Spray Dried Emulsifier Compositions for Drilling Fluids
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for emulsifier compositions with desirable emulsifying properties for invert emulsions used in oil well drilling that can be formulated with minimal solvent and additives, reducing transportation costs and environmental concerns, and providing flexibility in choosing a solvent system.
Innovation Solution
The development of spray dried emulsifier compositions comprising alkali or alkaline earth metal salts of carboxylic acid terminated fatty amine condensates or modified tall oils, which are easily incorporated into various oil bases, offering efficient dispersion and solubilization, and can be tailored for specific drilling operations, minimizing hazardous chemical use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional liquid emulsifier formulations are used, then emulsifying properties are achieved, but transportation costs increase and handling becomes complex due to high solvent content
Solution Approach 1:
The patent applies phase transition by converting the emulsifier from liquid phase to solid phase through spray drying. The liquid emulsifier composition is atomized into droplets that rapidly evaporate solvent, leaving solid particulate emulsifier. This phase change eliminates the need to transport large volumes of solvent, reducing transportation costs and improving ease of manufacture.
Solution Approach 2:
The patent changes the physical state parameter of the emulsifier from liquid to solid form. By controlling the spray drying parameters (temperature, atomization rate, drying time), the emulsifier is transformed into a free-flowing solid powder that can be easily stored and transported without the bulk and handling requirements of liquid formulations.
2Ease of manufacture
If spray dried emulsifier compositions are used, then transportation costs are reduced and handling is simplified, but emulsifying performance must be maintained
Solution Approach 1:
The patent applies preliminary action by pre-forming the emulsifier in a stable solid particulate form that preserves all emulsifying properties. The spray drying process is designed to maintain the molecular structure and surfactant characteristics of the original liquid emulsifier, ensuring that when added to drilling fluid, it performs equally well or better than the liquid formulation.
Solution Approach 2:
The controlled phase transition from liquid to solid through spray drying preserves the emulsifying performance while improving handling. The rapid evaporation of solvent during spray drying prevents degradation of the emulsifier molecules, maintaining their effectiveness in forming stable invert emulsions in drilling fluids.
3Reliability
If traditional emulsifier formulations are used, then emulsifying properties are achieved, but solvent and additive removal is required adding process complexity
Solution Approach 1:
The patent applies extraction by removing the solvent and additives from the emulsifier formulation through spray drying. The process extracts only the necessary water from the emulsifier composition, leaving behind a concentrated solid emulsifier that requires no further removal steps. This eliminates the complexity of multiple purification and drying steps required in traditional formulation methods.
4Reliability
If liquid emulsifiers are used in drilling fluids, then emulsifying performance is achieved, but environmental concerns and hazardous chemical use increase
Solution Approach 1:
The phase transition to solid form through spray drying reduces environmental impact by eliminating the need for large volumes of volatile organic solvents. The solid particulate emulsifier can be transported and stored without containment requirements for liquid solvents, reducing the risk of spills and environmental contamination while maintaining emulsifying performance.
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 spray dried emulsifier compositions reduce transportation costs, simplify logistics and handling, and provide stable invert emulsions with improved emulsifying and wetting characteristics, allowing for flexible solvent selection and reduced use of hazardous chemicals, enhancing drilling fluid performance.
Implementation Method 1
offering efficient dispersion and solubilization
Implementation Method 2
offering efficient dispersion and solubilization
Implementation Method 3
spray dried compositions
Data Source
AI summary
Spray dried emulsifier compositions are described, which have desirable emulsifying and wetting characteristics. Among other advantages, the solid particulate emulsifier compositions greatly reduce transportation costs and simplify the logistics and environmental concerns associated with shipping large volumes of solvent-containing liquids. The emulsifier comprises (1) a carboxylic acid terminated fatty amine condensate or (2) a modified tall oil or (3) a blend of (1) and (2) that is converted to its alkali or alkaline earth metal salt and spray dried.