Solid Invert Emulsion Drilling Additives for Logistics
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Solution Overview
Problem
Existing liquid drilling fluid additives face challenges at low temperatures, requiring carrier solvents that increase costs, logistical complexities, and environmental concerns, and are not suitable for wide temperature ranges or limited space applications like offshore platforms.
Innovation Solution
Converting liquid drilling fluid additives into free-flowing powdered forms by blending them with inert solid substrates at controlled temperatures, eliminating the need for solvents and improving handling and transportation logistics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid drilling fluid additives are used, then they provide good emulsifying and performance characteristics, but they require carrier solvents that increase costs, logistical complexities, and environmental concerns
Solution Approach 1:
The patent transforms liquid additives into solid powder form by changing the physical state parameter. This is achieved by blending liquid additives with inert solid carriers (such as diatomaceous earth, silica, or calcium carbonate) to create a solid composition that maintains the functional properties of the original liquid additive while eliminating the need for carrier solvents
Solution Approach 2:
The patent creates a composite material system consisting of the active liquid additive combined with an inert solid carrier. This composite solid composition allows the additive to be handled, stored, and transported in powder form while the inert carrier provides structural support and flowability, effectively resolving the logistical issues associated with liquid formulations
2Ease of operation
If liquid additives are used in cold environments, then they maintain flowability, but they require additional carrier solvents that increase environmental concerns and costs
Solution Approach 1:
The patent changes the physical state from liquid to solid, which fundamentally alters the temperature-dependent flow behavior. The solid powder formulation eliminates the pour point issue that plagues liquid additives in cold environments, as powders can be handled and transported regardless of temperature without requiring additional solvent carriers
3Ease of manufacture
If liquid additives are used, then they are easy to mix into drilling fluid, but they present transportation and storage challenges due to solvent requirements
Solution Approach 1:
The patent extracts and removes the carrier solvent component from the additive formulation, leaving only the essential active ingredients combined with an inert solid carrier. This extraction eliminates the bulk solvent volume that creates transportation and storage challenges, while the resulting solid powder can be easily dosed and mixed into drilling fluids
4Productivity
If solid powdered additives are used, then transportation and storage are simplified, but they must maintain flowability across temperature conditions
Solution Approach 1:
The patent uses inert solid carriers with specific physical properties (such as diatomaceous earth, silica, or calcium carbonate) that provide excellent flow characteristics. These carriers are selected and processed to ensure the composite powder maintains consistent flowability across a wide temperature range, enabling efficient transportation and storage while maintaining operational reliability
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 powdered additives enhance drilling fluid performance, stability, and safety by maintaining flowability across temperature conditions, reducing solvent use, and simplifying logistics and environmental impact.
Implementation Method 1
contacting (spraying or mixing) liquid invert emulsion additives at controlled temperature with a blend of inert fillers in specific proportions
Data Source
AI summary
Solid free-flowing powdered drilling fluid additives compositions having desirable emulsifying, wetting and other performance characteristics are described. Their method of preparation and their use in oil-based drilling fluid compositions are described. The manufacturing process comprises of contacting (spraying or mixing) different types of liquid invert emulsion additives individually at elevated temperature with a blend of inert fillers in specific proportions and of particular particle size in a blender for a specified time. The solid powdered additives thus obtained are controlled pulverized to obtain the final particle size which does not alter the performance of each individual additive. The solid invert emulsion additives obtained are added to drilling fluid compositions yielding drilling muds with improved performance. Solid powdered additives compositions greatly reduce transportation costs and simplify the logistics and environmental concerns associated with shipping large volumes of solvent-containing liquids and overcome the pour point issues associated with liquid additives.