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Mixing minerals, clays and thickeners

to manufacture drilling fluids using the Fristam Powder Mixer

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Introduction to the application and industry overview

Manufacturers producing drilling fluids, mineral slurries, and industrial mud systems must achieve reliable dispersion of thickeners, clays, and solid additives into both water-based and oil-based liquid phases. Uniform incorporation is essential to create stable suspensions with predictable rheology, consistent viscosity, and dependable drilling performance.

Inadequate powder-into-liquid mixing can result in poor suspension stability, uneven viscosity, and reduced operational efficiency during on-shore and off-shore drilling.

This case study demonstrates how a Fristam Powder Mixer with integrated high-shear blending enabled effective dissolution and dispersion of drilling-fluid components, delivering stable, homogeneous fluids and scalable industrial production performance.

Customer brief

A global producer of drilling fluids and mud systems required a dependable method for dissolving and dispersing multiple semi-solid and powdered ingredients into both:

  • Water-based drilling fluids
  • Oil-based drilling fluids

Formulations included thickeners, minerals, and bentonite, all of which must be uniformly incorporated to achieve:

  • Stable suspension behaviour
  • Consistent rheological performance
  • Reliable drilling functionality in demanding environments

The customer’s objective was to ensure repeatable product quality across different fluid types using high-shear powder-into-liquid processing capable of producing stable industrial suspensions at scale.

Previously unsuccessful methods

Prior to implementing the Fristam solution, the customer used a Venturi hopper powder-induction system. While suitable for basic solids induction into liquid, the Venturi method did not provide sufficient high-shear energy for immediate hydration and dispersion.

As a result, the process relied heavily on extended downstream circulation, which led to:

  • Longer batch preparation times
  • Inconsistent fluid homogeneity
  • Incomplete breakdown of minerals and thickeners
  • Unstable suspensions and uneven viscosity
  • Reduced functional performance during drilling operations

These limitations highlighted the need for controlled inline high-shear mixing capable of producing uniform, stable drilling fluids in a single continuous process.

Previously unsuccessful methods

Fristam’s solution

Fristam implemented a large-scale industrial powder-mixing system combining:

  • Fristam FZ25 self-priming liquid-ring pump for reliable liquid induction
  • Fristam FS Shear Blender with 3552 rotor-stator configuration for intensive high-shear dispersion

This configuration enabled:

  • Efficient powder incorporation into both water- and oil-based systems
  • Rapid wetting of minerals, clays, and thickeners in a closed mixing process
  • Intensive rotor-stator shear to produce fully homogeneous drilling fluids and slurries

Trial set-up

1. Thickeners, minerals, and bentonite were introduced into the mixer hopper at controlled intervals while the liquid base was drawn in by the Fristam FZ25, enabling instant powder wetting within the enclosed system when the wet and dry ingredients first met.

2. The pre-mixed slurry passed through the integrated FS high-shear blending stage, ensuring full dispersion of wet and dry ingredients into a uniform, homogeneous fluid.

3. The installed unit operated within an industrial environmental centre for drilling-fluid preparation, with successful performance leading to scale-up and purchase of a larger high-power shear system for production use.

Fristam’s solution

A successful outcome with the Fristam Powder Mixer

The Fristam powder-mixing system produced drilling fluids with stable suspension behaviour and consistent product quality.

Following successful operation, the customer expanded the installation to a larger high-shear production unit, confirming the system’s suitability for industrial-scale drilling-fluid manufacture.

Do you have any questions so far?

Please don’t hesitate to contact our customer support. We would be happy to answer any questions you may have about our case studies or similar challenges, and we will provide effective solutions tailored to your needs.

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Sustainability benefits

Sustainability benefits

  • Efficient dispersion supporting optimal raw-material utilisation
  • Stable fluids reducing reprocessing, correction, and waste
Financial benefits

Financial benefits

  • Successful scale-up from trial to full production system
  • Increased operational confidence through consistent fluid quality
  • Faster production compared with previous mixing approach
  • Reduced labour requirement, enabling operation by a single person instead of multiple operators
Other benefits

Other benefits

  • High-shear capability suitable for multiple drilling-fluid formulations
  • Industrial-scale installation supporting on-shore and off-shore operations
  • Improved health and safety due to lower operating height and reduced physical strain on workers
Process / Product quality benefits

Process / Product quality benefits

  • Reliable dispersion of thickeners, minerals, and bentonite
  • Stable suspension behaviour in water- and oil-based drilling fluids
  • Consistent fluid quality for demanding drilling environments
  • Simple, repeatable process delivering uniform batch production

Frequently Asked Questions

Controlled inline powder-into-liquid mixing with sufficient high shear is required to achieve immediate wetting, full hydration, and uniform dispersion of solids. This prevents agglomerates and supports stable suspension behaviour across both water-based and oil-based drilling fluids.

In addition to mixing & blending technology – check out Fristam’s full range of pumping technologies suitable for the chemical industry.

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