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Hydrocyclones
January 1998
Page 1 of 16
Hydrocyclones
1 Introduction .........................................................................................................................2
2 Principle of Operation.........................................................................................................2
3 Performance Parameters....................................................................................................4
3.1 Cone Diameter ..............................................................................................................5
3.2 Plastic Viscosity.............................................................................................................6
3.3 Feed Head.....................................................................................................................6
3.4 Underflow Diameter .......................................................................................................8
3.4.1 Spray Discharge...................................................................................................8
3.4.2 Rope Discharge ...................................................................................................8
4 Desanders.......................................................................................................................... 10
4.1 Recommended Desanders .......................................................................................... 10
5 Desilters............................................................................................................................. 10
5.1.1 Recommended Desilters.................................................................................... 12
7 Operating Guidelines........................................................................................................ 13
8 Troubleshooting................................................................................................................ 15
9 Summary............................................................................................................................ 16
FIGURES
Fig. 1.
Fig. 2.
Fig. 3.
Fig. 4.
Fig. 5.
CONFIDENTIAL
Section 600
January 1998
Hydrocyclones
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Schlumberger
Dowell
1 Introduction
Although the shale shaker is considered the primary solids removal device
on the rig, hydrocyclones are a cost-effective method of removing many of
the fine solids missed by the shaker in unweighted muds. In some
formations, the solids are too fine for the shakers to remove; hydrocyclones
must be relied upon to remove the majority of the solids. In these instances,
the shaker protects the hydrocyclones from oversize particles which may
cause plugging. Because the hydrocyclone has no moving parts, it can be a
very reliable piece of solids removal equipment when correctly operated and
maintained.
2 Principle of Operation
Think of a tornado inside a bottle and you have a rudimentary idea of how a
hydrocyclone operates. Fig. 1 illustrates the basic concepts of hydrocyclone
operating principles. Mud enters the feed chamber tangentially at a high
velocity provided by pump pressure. As the mud spirals downward through
the conical section, centrifugal force and inertia cause the solids to gravitate
towards the wall. The solids settle according to their mass, a function of both
density and volume. Since the density range of drilled solids is normally quite
narrow, size has the largest influence on settling. The largest particles will
settle preferentially.
As the cone narrows, the innermost layers of fluid turn back toward the
overflow creating a low pressure vortex in the center of the cone. This low
pressure area causes air to be pulled in from the underflow outlet. Correctlyoperating cones should exhibit a slight vacuum at the cone underflow. The
air and cleaned fluid then report to the overflow through the vortex finder.
The purpose of the vortex finder is to prevent some of the feed mud from
short-circuiting directly into the overflow.
Solids with sufficient mass cannot make the turn back towards the overflow
because of their momentum and continue out the underflow. Maximum cone
wear usually occurs at or near the underflow exit, where velocities are the
highest. In cones having a balanced design whole mud losses out the
underflow are slight. Only the solids and bound liquid will report to the
underflow. If the solids are too fine to be removed by the cyclone, no liquid
should be discharged. Unbalanced hydrocyclones will discharge mud
without the presence of solids in the mud.
CONFIDENTIAL
Section 600
SOLIDS CONTROL HANDBOOK
Schlumberger
Dowell
Hydrocyclones
January 1998
Page 3 of 16
CONFIDENTIAL
Section 600
January 1998
Hydrocyclones
Page 4 of 16
Schlumberger
Dowell
Because fine solids have more specific area (surface area per unit volume)
than large particles, the amount of liquid removed per pound of solids is
higher with fine solids than with coarse solids. Therefore, the difference
between the feed and underflow density is not a reliable indicator of
hydrocyclone performance. Fig. 2 shows the relationship between underflow
density and cone efficiency for an unweighted mud. Observe how overall
cone efficiency decreases as underflow density increases.
3 Performance Parameters
Oilfield hydrocyclones are available in cone diameters ranging from 1 in. to
12 in. Hydrocyclones were first used to reduce the API sand content (solids
larger than 74 microns). Hence the term desander. By convention,
hydrocyclones with diameters of 6 in. or larger are labeled as desanders.
As the benefits of smaller, more efficient hydrocyclones became apparent,
the term desilter was coined to reflect the smaller silt-sized particles these
CONFIDENTIAL
Section 600
SOLIDS CONTROL HANDBOOK
Schlumberger
Dowell
January 1998
Hydrocyclones
Page 5 of 16
smaller cones could remove. Hydrocyclones with diameters of less than 5 in.
are usually called desilters. However, these terms are not based on any
particular performance standard. Separation efficiency varies widely among
hydrocyclones classified as desilters.
Amoco Production Research has investigated the operational and geometric
design factors affecting hydrocyclone performance. Over 500 tests were
conducted using bentonite and ground silica slurries. The effect of these
variables on cone performance are summarized in Table 1. Selected
variables are discussed below.
Minor Effect
Cone Diameter
Yield Point
Plastic Viscosity
Inlet Type
Feed Head
Cylinder Length
Cone Angle
Underflow Diameter
Cone Capacity,
gpm @ 75 ft head
20
3 (Amoco)
50
50
75
100
125
10
500
12
500
CONFIDENTIAL
Section 600
SOLIDS CONTROL HANDBOOK
January 1998
Hydrocyclones
Page 6 of 16
Schlumberger
Dowell
CONFIDENTIAL
Section 600
SOLIDS CONTROL HANDBOOK
Schlumberger
Dowell
Hydrocyclones
January 1998
Page 7 of 16
Section 600
January 1998
Hydrocyclones
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Schlumberger
Dowell
CONFIDENTIAL
Section 600
SOLIDS CONTROL HANDBOOK
Schlumberger
Dowell
Hydrocyclones
January 1998
Page 9 of 16
Section 600
January 1998
Hydrocyclones
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Schlumberger
Dowell
4 Desanders
With the improved fine screening capability of shale shakers, the need for
desanders has diminished. The primary role of the desander should be to
reduce solids loading to the desilter cones in unweighted water-based muds.
Desanders are recommended when the shakers are unable to screen down
to 100 microns (140 mesh U.S. Sieve), or when large hole diameters are
drilled at 100 ft/hr or faster.
Considering that 75 microns is probably the best performance that can be
expected from a desander cone, one might conclude they would have an
application in weighted muds as well. This is generally not the case.
Hydrocyclones separate solids based on their mass and the density
difference between the solid particles and the fluid. Since barite's specific
gravity is substantially higher than drilled solids, it will tend to be
preferentially removed by hydrocyclones. Also, as shown in Fig. 3, the higher
plastic viscosities normally associated with weighted muds will greatly
reduce the desander's efficiency.
Desander underflows are normally quite dry and abrasive and should be
discarded directly. When processing expensive muds, the underflow may be
routed to a centrifuge to recover the liquid, provided the solids are not
abrasive and the underflow is diluted with whole mud before centrifuging.
Another option is to screen the desander underflow down to 200 mesh
(74 microns) to remove the larger, abrasive solids before processing with the
centrifuge.
5 Desilters
Desilters should be used on all unweighted, water-based muds. They are not
recommended for use on weighted muds since barite will be lost. When
using expensive muds, process the desilter underflow with a centrifuge.
APR has developed a 3-in. hydrocyclone which is up to 50% more efficient
than some existing oilfield desilters. Fig. 6 shows the improvement in
performance over a typical 50 gpm, 4-in. cone.
The Amoco-designed, 3-in. cone is not a balanced cone; it will discharge
fluid even when no solids are present. In many cases, this cone's underflow
should be processed by a centrifuge. The economics of centrifuging the
underflow should be checked using the SECOP program. Estimated discard
rates per cone are plotted as a function of underflow diameter in Fig. 7. Size
CONFIDENTIAL
Section 600
SOLIDS CONTROL HANDBOOK
Schlumberger
Dowell
Hydrocyclones
January 1998
Page 11 of 16
the centrifuge for the calculated underflow rate. Run the cones intermittently
on unweighted mud when no centrifuge is available.
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Hydrocyclones
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Schlumberger
Dowell
Since the underflow opening of the 3-in. cone is smaller than a typical 4-in.
cone, it is more susceptible to plugging. Ensure that all of the mud is finescreened or run an efficient, properly installed desander ahead of the 3-in.
cones.
Desilters can also be used in certain weighted mud applications to reduce
the barite loading to the centrifuge thereby improving its efficiency in barite
recovery mode (see Chapter 8, Centrifuges). Here, the underflow of the
desilter cones are returned to the active system and the overflow is fed to the
Barite Recovery centrifuge. The upper limit for this application is generally
limited to mud densities of 15 ppg or less due to viscosity and solids content
limitations or cone performance. Use only enough 3-in. hydrocyclones to
match the feed rate to the centrifuge. Blank off the remaining cones. Use the
largest underflow nozzle diameter available to prevent plugging or rope flow.
This equation does not consider solids loading. If penetration rates in excess
of 100 ft/hr are anticipated, the number of cones should be increased.
Specific head requirements and flow capacities for each cone are listed in
Appendix F, Equipment Specifications. Table 2 may be used to estimate the
flow capacity of each cone operating at 75 ft of head.
Hydrocyclones are normally provided in banks of 8, 10, 12 and 16 cones per
manifold (Fig. 8). Increase the required number of cones to one of these
standard manifold sizes.
CONFIDENTIAL
Section 600
SOLIDS CONTROL HANDBOOK
Schlumberger
Dowell
Hydrocyclones
January 1998
Page 13 of 16
7 Operating Guidelines
1.
2.
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Section 600
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Hydrocyclones
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3.
4.
5.
Spray discharge at the cone underflow is desired. Rope flow will cause
premature wear and is less efficient. Rope flow indicates that either
more hydrocyclones or finer shaker screens are required or that the
underflow apex size is too small.
6.
7.
8.
9.
CONFIDENTIAL
Section 600
SOLIDS CONTROL HANDBOOK
Schlumberger
Dowell
January 1998
Hydrocyclones
Page 15 of 16
8 Troubleshooting
Symptoms
Probable Causes
not
Cone discharge
varying feed head.
is
unsteady,
opening,
bypassed
Cavitation in the pump - flow rate is too high need larger lines.
Suction line blockage - check for obstructions.
of
CONFIDENTIAL
Section 600
January 1998
Page 16 of 16
Hydrocyclones
Schlumberger
Dowell
9 Summary
Cone diameter, cone angle, underflow diameter, feed head, and plastic
viscosity have the largest effect on hydrocyclone performance.
CONFIDENTIAL