A production device and method for a fluid loss additive for cementing

Abstract

The application relates to the technical field of reaction kettles, and discloses a fluid loss additive production device for well cementing and a production method thereof. The fluid loss additive production device for well cementing comprises a reaction modification unit, the reaction modification unit comprises a reaction kettle main body, a stirring mechanism, an online monitoring mechanism and a control end, the stirring mechanism comprises an upper stirring assembly and a bottom stirring assembly arranged at the lower end of the upper stirring assembly, and the upper stirring assembly comprises a driving motor, a stirring shaft, a lifting base, a plurality of stirring blades and an angle adjusting piece. The stirring mechanism is designed, the layered stirring structure form of the bottom fixed stirring piece and the upper adjustable stirring piece is adopted, and the self-adaptive adjusting algorithm is matched, so that the real-time dynamic automatic adjustment of the stirring height and the angle is realized, the dynamic change of the material parameters in the whole period of the fluid loss additive synthesis can be adapted, the uniformity of the material mixing in the kettle is improved, and the problems of kettle bottom deposition, local overtemperature and uneven mixing are solved.

Description

Technical Field

[0001] This invention relates to the field of fluid loss reducing agent production technology, and more specifically, to a production apparatus and method for a cementing fluid loss reducing agent. Background Technology

[0002] Cementing is a crucial step in the construction of oil and gas wells, aiming to isolate the formation, support the casing, and prevent formation fluid cross-contamination. During cementing, cement slurry is injected into the annulus between the casing and the formation. To control the slurry's fluid loss, a fluid loss reducer is typically added.

[0003] Currently, the production of water loss control agents typically involves multiple processes, including raw material metering, polymerization / modification reaction, neutralization and maturation, drying, pulverization, and packaging. Among these, the reaction modification unit is the core step that determines the final performance of the water loss control agent. This unit usually uses a reaction vessel as the main equipment, and a stirring mechanism is used to achieve uniform material mixing, heat transfer, and reaction.

[0004] However, the stirring mechanisms in existing reactors for fluid loss control agents are mostly fixed, making them unadjustable in actual production. They operate only according to a fixed stirring trajectory and shear force. For polymer-based fluid loss control agents, the synthesis process has distinct stages: in the initial feeding stage, it's crucial to prevent monomer sedimentation and agglomeration; during the polymerization stage, the system viscosity increases and heat release is concentrated, requiring enhanced shear mixing; and in the modification and maturation stage, high uniformity of mixing is required for the grafting reaction, leading to increased material viscosity. While existing technologies have developed adjustable stirring mechanisms to address the dynamic changes in material parameters throughout the entire process, these are largely limited to single-dimensional adjustments and rely on manual experience. They lack real-time linkage with the material's condition, making it difficult for operators to accurately judge the timing and extent of adjustments, resulting in poor adjustment effects and insufficient precision in matching stirring conditions with material requirements.

[0005] Therefore, enabling the reactor stirring mechanism to adaptively match the changes in material characteristics throughout the entire synthesis cycle of the dehydration agent, thereby achieving precise and efficient mixing and heat transfer, and improving the level of production automation and batch consistency of products, remains a technical problem to be solved in this field. Summary of the Invention

[0006] The purpose of this invention is to provide a production apparatus and method for cementing fluid loss reducing agent to solve the aforementioned technical problems.

[0007] The present invention solves the above-mentioned technical problems through the following technical solutions:

[0008] This invention provides a production apparatus for a cementing fluid loss reducing agent, comprising: a reaction modification unit, wherein the reaction modification unit includes: a reaction vessel body, a stirring mechanism, an online monitoring mechanism, and a control terminal;

[0009] The stirring mechanism includes an upper stirring assembly and a bottom stirring assembly disposed at the lower end of the upper stirring assembly;

[0010] The upper stirring assembly includes a drive motor, a stirring shaft, a lifting base, multiple stirring blades, an angle adjustment component, and a lifting drive component;

[0011] The drive motor is fixedly installed on the top of the reactor body, and the stirring shaft is set inside the reactor body, with its top end connected to the output end of the drive motor; the lifting base is slidably installed on the stirring shaft, and the lifting drive component is connected to the lifting base to drive the lifting base to move linearly up and down along the surface of the stirring shaft.

[0012] The angle adjustment component is connected to multiple stirring blades in a transmission connection, and is used to synchronously drive multiple stirring blades to rotate around the connection point to adjust the angle between them and the stirring shaft.

[0013] The online monitoring device is used to collect the physical parameters of the materials inside the reactor body in real time. The physical parameters include at least the average viscosity η, the maximum temperature difference ΔT, the solid content deviation at the bottom of the reactor ΔS, and the salt concentration C.

[0014] The control terminal is electrically connected to the drive motor, angle adjustment component, lifting drive component, and online monitoring mechanism, and is configured as follows:

[0015] Receive physical parameters collected in real time by online monitoring agencies;

[0016] Based on the characteristics of the water loss reducing agent synthesis process, identify the current reaction condition and retrieve the corresponding baseline height value H. base and the basic value of angle θ base ;

[0017] Based on physical parameters, calculate the viscosity correction factor k respectively. η Temperature difference correction coefficient k ΔT Correction factor k for solid content deviation at the bottom of the vessel ΔS Salt concentration correction factor k C ;

[0018] The optimal height H0 and optimal angle θ0 of the upper stirring component are calculated using a weighted summation formula.

[0019] Physical limit constraint verification is performed on the calculated optimal height H0 and optimal angle θ0;

[0020] Based on the verified optimal height H0 and optimal angle θ0, the lifting drive is driven to adjust the lifting base, and the angle adjustment is driven to adjust the stirring blades.

[0021] It receives feedback on the actual adjustment value, compares it with the target value, and performs a second correction when the deviation exceeds the threshold.

[0022] Preferably, the number of stirring blades is four, and the four stirring blades are circumferentially equidistantly mounted on the outside of the lifting base.

[0023] Preferably, the angle adjustment component includes a drive source and a transmission structure. The transmission structure is connected to the rotating ends of the four stirring blades respectively, and is used to synchronously drive the four stirring blades to rotate around the connection point under the drive of the drive source.

[0024] Preferably, the lifting drive component includes an electric push rod fixedly installed on the upper end of the stirring shaft and a telescopic protective sleeve sleeved on the outside of the electric push rod. The telescopic end of the electric push rod is fixedly connected to the top of the lifting base, and the bottom end of the telescopic protective sleeve is fixed to the top of the lifting base.

[0025] Preferably, the online monitoring mechanism is a multi-point distributed sensor group, which includes an online rotational viscosity sensor, a temperature sensor, a microwave solid content sensor, and a conductivity salt concentration sensor; the sensor group is arranged along the bottom, middle, top, and circulation pipeline of the reactor body.

[0026] Preferably, the bottom stirring assembly is a U-shaped fixed stirring component fixedly installed at the bottom end of the stirring shaft, located at the bottom of the reactor body.

[0027] Preferably, the angle between the stirring blades and the stirring shaft is adjustable from 30° to 90°, and the adjustment range of the lifting base is 0.5 to 0.8 × H. max H max This refers to the effective height of the reactor body.

[0028] Preferably, the apparatus further includes a raw material storage and metering unit for precise metering and sealed addition of solid and liquid raw materials, a post-processing unit for drying, pulverizing and classifying reaction products, and a finished product collection and packaging unit for buffering and automated packaging of finished products.

[0029] Secondly, the present invention also provides a method for producing a cementing fluid loss reducing agent, applied to the aforementioned cementing fluid loss reducing agent production apparatus, comprising the following operating steps:

[0030] S100, Feeding preparation: The dispersion medium and additives are fed into the main body of the reactor via a metering pump, and the powder monomers are quantitatively added by a closed feeder with a loss-in-weight feeder.

[0031] S200, Pretreatment before reaction modification: Start the heat exchange assembly to preheat the material, and start the bottom stirring assembly and circulation pump;

[0032] S300, Adaptive Adjustment of Reaction Modification and Stirring Mechanism: The reaction is initiated by adding an initiator or regulator. An online monitoring mechanism collects material physical parameters in real time and transmits them to the control terminal. An adaptive adjustment algorithm for the stirring mechanism calculates the optimal stirring conditions and drives the upper stirring assembly to complete adaptive adjustment. The adaptive adjustment algorithm includes:

[0033] Receive real-time acquired physical parameters, which include at least the average viscosity η, maximum temperature difference ΔT, bottom solids deviation ΔS, and salt concentration C;

[0034] Identify the current reaction condition and retrieve the corresponding baseline height value H. base and the basic value of angle θ base ;

[0035] The viscosity correction factor k is calculated based on the physical parameters. η Temperature difference correction coefficient k ΔT Correction factor k for solid content deviation at the bottom of the vessel ΔS Salt concentration correction factor k C ;

[0036] The optimal height H0 and optimal angle θ0 of the upper stirring component are calculated using a weighted summation formula.

[0037] Physical limit constraint verification is performed on the calculated optimal height H0 and optimal angle θ0;

[0038] Based on the verified optimal height H0 and optimal angle θ0, the lifting drive is driven to adjust the lifting base, and the angle adjustment is driven to adjust the stirring blades.

[0039] It receives feedback on the actual adjustment value, compares it with the target value, and performs a second correction when the deviation exceeds the threshold.

[0040] S400, Neutralization and Maturation: The material is fed into the neutralization and maturation tank, neutralizing agent is added, and the material is kept warm and matured.

[0041] S500, Post-processing: The material is dried, dusted, crushed and classified to obtain the intermediate;

[0042] S600, Finished Product Collection and Packaging: After being buffered in the finished product silo, the intermediates are quantitatively packaged by an automatic weighing and packaging machine.

[0043] Preferably, the weighted summation formula in S300 is:

[0044] Where a1, a2, a3, and a4 are height weighting coefficients, and b1, b2, b3, and b4 are angle weighting coefficients, and a1+a2+a3+a4=1, b1+b2+b3+b4=1.

[0045] The beneficial effects of this invention are as follows:

[0046] The present invention designs a stirring mechanism that adopts a layered stirring structure with a fixed bottom stirring component and an adjustable top stirring component, and combined with an adaptive adjustment algorithm, to achieve real-time dynamic automatic adjustment of stirring height and angle. This can adapt to the dynamic changes of material parameters throughout the entire synthesis cycle of the dehydration reducer, improve the uniformity of material mixing in the reactor, and solve the problems of bottom sedimentation, local overheating, and uneven mixing that exist in traditional fixed stirring.

[0047] This invention achieves simultaneous adjustment of stirring height and blade angle in two dimensions through the integrated design of lifting base and angle adjustment component. Furthermore, by using a weighted fusion algorithm, the height adjustment prioritizes response to solid content and temperature difference, while the angle adjustment prioritizes response to viscosity and salt concentration, thereby improving the adjustment effect.

[0048] This invention collects four physical parameters in real time—average viscosity, maximum temperature difference, solid content deviation at the bottom of the vessel, and salt concentration—through an online monitoring mechanism. The control terminal has a built-in adaptive adjustment algorithm that automatically identifies the operating conditions, calculates the optimal parameters, and drives the actuator to adjust. Feedback verification ensures execution accuracy. The entire process requires no manual intervention, thus improving the level of automation and operational stability of production. Attached Figure Description

[0049] Figure 1 This is a schematic diagram of the overall structural frame of a cementing fluid loss reducing agent production device according to the present invention;

[0050] Figure 2 This is a schematic diagram of the external structure of the reaction modification unit in a cementing fluid loss reducing agent production device of the present invention;

[0051] Figure 3 This is a schematic diagram of the internal structure of the reaction vessel body in a cementing fluid loss reducing agent production device of the present invention;

[0052] Figure 4 This is a schematic diagram of the stirring mechanism in a cementing fluid loss reducing agent production device of the present invention;

[0053] Figure 5 This is a schematic diagram of the upper stirring assembly in a cementing fluid loss reducing agent production device of the present invention;

[0054] Figure 6 This is a schematic diagram of the internal structure of the lifting slide in a cementing fluid loss reducing agent production device of the present invention;

[0055] Figure 7 This is the present invention. Figure 6 A magnified view of a portion of point A in the middle;

[0056] Figure 8 This is a flowchart of the production method of a cementing fluid loss reducing agent according to the present invention.

[0057] In the figure: 1. Reactor body; 2. Stirring mechanism; 21. Upper stirring assembly; 211. Drive motor; 212. Stirring shaft; 213. Lifting base; 214. Stirring blades; 215. Electric push rod; 216. Telescopic protective sleeve; 217. Micro motor; 218. Transmission gear; 219. Bevel gear ring; 2110. Bevel gear; 22. Bottom stirring assembly; 3. Online monitoring mechanism. Detailed Implementation

[0058] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and implement the subject matter described herein, and changes may be made to the function and arrangement of the elements discussed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the examples. Furthermore, features described in some examples may be combined in other examples.

[0059] Example 1

[0060] Please refer to the following: Figures 1 to 7 A cementing fluid loss reducing agent production device includes: a raw material storage and metering dosing unit, a reaction modification unit, a post-processing unit, a finished product collection and packaging unit, and a main control unit. The units are connected to each other through closed pipelines and conveying equipment to achieve fully automated and closed production.

[0061] The raw material storage and metering unit is mainly used to accurately meter and add solid and liquid raw materials into the reaction modification unit in a closed manner. It mainly includes liquid raw material tank, powder silo, loss-in-weight feeder, metering pump, and liquid mixing tank.

[0062] The post-processing unit is mainly used for drying, pulverizing, and classifying the reaction products. It includes a neutralization and maturation tank, a fluidized bed dryer, a cyclone separator, a bag filter, a pulverizer, and a classifying sieve. After drying, the powder is efficiently recovered through cyclone separation and bag filter dust collection, and the exhaust gas is sent to the exhaust gas treatment unit.

[0063] The finished product collection and packaging unit is used for buffering and automated packaging of finished products, and includes a finished product silo and an automatic weighing and packaging machine.

[0064] The reaction modification unit is mainly used to realize the polymerization and modification reaction of the water loss reducing agent. It includes the main body of the reactor 1, the stirring mechanism 2, the online monitoring mechanism 3, and the control terminal.

[0065] The reactor body 1 is a closed structure with a feeding port at the top, which connects to the raw material storage and metering unit, and a discharge port at the bottom, which connects to the post-processing unit. The side wall has a sampling port and multiple sensor mounting ports. The reactor body 1 is equipped with a jacket and coil heat exchange components, which are either encased in the outer wall of the reactor body 1 or built into the reactor. Precise temperature control of the reaction system can be achieved by introducing heat transfer oil, steam, or cooling water. A circulation pump is also connected to one side of the reactor body 1 to achieve forced circulation of the materials within the reactor, enhancing heat transfer and mixing.

[0066] The stirring mechanism 2 includes an upper stirring component and a bottom stirring component 22 located at the lower end of the upper stirring component 21. The two work together to achieve stirring of materials in the vessel without dead angles.

[0067] The upper stirring assembly 21 includes a drive motor 211, a stirring shaft 212, a lifting base 213, multiple stirring blades 214, an angle adjustment component, and a lifting drive component. The drive motor 211 is fixedly installed on the top of the reactor body 1, and its output end is connected to the top of the stirring shaft 212, providing rotational power for the entire stirring mechanism 2. The stirring shaft 212 is vertically arranged inside the reactor body 1, penetrating the entire reactor body.

[0068] The lifting base 213 is slidably mounted on the stirring shaft 212 and can slide freely along the axial direction of the stirring shaft 212. The lifting drive is connected to the lifting base 213 and is used to drive the lifting base 213 to linearly rise and fall along the surface of the stirring shaft 212. In this embodiment, the lifting drive mainly adopts an electric push rod 215 and a telescopic protective sleeve 216 structure. The electric push rod 215 is fixedly mounted on the upper end of the stirring shaft 212, and its telescopic end is fixedly connected to the top of the lifting base 213. To prevent material from corroding the electric push rod 215, a telescopic protective sleeve 216 is fitted on the outside of the electric push rod 215. The bottom end of the telescopic protective sleeve 216 is fixed to the top of the lifting base 213, and the top end is connected to a fixed point on the stirring shaft 212, extending and retracting with the rise and fall of the lifting base 213. The lifting drive can also adopt alternative solutions such as a hydraulic cylinder, a pneumatic cylinder, or a screw and nut mechanism.

[0069] Multiple stirring blades 214 are installed on the outside of the lifting base 213. As a preferred embodiment, the number of stirring blades 214 is set to four. The four stirring blades 214 are equidistantly distributed along the circumference of the lifting base 213 to form a cross-shaped layout. The root of each stirring blade 214 is rotatably connected to the lifting base 213 through a rotating shaft, so that the stirring blade 214 can rotate around the connection point, thereby changing its angle with the stirring shaft 212.

[0070] An angle adjustment component is connected to multiple stirring blades 214 for synchronously driving all stirring blades 214 to rotate around the connection point, thereby achieving synchronous adjustment of the stirring blade angle. The specific structure of the angle adjustment component can be implemented in various ways. In this embodiment, the angle adjustment component adopts a gear transmission structure, which mainly includes a micro motor 217, a transmission gear 218, a bevel gear ring 219, and four bevel gears 2110. The micro motor 217 is installed inside the lifting base 213, and its output end is connected to the transmission gear 218. The bevel gear ring 219 is rotatably installed inside the lifting base 213, and its bottom has an external gear ring that meshes with the transmission gear 218. The four bevel gears 2110 are respectively fixedly connected to the rotating ends of the four stirring blades 214, and the four bevel gears 2110 simultaneously mesh with the inner bevel teeth at the top of the bevel gear ring 219. The angle adjustment range between the stirring blades 214 and the stirring shaft 212 is 30°~90°, and the adjustment range of the lifting base 213 is 0.5~0.8×H. max H max This refers to the effective height of the reactor body 1. During operation, the micro motor 217 drives the transmission gear 218 to rotate, which in turn drives the bevel gear ring 219 to rotate. Simultaneously, the bevel gear ring 219 drives four bevel gears 2110 to rotate synchronously, thereby causing the four stirring blades 214 to rotate synchronously around their respective connection points, achieving synchronous adjustment of the stirring blade angle. Besides gear transmission, the angle adjustment mechanism can also employ other transmission methods such as linkage mechanisms, synchronous belt drives, or worm gear drives, as long as they can achieve synchronous angle adjustment of multiple stirring blades.

[0071] The working process of the upper stirring assembly 21 is as follows: while the drive motor 211 drives the stirring shaft 212 to rotate, according to the command from the control terminal, the lifting drive can drive the lifting base 213 to move up and down along the stirring shaft 212, thereby changing the height position of the stirring blades 214 in the vessel; the angle adjustment component can synchronously drive all the stirring blades 214 to rotate, changing the angle between the stirring blades and the stirring shaft 212, thereby changing the shear force and pumping capacity of the stirring blades 214. Through the combined adjustment of height and angle, the upper stirring assembly 21 can adapt to the stirring requirements of different material viscosities and different reaction stages.

[0072] The bottom stirring assembly 22 is a U-shaped fixed stirring component, fixedly installed at the bottom end of the stirring shaft 212, located at the bottom of the reactor body 1. The outline of this U-shaped stirring component matches the shape of the bottom of the reactor body 1, and it typically adopts an anchor or frame structure. When the drive motor 211 drives the stirring shaft 212 to rotate, the U-shaped fixed stirring component rotates accordingly, forcibly agitating the material in the bottom area of ​​the reactor, forming an axial flow from bottom to top, preventing the deposition and agglomeration of powder monomers in high-salt systems, and providing a basic flow field for the upper stirring assembly 21. This structural design ensures that no dead zone will appear at the bottom of the reactor, even under conditions of high solids content and high-density materials.

[0073] The online monitoring unit 3 is used to collect the physical parameters of the materials inside the reactor body 1 in real time, providing a data basis for adaptive adjustment of the stirring conditions. This unit includes a multi-point distributed sensor group and a data acquisition module.

[0074] The sensor array is arranged at different locations along the main body 1 of the reactor and the circulation pipeline to achieve three-dimensional monitoring. Specifically, it includes:

[0075] Online rotational viscosity sensors: Three are installed at the bottom, middle and top of the reactor body 1, respectively, to measure the apparent viscosity of materials at different heights. Through data processing, the average viscosity η and viscosity distribution information can be obtained.

[0076] Platinum resistance temperature sensor: Multiple points are arranged at the bottom, middle, and top of the reactor body 1 and at the inlet and outlet of the circulation pipeline to monitor the temperature at different locations. The maximum temperature difference ΔT is obtained by calculating the difference between the highest and lowest temperatures, which reflects the temperature uniformity of the system.

[0077] Online microwave solid content sensor: installed at the bottom of the vessel and in the circulation pipeline, it uses the attenuation characteristics of microwaves when penetrating materials to measure the solid content in real time. By comparing with the set value, the solid content deviation value ΔS at the bottom of the vessel is obtained, which reflects the powder settling situation.

[0078] Online conductivity salt concentration sensor: installed in the liquid phase zone and feed port inside the vessel, it calculates the salt concentration C by measuring the conductivity of the material, reflecting the ionic strength of the system;

[0079] The data acquisition module is electrically connected to each sensor and synchronously acquires the measurement data of each sensor according to the set acquisition frequency. After preliminary processing, the data is transmitted to the control terminal in real time via the industrial bus.

[0080] The control terminal typically uses an industrial PLC, which communicates with the main control unit and primarily serves as the control center within the reaction modification unit. It is electrically connected to the drive motor 211, angle adjustment components, lifting drive components, and the online monitoring mechanism 3. It has a built-in algorithm that adaptively adjusts the position, height, and angle of the stirring blades in the stirring mechanism 2 based on the real-time status of the material inside the vessel. This adaptive adjustment algorithm is specifically as follows:

[0081] Receive physical parameters collected in real time by the online monitoring agency 3.

[0082] Based on the characteristics of the water loss reducing agent synthesis process, identify the current reaction condition and retrieve the corresponding baseline height value H. base and the basic value of angle θ base .

[0083] Based on physical parameters, calculate the viscosity correction factor k respectively. ηTemperature difference correction coefficient k ΔT Correction factor k for solid content deviation at the bottom of the vessel ΔS Salt concentration correction factor k C The specific calculation formula is as follows:

[0084]

[0085] Temperature difference correction factor k ΔT :

[0086]

[0087] Where β is the temperature difference sensitivity coefficient (which can be taken as 0.02), and ΔT is in °C;

[0088] Correction factor k for solid content deviation at the bottom of the vessel ΔS ;

[0089]

[0090] Where γ is the solid content sensitivity coefficient (which can be taken as 0.04), and ΔS is in the percentage of %

[0091] Salt concentration correction factor k C :

[0092]

[0093] Where δ is the salt concentration sensitivity coefficient (which can be taken as 0.005).

[0094] The optimal height H0 and optimal angle θ0 of the upper stirring component are calculated using a weighted summation formula, as follows:

[0095]

[0096] Where a1, a2, a3, and a4 are height weighting coefficients, and b1, b2, b3, and b4 are angle weighting coefficients, and a1+a2+a3+a4=1, b1+b2+b3+b4=1;

[0097] In this embodiment, the preferred values ​​are: a1=0.4, a2=0.3, a3=0.2, a4=0.1, b1=0.4, b2=0.3, b3=0.2, b4=0.1.

[0098] The design principle of the weighting coefficients is as follows:

[0099] Height adjustment: preferential response to bottom deposition (k ΔS ) and temperature uniformity (k ΔT Because changes in height directly affect the bottom flow field and the overall circulation;

[0100] Angle adjustment: preferentially responds to viscosity changes (k η ) and the effect of salt concentration (k C Because the angle change directly affects the shear force of the stirring blade 214, and the shear force requirement is mainly determined by viscosity and rheological properties.

[0101] Physical limit constraint verification is performed on the calculated optimal height H0 and optimal angle θ0 to ensure that they are within the allowable adjustment range of the equipment and to avoid damage to the mechanism;

[0102] Among them, the height constraint is: H corresponds to 0.5~0.8×Hmax, and the angle constraint is: θ must be between 30° and 90°; if the calculated value exceeds the constraint range, the boundary value will be automatically taken.

[0103] Based on the verified optimal height H0 and optimal angle θ0, the lifting drive component is driven to adjust the lifting base, and the angle adjustment component is driven to adjust the stirring blade 214. Feedback on the actual adjustment value is received and compared with the target value. If the deviation exceeds the threshold, a second correction is performed.

[0104] Example 2

[0105] Please refer to the following: Figure 8 Based on the apparatus of Embodiment 1, the present invention also provides a method for producing a cementing fluid loss reducing agent, comprising the following steps:

[0106] Step S100, Material preparation:

[0107] The operator retrieves the formula parameters of the high-temperature salt-resistant water loss reducing agent through the host computer, and the control system automatically performs the following operations:

[0108] Open the feed valve of the mixing tank, add deionized water (dispersion medium) and dispersant to the mixing tank according to the preset formula ratio, and start the mixing tank agitator for premixing;

[0109] Acrylamide-based powder monomers and sulfonic acid salt-resistant monomers are added to the powder silo according to a preset mass ratio;

[0110] Start the metering pump to send the mixed liquid in the mixing tank into the main body of the reactor 1 through the closed pipeline at a preset flow rate. At the same time, the flow meter provides real-time feedback control to ensure accurate delivery.

[0111] The loss-in-weight feeder is started synchronously to add the powder monomer mixture into the reactor body 1 in a sealed and quantitative manner at a preset rate. The loss-in-weight feeder controls the feeding speed through real-time weighing feedback and automatically stops when the cumulative amount added reaches the set value.

[0112] During the feeding process, the stirring mechanism 2 of the reactor body 1 operates at a low speed to prevent the powder from settling.

[0113] This step enables precise metering and fully enclosed addition of solid and liquid raw materials, avoiding errors from manual weighing and dust pollution.

[0114] Step S200, Pretreatment before reaction modification:

[0115] After feeding is completed, the control system performs the following preprocessing operations:

[0116] Start the heating system of the jacket / coil heat exchanger assembly, introduce heat transfer oil, and heat the material in the reactor to the preset initial temperature of the polymerization reaction at a preset heating rate;

[0117] Start the fixed agitator and rotate it at the preset speed to forcibly agitate the material at the bottom of the vessel to prevent high-density powder from settling.

[0118] Start the circulation pump, set the circulation flow rate, and realize the forced circulation flow of materials in the reactor to enhance heat transfer and mixing, and form a uniform basic flow field;

[0119] The online monitoring unit 3 begins operation, with each sensor collecting initial material parameters at a preset frequency and transmitting them to the control terminal;

[0120] When the pretreatment time is reached and the temperature inside the vessel reaches the preset temperature value, the materials are initially mixed evenly.

[0121] Step S300, adaptive adjustment of reaction modification and stirring mechanism 2:

[0122] Step S310, Reaction Start-up and Parameter Acquisition:

[0123] Ammonium persulfate initiator (injected in a closed manner through a metering pump) is added into the main body 1 of the reactor to start the polymerization reaction. The reaction is an exothermic process. The control end controls the reaction temperature within the preset range by adjusting the flow rate of the heat exchange medium.

[0124] Online monitoring agency 3 continuously collects material parameters in real time, including:

[0125] Average viscosity η: obtained by averaging the measurements from three rotational viscosity sensors;

[0126] Maximum temperature difference ΔT: obtained by subtracting the lowest value from the highest value of the multi-point temperature sensor;

[0127] The solid content deviation value ΔS at the bottom of the vessel is the difference between the measured value of the microwave solid content sensor at the bottom of the vessel and the process setting value (such as 30%).

[0128] Salt concentration C: Calculated from the value measured by the conductivity sensor;

[0129] The data acquisition module updates the above parameters once at a preset time and transmits them to the control terminal in real time.

[0130] S320, Operating Condition Identification and Base Value Retrieval:

[0131] The built-in algorithm module in the control terminal first identifies the current reaction condition based on the reaction timing or process trigger signal. In this embodiment, the synthesis process of the water loss reducing agent is divided into three typical conditions:

[0132] Feeding and dispersion stage: In the initial stage of the reaction, the viscosity of the materials is low, and the main goal is to inhibit salting-out agglomeration and achieve uniform mixing;

[0133] Polymerization reaction stage: In the middle of the reaction, the viscosity of the system rises rapidly, the heat release of the reaction is concentrated, and the main goal is to enhance shear, eliminate local high temperature, and improve reaction uniformity.

[0134] Modification and maturation stage: In the later stage of the reaction, the functional monomer grafting reaction is carried out. The main goal is to ensure uniform grafting through high-intensity shearing and prevent adhesion to the wall.

[0135] Based on the identification results, the algorithm module retrieves the basic stirring value corresponding to this operating condition from the recipe management module. In this embodiment, the basic values ​​are set as follows:

[0136]

[0137] S330, Correction factor calculation:

[0138] Based on the real-time collected material parameters, the viscosity correction factor k is calculated respectively. η Temperature difference correction coefficient k ΔT Correction factor k for solid content deviation at the bottom of the vessel ΔS Salt concentration correction factor k C Four correction coefficients are used to reflect the deviation between the current material state and the ideal state. The value range is designed to be 0.8~1.2. The further the deviation from 1, the greater the adjustment is required.

[0139] S340, Weighted Calculation of Optimal Values:

[0140] Based on the characteristics of the layered stirring structure, the height adjustment prioritizes the solid content and temperature difference requirements at the bottom of the vessel (to solve the problems of sedimentation and local overheating), while the angle adjustment prioritizes the viscosity and salt concentration requirements (to solve the problem of shear force matching). The algorithm uses a weighted summation formula to calculate the optimal height H0 and the optimal angle θ0.

[0141] S350, Constraint Verification:

[0142] The calculated optimal value is checked against physical limit constraints to ensure it is within the allowable adjustment range of the equipment and to avoid damage to the mechanism; if the calculated value exceeds the constraint range, the boundary value is automatically taken.

[0143] S360, Drive Adjustment and Feedback Verification:

[0144] The control unit outputs a control signal based on the verified optimal value:

[0145] Send a command to the lifting drive component to move the lifting base 213 from its current position to a specified height position, and send a command to the micro motor 217 of the angle adjustment component to drive the four stirring blades 214 to rotate synchronously to a specified angle.

[0146] After adjustment, the control unit receives the actual position and angle feedback values ​​and compares them with the target values:

[0147] If the height deviation is greater than ±0.05m or the angle deviation is greater than ±1°, a second correction adjustment will be performed until the deviation is within the allowable range. If the deviation still exceeds the tolerance after the second correction, an alarm will be triggered, prompting manual intervention.

[0148] This step enables real-time adaptive adjustment of the stirring conditions. Throughout the reaction process, the algorithm executes once at a preset time interval, continuously tracking changes in the material state and fine-tuning the stirring parameters to ensure that the reaction is always in the optimal mixing state.

[0149] S370, Operating Condition Transition and Continuous Adjustment:

[0150] Once the polymerization reaction is essentially complete, the system automatically identifies the entry point into the modification and ripening stage based on timing. At this point, the algorithm automatically retrieves the baseline value H for the new operating condition. base θ base Simultaneously, it acquires real-time online monitoring data and recalculates the viscosity correction coefficient k based on a built-in algorithm. η Temperature difference correction coefficient k ΔT Correction factor k for solid content deviation at the bottom of the vessel ΔS Salt concentration correction factor k C .

[0151] After constraint verification, the control terminal drives the lifting base 213 and stirring blade 214 to adjust again according to the calculation results, and enters the high shear and high intensity mixing mode to ensure uniform grafting of functional units.

[0152] Step S400, neutralization and maturation:

[0153] After the reaction modification is completed, open the discharge valve at the bottom of the reactor body 1 and send the material (at this time, it is a viscous liquid or slurry) into the neutralization and maturation tank through a closed pipe. Add sodium hydroxide solution (neutralizing agent) to the neutralization and maturation tank, and adjust the pH value of the material to the preset value by monitoring with an online pH meter. Start the agitator and heating system of the neutralization and maturation tank, and keep it at the preset temperature for maturation, so that the polymer molecular chains can be fully extended, the functional groups can be stabilized, and the product performance can be guaranteed to be stable.

[0154] Step S500, Post-processing:

[0155] After maturation, the material is pumped into the fluidized bed dryer 17. The dryer uses hot air as the drying medium, and the inlet air temperature is set. The material is in a boiling state in the fluidized bed, and the moisture evaporates rapidly. The dried powder enters the cyclone separator with the airflow. Under the action of centrifugal force, most of the powder (with a larger particle size) is separated and discharged through the discharge valve. The gas containing a small amount of fine powder enters the bag filter dust collector, where gas-solid separation is achieved through filter bag filtration. The fine powder is intercepted and periodically recovered. The purified exhaust gas enters the exhaust gas treatment component, and after washing and activated carbon adsorption, it meets the emission standards.

[0156] After the recovered powder is mixed with the powder discharged from the drying device, it is pneumatically conveyed into the pulverizer 20. The pulverizer uses mechanical impact pulverization to break up any agglomerated particles. The pulverized material enters the grading screen and is screened through two layers of screens to obtain the water loss reducing agent intermediate. The material on the screen is returned to the pulverizer for further pulverization, while the material under the screen is returned to the drying device as fine powder or collected separately.

[0157] Step S600, Finished Product Collection and Packaging:

[0158] The water loss reducing agent intermediate obtained after post-processing is pneumatically conveyed into the finished product silo for buffer storage. When packaging is required, the discharge valve at the bottom of the finished product silo is opened, and the material enters the weighing hopper of the automatic weighing and packaging machine. The packaging bag is automatically bagged, filled, sealed, and the production date is printed to complete the packaging. The packaged finished product is conveyed to the palletizing area by a conveyor belt.

[0159] The embodiments of the present invention have been described above, but the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention, all of which are within the protection scope of the present invention.

Claims

1. A production apparatus for a cementing fluid loss reducing agent, characterized in that, include: The reaction modification unit includes: a reaction vessel body, a stirring mechanism, an online monitoring mechanism, and a control terminal; The stirring mechanism includes an upper stirring assembly and a bottom stirring assembly disposed at the lower end of the upper stirring assembly; The upper stirring assembly includes a drive motor, a stirring shaft, a lifting base, multiple stirring blades, an angle adjustment component, and a lifting drive component; The drive motor is fixedly installed on the top of the reactor body, and the stirring shaft is set inside the reactor body, with its top end connected to the output end of the drive motor; the lifting base is slidably installed on the stirring shaft, and the lifting drive component is connected to the lifting base to drive the lifting base to move linearly up and down along the surface of the stirring shaft. The angle adjustment component is connected to multiple stirring blades in a transmission connection, and is used to synchronously drive multiple stirring blades to rotate around the connection point to adjust the angle between them and the stirring shaft. The online monitoring device is used to collect the physical parameters of the materials inside the reactor body in real time. The physical parameters include at least the average viscosity η, the maximum temperature difference ΔT, the solid content deviation at the bottom of the reactor ΔS, and the salt concentration C. The control terminal is electrically connected to the drive motor, angle adjustment component, lifting drive component, and online monitoring mechanism, and is configured as follows: Receive physical parameters collected in real time by online monitoring agencies; Based on the characteristics of the water loss reducing agent synthesis process, identify the current reaction condition and retrieve the corresponding baseline height value H. base and the basic value of angle θ base ; Based on physical parameters, calculate the viscosity correction factor k respectively. η Temperature difference correction coefficient k ΔT Correction factor k for solid content deviation at the bottom of the vessel ΔS Salt concentration correction factor k C ; The optimal height H0 and optimal angle θ0 of the upper stirring component are calculated using a weighted summation formula. Physical limit constraint verification is performed on the calculated optimal height H0 and optimal angle θ0; Based on the verified optimal height H0 and optimal angle θ0, the lifting drive is driven to adjust the lifting base, and the angle adjustment is driven to adjust the stirring blades. It receives feedback on the actual adjustment value, compares it with the target value, and performs a second correction when the deviation exceeds the threshold.

2. The cementing fluid loss reducing agent production device according to claim 1, characterized in that, The number of stirring blades is set to four, and the four stirring blades are equidistantly mounted on the outside of the lifting base.

3. The cementing fluid loss reducing agent production device according to claim 2, characterized in that, The angle adjustment component includes a drive source and a transmission structure. The transmission structure is connected to the rotating ends of the four stirring blades respectively, and is used to synchronously drive the four stirring blades to rotate around the connection point under the drive of the drive source.

4. The cementing fluid loss reducing agent production device according to claim 1, characterized in that, The lifting drive component includes an electric push rod fixedly installed on the upper end of the stirring shaft and a telescopic protective sleeve sleeved on the outside of the electric push rod. The telescopic end of the electric push rod is fixedly connected to the top of the lifting base, and the bottom end of the telescopic protective sleeve is fixed to the top of the lifting base.

5. The cementing fluid loss reducing agent production device according to claim 1, characterized in that, The online monitoring mechanism is a multi-point distributed sensor group, which includes an online rotational viscosity sensor, a temperature sensor, a microwave solid content sensor, and a conductivity salt concentration sensor; the sensor group is arranged along the bottom, middle, top and circulation pipeline of the reactor body.

6. The cementing fluid loss reducing agent production apparatus according to claim 1, characterized in that, The bottom stirring assembly is a U-shaped fixed stirring component that is fixedly installed at the bottom of the stirring shaft and is located at the bottom of the reactor body.

7. The cementing fluid loss reducing agent production apparatus according to claim 1, characterized in that, The angle between the stirring blades and the stirring shaft is adjustable from 30° to 90°, and the adjustment range of the lifting base is 0.5 to 0.8 × H. max H max This refers to the effective height of the reactor body.

8. The cementing fluid loss reducing agent production apparatus according to claim 1, characterized in that, The device also includes a raw material storage and metering unit for precise metering and sealed addition of solid and liquid raw materials, a post-processing unit for drying, pulverizing and classifying reaction products, and a finished product collection and packaging unit for buffering and automated packaging of finished products.

9. A method for producing a cementing fluid loss reducing agent, applied to a cementing fluid loss reducing agent production apparatus as described in any one of claims 1-8, characterized in that, The following steps are included: S100, Feeding preparation: The dispersion medium and additives are fed into the main body of the reactor via a metering pump, and the powder monomers are quantitatively added by a closed feeder with a loss-in-weight feeder. S200, Pretreatment before reaction modification: Start the heat exchange assembly to preheat the material, and start the bottom stirring assembly and circulation pump; S300, reaction modification and adaptive adjustment of stirring mechanism: the reaction is started by adding an initiator or regulator, the online monitoring mechanism collects the physical parameters of the material in real time and transmits them to the control terminal, and the optimal stirring conditions are calculated by the adaptive adjustment algorithm of the stirring mechanism and the upper stirring component is driven to complete the adaptive adjustment. Adaptive adjustment algorithms include: Receive real-time acquired physical parameters, which include at least the average viscosity η, maximum temperature difference ΔT, bottom solids deviation ΔS, and salt concentration C; Identify the current reaction condition and retrieve the corresponding baseline height value H. base and the basic value of angle θ base ; The viscosity correction factor k is calculated based on the physical parameters. η Temperature difference correction coefficient k ΔT Correction factor k for solid content deviation at the bottom of the vessel ΔS Salt concentration correction factor k C ; The optimal height H0 and optimal angle θ0 of the upper stirring component are calculated using a weighted summation formula. Physical limit constraint verification is performed on the calculated optimal height H0 and optimal angle θ0; Based on the verified optimal height H0 and optimal angle θ0, the lifting drive is driven to adjust the lifting base, and the angle adjustment is driven to adjust the stirring blades. It receives feedback on the actual adjustment value, compares it with the target value, and performs a second correction when the deviation exceeds the threshold. S400, Neutralization and Maturation: The material is fed into the neutralization and maturation tank, neutralizing agent is added, and the material is kept warm and matured. S500, Post-processing: The material is dried, dusted, crushed and classified to obtain the intermediate; S600, Finished Product Collection and Packaging: After being buffered in the finished product silo, the intermediates are quantitatively packaged by an automatic weighing and packaging machine.

10. A method for producing a cementing fluid loss reducing agent according to claim 9, characterized in that, The weighted summation formula in S300 is as follows: Where a1, a2, a3, and a4 are height weighting coefficients, and b1, b2, b3, and b4 are angle weighting coefficients, and a1+a2+a3+a4=1, b1+b2+b3+b4=1.

Images