Vibratory Drilling Fluid Separator Using Excitation Element
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Solution Overview
Problem
Existing methods for removing particulate matter from drilling fluids in subterranean operations are inefficient, costly, and energy-intensive, with issues such as slow centrifugation, clogged filters, and base oil breakdown in thermal treatments.
Innovation Solution
A vibratory separation apparatus and method that uses a fluid container with an excitation element to impart a pre-determined vibratory force based on rheological characteristics, particle size, and density, separating drilling or completion fluids into base and particulate portions using a vibrating probe or motor, and an inclined pipe to facilitate separation via the Boycott effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If centrifugation is used to remove particulate matter, then separation is achieved, but the process becomes slow and requires frequent maintenance
Solution Approach 1:
The patent applies vibratory motion through an excitation element (such as a vibrating screen or shaker) to accelerate the separation of particulate matter from drilling fluid. The vibration causes particles to move more rapidly through the separation medium, significantly increasing separation speed compared to static centrifugation while maintaining effective particle removal
2Reliability
If physical filtration is used to remove particulate matter, then separation is achieved, but filter media becomes easily clogged requiring replacement and cleaning
Solution Approach 1:
The patent employs porous separation media with specifically engineered pore sizes and distributions that allow particulate matter to be captured while maintaining high fluid flow rates. The porous structure prevents clogging by allowing particles to be trapped on the surface or within the pore network without blocking entire flow paths, reducing maintenance requirements
Solution Approach 2:
Vibratory motion is applied to the filtration system to prevent particle accumulation and clogging of filter media. The vibration keeps particles moving and prevents them from settling and blocking filter pores, extending filter life and reducing cleaning frequency
3Reliability
If thermal treatment is used to remove particulate matter, then separation is achieved, but energy consumption increases and base oils break down
Solution Approach 1:
The patent uses vibratory energy instead of thermal energy to achieve separation. The mechanical vibration provides sufficient energy to move particles through the separation medium and facilitate phase separation without heating the drilling fluid, thereby avoiding base oil breakdown and significantly reducing energy consumption compared to thermal treatment methods
4Reliability
If existing separation methods are used, then particulate removal is achieved, but cost increases due to maintenance and energy requirements
Solution Approach 1:
The vibratory separation system provides an energy-efficient alternative to centrifugation, filtration, and thermal treatment. By using mechanical vibration to drive separation, the system reduces energy consumption and associated operational costs while maintaining effective particulate removal and base fluid recovery
Solution Approach 2:
The separation apparatus is designed to operate continuously with minimal intervention. The vibratory mechanism maintains separation efficiency automatically, and the system requires less frequent maintenance compared to centrifuges and filters, reducing both energy loss and operational costs over time
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 solution provides a cost-effective, efficient method for separating drilling fluids, restoring desired rheological properties, and recovering base fluids, reducing maintenance and energy costs while minimizing additive breakdown.
Implementation Method 1
an excitation element, wherein the excitation element is operable to impart a pre-determined vibratory force on the drilling or completion fluid
Implementation Method 2
an inclined pipe to facilitate separation via the Boycott effect
Data Source
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AI summary
A method and apparatus for separating drilling or completion fluids is described. The apparatus may include a fluid container that is operable to at least temporarily contain a drilling or completion fluid. The fluid container may have an inlet port and at least one outlet port. The apparatus may further include an excitation element. The excitation element may be operable to impart a pre-determined vibratory force on the drilling or completion fluid within the fluid container.