilling operations.
Implementation Method 1
a vibratory shaker configured to separate a solid-liquid mixture into a first solids-containing component and a shaker effluent
Implementation Method 2
a centrifuge configured to separate the shaker effluent into a second solids-containing component and a centrifuge effluent
Data Source
AI summary
A material separation system is disclosed that may include a vibratory shaker, a centrifuge, a sensor, and/or a processor circuit. The vibratory shaker may be configured to separate a solid-liquid mixture into a first solids-containing component and a shaker effluent. The sensor may be configured to measure a property of one or more of the solid-liquid mixture, the first solids-containing component, the shaker effluent, and the second solids-containing. A well-performance analysis system may be configured to analyze mud reports of drilling rigs within a geographic basin to determine which rigs are performing inefficiently. The system may allow recommendations and send control signals to improve the efficiency of the solid-liquid separation system. The system may allow an operator to view agglomerated well performance data to identify which rigs are performing below a geographic basin baseline and make informed decisions to improve the functioning of a solid-liquid separation system associated with one or more drilling rigs.