Apparatuses and systems for inducing dual vortex flow

Abstract

An apparatus for receiving a fluid stream therethrough comprises a body having an inlet end and an outlet end and defining a passage axially therethrough from the inlet end to the outlet end. The body comprises a first portion comprising first helical angle elements for inducing a first vortex flow component in the fluid stream, and a second portion comprising second helical angle elements for inducing a second vortex flow component in the fluid stream. The first helical angle elements have one of a left-handed or a right-handed orientation, and the second helical elements have the other of the left-handed or the right-handed orientation. The apparatus may be a tubing insert.

Description

APPARATUSES AND SYSTEMS FOR INDUCING DUAL VORTEX FLOWRELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 683,887, filed on August 16, 2024, the entire contents of which are incorporated herein by reference.BACKGROUND

[0002] Frictional losses in fluid transport systems, particularly in tubing, can significantly impact efficiency and energy consumption. Fluids flowing through tubing may experience friction loss due to characteristics of the fluid flow and interactions between the fluid and the inner surface of the tubing. Fluid flow through pipes or other tubing may encounter friction loss due to various factors, including viscous effects. Friction loss may be dependent on characteristics of the fluid flow, such as whether the flow is laminar or turbulent. Friction loss may contribute to or cause pressure drops, increased pumping costs (e.g., Power requirements, hydraulic horse power), and decreased overall system performance. Conventional approaches to reduce friction include using smoother surfaces, optimizing tubing diameter, adding polymeric additives, adding lubricants, and minimizing bends. However, these approaches have limitations. Other approaches include modifying the flow profile of fluid in the tubing.

[0003] It may be beneficial in various operations involving fluid flow through tubing (pumping and / or injecting fluids, for example), to reduce friction loss. Improving fluid flow and reducing friction loss may be beneficial in any technical field or application where fluid is transported in tubing. Reducing friction loss may be particularly beneficial where fluid is transported in tubing over long distances.SUMMARY

[0004] According to an aspect of the disclosure, there is provided an apparatus for receiving a fluid stream therethrough, the apparatus comprising: a body having an inlet end and an outlet end and defining a passage axially therethrough from the inlet end to the outlet end, the body comprising: a first portion comprising first helical angle elements for inducing a first vortex flow component in the fluid stream; a second portion comprising second helical angle elements for inducing a second vortex flow component in the fluid stream, wherein the first helical angle elements have one of a right-handed or a lefthanded orientation, and the second helical elements have the other of the right-handed or the left-handed orientation.

[0005] In some embodiments, the apparatus is a tubing insert.

[0006] In some embodiments, the first vortex flow component is a right-handed vortex flow component and the second vortex flow component is a left-handed vortex flow component.

[0007] In some embodiments, the first vortex flow component is a left-handed vortex flow component and the second vortex flow component is a right-handed vortex flow component.

[0008] In some embodiments, the second portion is positioned downstream of the first portion.

[0009] In some embodiments: wherein the body is a hollow cylindrical body having an inner body surface and an outer body surface; wherein the first helical angle elements of the first portion comprise a first plurality of helically-oriented side channels extending radially through the hollow cylindrical body from the inner surface to the outer surface; and wherein the second helical angle elements of the first portion comprise a second plurality of helically-oriented side channels extending radially through the hollow cylindrical body from the inner surface to the outer surface.

[0010] In some embodiments, the hollow cylindrical body comprises: an upper ring portion at the outlet end; a lower ring portion at the inlet end; an intermediate ring portion positioned intermediate the lower and upper ring portions; lower helically-oriented ribsinterconnecting the intermediate ring portion and the lower ring portion, wherein the lower ribs, the lower ring portion and the intermediate ring portion collectively define the first plurality of helically-oriented side channels; upper helically-oriented ribs interconnecting the intermediate ring portion and the upper ring portion, wherein the upper ribs, the upper ring portion and the intermediate ring portion collectively define the second plurality of helically-oriented side channels.

[0011] In some embodiments, the first portion further comprises first projections extending from the inner surface of the cylindrical body to a first central node; and the second portion further comprises second projections extending from the inner surface of the cylindrical body to a second central node.

[0012] In some embodiments, each of the first projections and each of the second projections comprises a respective beam.

[0013] In some embodiments, each of the first projections has a respective lower face, the lower have defining a parabolic curvature.

[0014] In some embodiments, each of the second projections has a respective lower face, the lower have defining a parabolic curvature.

[0015] In some embodiments, each of the first projections is aligned with a respective one of the lower helically-oriented ribs.

[0016] In some embodiments, each of the second projections is aligned with a respective one of the upper helically-oriented ribs.

[0017] In some embodiments, each of the lower helically-oriented ribs has a respective upper end aligned with a respective lower end of one of the upper helically- oriented ribs.

[0018] In some embodiments, the first portion is a first insert section, the second portion is a second insert section, and the first and second insert sections are joined in an axially stacked configuration.

[0019] In some embodiments, the apparatus is formed as a single unitary piece of material.

[0020] According to an aspect of the disclosure, there is provided a system comprising: a section of tubing; the apparatus as described herein positioned within the section of tubing to receive a fluid stream therethrough.

[0021] In some embodiments, the system further comprises one or more additional apparatuses as described herein positioned within the section of tubing.

[0022] According to an aspect of the disclosure, there is provided a method comprising: positioning the apparatus as described herein within a section of a conduit; and flowing a fluid stream through the conduit and the apparatus.

[0023] According to another aspect of the disclosure, there is provided an apparatus for receiving a fluid stream therethrough and comprising: a first section for inducing a first vortex flow component in the fluid stream; and a second section for inducing a second vortex flow component in the fluid stream.

[0024] Other aspects and features of the present disclosure will become apparent, to those ordinarily skilled in the art, upon review of the following description of the specific embodiments of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present disclosure will be better understood having regard to the drawings in which:

[0026] FIGs. 1A to 1 D are perspective, side, outlet end and inlet end views of an example apparatus according to some embodiments;

[0027] FIGs. 2A and 2B are side and end views of an example first section of the apparatus of FIGs. 1 A to 1 D;

[0028] FIG. 3 is a side view of an example system including the apparatus of FIGs. 1A to 1 D positioned in a tubing section;

[0029] FIGs. 4A to 4C are side, outlet end, and inlet end views, respectively, of another example apparatus according to some embodiments;

[0030] FIG. 5 is a perspective view of another example apparatus according to some embodiments;

[0031] FIGs. 6A to 6D are perspective, side, outlet end and inlet end views of another example apparatus according to some embodiments;

[0032] FIGs. 6E is a cross sectional view of the apparatus of FIGs. 6A to 6D, taken along the line A-A in FIG. 6B;

[0033] FIG. 6F is a cross sectional view of the apparatus of FIGs. 6A to 6D, taken along the line B-B in FIG. 6B;

[0034] FIGs. 7 A and 7B are perspective and end views of yet another example apparatus according to some embodiments;

[0035] FIG. 8 is a flowchart of an example method according to some embodiments;

[0036] FIG 9A shows four still images captured from a flow experiment with annotations at four sample times;

[0037] FIG 9B illustrates samples of an estimated bubble flow path within the fluid stream of the annotated images in FIG. 9A;

[0038] FIG 10A shows four still images captured from a flow experiment with annotations at four sample times;

[0039] FIG 10B illustrates samples of an estimated bubble flow path within the fluid stream of the annotated images in FIG. 10A; and

[0040] FIG. 11 is a side view of an example system including multiple apparatuses of the form shown in FIGs. 7A and 7B positioned in a tubing section.DETAILED DESCRIPTION

[0041] As noted above, it may be beneficial in systems or operations involving fluid flow through a conduit such as tubing (e.g., pipe) to reduce friction loss. The term “tubing” as used herein may refer generically to any tubular structure or section thereof suitable for transporting fluid therein, such as a pipe or pipeline, hose, duct, or any other similar structure. Embodiments are not limited to any particular form of tubing or other type of conduit structure for fluid flow.

[0042] According to an aspect, one or more apparatuses are provided that are positionable in tubing for altering flow characteristics of a fluid stream that flows through the apparatus. Particularly, the apparatus may induce dual helical vortex flow characteristics, as described below. The dual helical vortex flow may reduce friction loss and / or provide other benefits, such as improved mixing and / or other benefits for an extended and sustained distance. The fluid stream may be any fluid or combination of fluids. The fluid(s) may be Newtonian or non-Newtonian. Solids and gas may also be entrained within the fluid stream.

[0043] The apparatus includes a first portion for inducing a first vortex flow component and a second portion for inducing a second vortex flow component. The first and second vortex flow components may be left-handed and right-handed vortex flow components respectively (or vice versa). Vortices are discussed in: Alekseenko et aL, Theory of Concentrated Vortices: An Introduction, Springer, August 2007, the entire contents of which are incorporated by reference.

[0044] The apparatus has an inlet end and an outlet end, with a longitudinal axis extending through the inlet and outlet ends. The first and second portions are aligned on the longitudinal axis, with fluid flow through the apparatus flowing through the first and second portions. The first and second portions may be formed as a unitary body, or the first and second portions may be provided as separate first and second sections that are joined together.

[0045] The apparatus described herein may be positioned in tubing (e.g. pipe) for fluid flow therethrough. The apparatus may induce first and second helical vortex flow components, each rotating in opposite directions simultaneously and guiding the fluid in a dual helical path. As the fluid flows through the apparatus, vortices are created and may reduce friction loss, promote mixing, and / or enhance heat transfer or mass transport.The dual helical vortex flow may disrupt the boundary layer at the inner surface of the tubing, which may reduce friction losses. The disrupted boundary layer may decrease the effective viscosity near the inner wall of the tubing, resulting in reduced frictional losses and minimizing the energy required for fluid transport. Additional examples of industries and applications that may benefit from the principles described herein are discussed below.

[0046] By way of nonlimiting example, the apparatus described herein may have beneficial application in fluid transport systems with friction reduction at high flow rates (such as but not limited to: 70 to 120 BPM) and / or high pressures, such as but not limited to up to 20,000 psi (or more). Embodiments described herein may transform higher rate turbulent gas / liquid / solid slurries into a dual vortexial flow pattern with significantly lower differential pressure and / or lower pressure fluctuations at the pipe / tubing wall boundary layer. Embodiments described herein may induce sustained dual helical flow. The apparatus may enhance liquid and / or gas (e.g. air) transportation pipelines, well operations (such as fracturing, well treatment or stimulation (acidizing, remediation, etc.), drilling, waterflooding, improved oil recovery, and more, and aspects of the present disclosure may reduce power / horsepower requirements and therefore costs. The principles discussed herein may also be beneficial in other fields. For example, medical devices may benefit from improved fluid flow in catheters and stints within blood vessels. Chemical processing applications may benefit from efficient transport, mixing and / or dispersion of chemicals, solvents, micro / nanoparticles, and solids. In HVAC systems, improved flow using the principles described herein may enhance heat exchange in air conditioning and refrigeration, including compression systems, turbines and propeller blades could perform better by establishing a more evenly distributed flow pattern prior to interacting with the blades. The apparatus described herein may be designed to fit any tubular configuration. The device induced flow regimes may include, but are not limited to pipelines, transfer flowlines, water distribution systems, medical devices, or any conduit where fluids need to ideally flow at reduced pressures and higher rates to more economically and efficiently flow fluids from their origin to their destination point or back, or be circulated with as low a horsepower requirement as possible.

[0047] The apparatus described herein may be in the form of a tubing insert, which can be designed to fit any tubing (or other conduit) configuration (i.e., helix angle, amplitude, and channel dimensions, and Reynolds number) and withstand the vortices and fluid or slurry composition created. The apparatus may comprise a variety of materials, including but not limited to a cast cobalt alloy and / or plastic. Embodiments are not limited to any particular material or combination of materials. The material(s) may be selected to be suitable for the particular application (e.g. flow rates and pressures, type(s) of fluids, environment, etc.).

[0048] FIG. 1A is a perspective view of an example apparatus 100 according to some embodiments. FIG. 1 B is a side view of the example apparatus 100. With reference to FIGs. 1A and 1 B, the apparatus 100 may provide one or more of the advantages described above. The apparatus may 100 in this embodiment may be referred to as a tool or tubing insert. The apparatus 100 (or ‘tool’) may be positioned in tubing or another type of conduit to alter flow characteristics of a fluid stream flowing therethrough. The apparatus 100 may induce dual helical vortex flow in the fluid stream. The apparatus 100 in this embodiment is in the form of a tubing insert. More particularly, the apparatus 100 may be inserted and positioned within the interior of the tubing (see FIG. 3 described below, for example) for receiving a fluid stream therethrough. In other embodiments, the apparatus may be formed integral with a section of tubing. The apparatus generally has an inlet end 109 and an outlet end 111 , and a fluid stream may flow through the apparatus 100 generally in the illustrated by arrow “F” in FIG. 1A. The inlet end 109 may be referred to as a “bottom end” or an “upstream end”. The outlet end 111 may be referred to as a “top end” or a “downstream end”. Such terminology is used herein for ease of description and does not limit the apparatus to a particular orientation in operation or to a particular application.

[0049] The apparatus 100 in this example embodiment includes a first insert section 102 and a second insert section 104 that is axially stacked with the first insert section 102. The first and second insert sections 102 and 104 may be formed as separate components and then joined together in the stacked formation shown in FIG. 1 . In other embodiments, the first and second insert sections 102 and 104 may be integrated as a single piece of material (i.e. a unitary body). Embodiments are not limited to these particular examples.

[0050] The first insert section 102 may induce a first vortex flow component in fluid flowing through the apparatus 100. The second insert section 104 may induce a second vortex flow component in the fluid flowing through the apparatus 100. The first and second vortex flow components in this example are right-handed and left-handed helical flow components, respectively. That is, each of the first and second vortex flow components may flow in the same axial direction, but with opposite rotational directions. In other embodiments, the apparatus 100 may be configured such that the first and second vortex flow components are left-handed and right-handed helical flow components, respectively.

[0051] The apparatus 100 has an outer diameter D1. The outer diameter D1 may be selected such that the insert 102 may be securely positioned in tubing for a given application. The outer diameter D1 may be selected to provide a friction fit with a section of tubing, for example. The second insert section 104 has a similar structure (with differences described below). As one non-limiting example, the outer diameter may be 2.5 inches (6.4 cm) or more. The inner diameter of the cylindrical body 106a / 106b may be approximately 2 inches (5 cm) or more. The total length of the apparatus 100 may be approximately 6 inches (15 cm) or more. However, embodiments are not limited to these specific dimensions. Each of these dimensions may be larger or smaller in other embodiments. The size and configuration of the apparatus 100, including dimensions and configuration of the first and second insert sections 102 and 104, may vary.

[0052] The first insert section 102 is shown in isolation in FIGs. 2A and 2B. FIGs. 2A and 2B are side and end views of the first insert section, respectively. The first insert section 102 comprises a generally hollow cylindrical body 106a and has an inlet end 103 and an outlet end 105. The body 106a defines a flow passage 116 axially therethrough from the inlet end 103 to the outlet end 105. The body 102 may have other shapes in other embodiments.

[0053] The body 106a of the first insert section 102 defines a plurality of circumferentially spaced side channels 112a, which are openings in the body 106a in this embodiment. In this example, the body 106a comprises an upper ring portion 107a and a lower ring portion 108a with a plurality of circumferentially spaced ribs 110a extending therebetween. The side channels 112a extend in a helix angle. The helix angle may, for example, be between 10 and 30 degrees relative to the longitudinal axis. The helix anglemay be 15 degrees or more. Embodiments are not limited to these example angles or ranges. With reference to FIG. 2A, each side channel 112a has top end 115, bottom end 117, and sides 119a and 119b, where at least one side 119a and 119b extends along a helically aligned path. These channels 112a may, thus, induce a helical vortex flow component in fluid flowing through the first insert section 102. The channels 112a extend radially from an inner surface 121 to an outer surface 123 of the body. In other embodiments, the channels 112a may be recessed into the inner surface 121 and extend only partially towards the outer surface (e.g. helical inner grooves).

[0054] The ribs 110a and upper / lower ring portions 107 / 108 collectively define the plurality of side channels 112a. In this embodiment, the ribs 110a extend at a left-handed helical angle relative to a longitudinal center axis 118 and direction ‘F’ (FIG. 1A), such that each of the side channels 112a extends along a left-handed helical path about the axis 118. The channels 112a are in the form of elongate channels extending at a helical angle. Thus, incoming fluid may be induced to adopt a right-handed helical vortex flow component as it moves through the first insert section 102. The example first insert section 102 includes three ribs 110a defining three side channels 112a. However, the number of ribs and openings and the helical angle thereof may vary. For example, other embodiments may include six or more circumferentially distributed side channels 112a. In some embodiments, each insert section 102 and 104 may include multiple axially spaced groups of side channels, each group including a plurality of circumferentially spaced side channels. Other variations are also possible.

[0055] Different and or additional helical angle structural elements may be included in addition to or as alternatives to the ribs 110a and / or side channels 112a in other embodiments. For example, rather than the channels 112a shown, narrow slots, inner grooves, and / or inner ridge projections (on an inner surface of the body 106a) may be provided.

[0056] The first insert section 102 optionally includes a plurality of radial supports in the form of beams 124a extending from the upper ring portion 107a to a central node 113. These beams 124a and 124b may provide structural support while leaving the axial passageway 116 through the apparatus 100 substantially open for fluid flow. In this embodiment, the first insert section 102 includes three beams 124a and the second insert section 104 includes three beams 124b, although the number of such beams may vary.Each beam 124b is aligned with a respective rib 110a in this example. More specifically, each beam 124b is aligned with an upper end of a respective one of the ribs 110a.

[0057] Turning again to FIGs. 1A and 1B, the second insert section 104 in this example has a similar configuration with a body 106b comprising upper and lower ring portions 107b and 108b with ribs 110b extending therebetween forming side channels 112b, and beams 124b. However, the ribs 110b of the second insert section 104 extend at a left-handed helical angle relative to the axis 118 of the apparatus 100, such that each of the side channels 112b extends along a substantially left-handed helical path about the axis. Thus, incoming fluid may be induced to adopt a right-handed helical vortex flow component as it moves through the second insert section 104. The upper ring portion 107a of the first insert section 102 and the lower ring portion 108b of the second insert section 104, when joined, form an intermediate ring portion of the apparatus 100, positioned intermediate the lower ring portion 108a of the first insert section 102) and the upper ring portion 107b of the second insert section 104.

[0058] In other embodiments, the positioning of the right-handed and left-handed helical configurations of the first and second insert sections 102 and 104 may be swapped.

[0059] FIGs. 1C and 1 D are outlet end and inlet end views of the apparatus 100 of FIG. 1 , respectively. The beams 124a of the first insert section 102 are rotationally or angularly offset from the beams 124b of second insert section 104. As a result, the beams 124a and 124 define or induce six channels 130a to 130f for the helical fluid flows through the apparatus. Another example with beams rotationally or angularly aligned to define three flow channels is discussed below with reference to FIGs. 4A to 4C. Embodiments are not limited to these two example configurations. By varying the number, angular alignment, and / or configuration of the beams (124a and 124b), the number and / or configuration of such channels may likewise be varied.

[0060] The example apparatus 100 may be inserted into tubing as described above. FIG. 3 is a side view of an example system including the apparatus 100 positioned in a tubing section 129. The tubing section 129 is shown in cross-section so that the apparatus 100 is visible. As fluid flows through the first insert section 102 (such as within tubing containing the apparatus 100), the first (right-handed) vortex flow component maybe induced in the flow. As the fluid flows through the second insert section 104, the second (left-handed) vortex flow component may be induced in the flow. With reference to FIG. 9, fluid stream ‘F’ may flow through the apparatus 100, and the apparatus may induce sustained dual helical flow components generally represented using arrows V1 and V2 in FIG. 3. The arrows V1 and V2 are merely for illustrative purposes and do not indicate or limit the apparatus 100 to specific amplitudes, angles, positioning, numbers, etc. of the vortex flow components.

[0061] The tubing section 129 is an example of a conduit section in which the apparatus 100 may be positioned. In other embodiments, another type of conduit section may be used in place of the tubing section 129.

[0062] The dual helical vortex flow components induced in the fluid stream by the apparatus 100 may be sustained for a distance downstream from the apparatus 100. Interwoven helical flow patterns may follow a path that, when projected to 1 D, is a straight line equal to Tangent q = p of the centerline. Projected to 2D, the path may follow a sinusoidal wave trajectory y(t) = A tan(pt -f). In 3D, the path may be a 3D Vortex flow pattern.

[0063] The relative phase (i.e. phase shift) of the first helical flow (V1 ) may be phase shifted relative to the second helical flow (V2). The phase shift is approximately 90 / pi for a Newtonian fluid and may change with non-Newtonian fluids. The degree of phase shift may be dependent on the configuration of the apparatus 100. For example, it may be possible to adjust the phase shift by adjusting the axial length and / or spacing between the first and second insert sections 102 and 104.

[0064] In other embodiments, the components of the apparatus 100 may be integrated with the tubing 129. Any suitable method to provide the inner passage of tubing with the structure to induce the dual helical vortex components may be used, and embodiments are not limited to the particular insert form shown in FIGs. 1 A to 1 D and 3.

[0065] FIGs. 4A to 4C are side, outlet (top) end, and inlet (bottom) end views, respectively, of another example apparatus 200 according to some embodiments. The apparatus 200 is similar to the apparatus 100 of FIGs. 1A to 1D, with differences discussed below and like reference numbers denoting like elements. Similar to theembodiment of FIGs. 1A to 1 D, the apparatus 200 is in the form of an insert to be positioned within a section of tubing, including a first insert section 102 and a second insert section 104.

[0066] In this example, with reference to FIGs. 4B and 4C, first and second insert sections 102 and 104 are positioned, relative to one another, with the beams 124a of the first insert section 102 angularly aligned with the beams 124b of second insert section 104. As a result, the beams 124a and 124b define three channels 230a to 230c for the helical fluid flows through the apparatus.

[0067] FIG. 5 is a perspective view of another apparatus 300 according to some embodiments. The apparatus 300 is in the form of an insert to be positioned within tubing. The apparatus 300 is similar to the example of FIGs. 4A to 4C including first and second axially aligned portions 302 and 304 for inducing left-handed and right-handed vortex components respectively. However, in this embodiment, the apparatus 300 is formed as a unitary body rather than two separate sections. More specifically, the apparatus 300 includes a hollow cylindrical body 306 having an inlet end 303 and an outlet end 305.

[0068] The apparatus 300 includes a hollow cylindrical body 306 comprising an upper ring portion 307, a lower ring portion 309 and an intermediate ring portion 311 positioned intermediate the upper ring portion 307 and the lower ring portion 309. Lower ribs 310a extend at a left-handed helical angle between the lower ring portion 309 and the intermediate ring portion 311. The first portion 302 includes three circumferentially spaced lower side channels 312a defined by the intermediate ring 311 , the lower ring portion 309, and the lower ribs 310a. The second portion 304 includes three circumferentially spaced upper side channels 312b defined by the intermediate ring portion 311 , the upper ring portion 307, and the upper ribs 310b. The number, size, positioning, spacing, shape and other details of the channels 312a and 312b may vary in other embodiments. Other embodiments may include more (or fewer) than three lower side channels 312a and more (or fewer) than three upper side channels 312b. For example, other embodiments may include six or more lower side channels 312a and six or more upper side channels 312b. Similar modifications may be made to other embodiments shown in the drawings and described herein.

[0069] The lower channels 312a are openings with helically angled side walls extending in a left-handed helical angle path (relative to flow from the inlet end 303 to the outlet end 305). The upper channels 312b are openings with helically angled side walls with in a right-handed helical angle path (relative to flow from the inlet end 303 to the outlet end 305)

[0070] The first portion 302 further comprises lower beams 324a extending radially inward from an inner face of the cylindrical body 306 to a lower central node 313a. The first portion 302 further comprises upper beams 324b extending radially inward from an inner face of the cylindrical body 306 to an upper central node 313b. The lower beams each extend from the intermediate ring portion 311 and are each aligned with a respective one of the lower ribs 310a. The upper beams each extend from the upper ring portion 307 and are each aligned with a respective one of the upper ribs 310b. However, the position, number, shape, alignment, and other details of the upper and lower beams 324a and 324b may vary in other embodiments.

[0071] FIGs. 6A and 6B are perspective and side views of another example apparatus 600 according to some embodiments. The apparatus 400 is in the form of an insert to be positioned within tubing. In other embodiments, the apparatuses described herein may be integrated with a section of tubing, such as a tubing joint that may be coupled between two other tubing segments.

[0072] The apparatus 400 is similar to the examples of FIG. 5, in that it comprises first and second axially aligned portions 402 and 404 for inducing left-handed and right- handed vortex components respectively. The apparatus 400 includes a hollow cylindrical body 406 comprising an upper ring portion 407, a lower ring portion 409 and an intermediate ring portion 411 positioned intermediate the upper ring portion 407 and the lower ring portion 409. Lower ribs 410a extend at a left-handed helical angle between the lower ring portion 409 and the intermediate ring portion 411 . The first portion 402 includes three circumferentially spaced lower side channels 412a defined by the intermediate ring portion 411 , the lower ring portion 409, and the lower ribs 410a. The second portion 404 includes three circumferentially spaced upper side channels 412b defined by the intermediate ring 411 , the upper ring portion 407, and the upper ribs 410b. The number, size, shape and other details of the channels 412a and 412b may vary in other embodiments.

[0073] In this embodiment, with reference to FIG. 6A, the apparatus 400 includes lower and upper radial supports 424a and 424b that extend from the inner surface of the hollow cylindrical body 406 to lower and upper nodes 413a and 413b respectively. More specifically, the first portion 402 includes the lower radial projections 424a (or supports) and the upper portion 404 includes the upper radial projections 424b (or supports). The structure of the projections 424a and 424b is better shown in FIGs. 6C to 6F, described below. The first portion 402 includes one lower projection 424a for each of the three lower ribs 410a. The second portion 404 includes one lower projection for each of the three upper ribs 410b.

[0074] The apparatus 400 may further include a rod or other connecting structure (not shown) interconnecting the lower central node 413a and the upper central node 413b. A rod or other type of extension may also extend axially (upward) from the upper central node 413b. Other embodiments described herein may also include such modifications.

[0075] FIGs. 6C and 6D are outlet (top) end and inlet (bottom) end views of the apparatus 400 respectively.

[0076] FIGs. 6E is a cross sectional view of the apparatus 400 taken along the line A-A in FIG. 6B. At the inner face 421 of the cylindrical body 406, each lower radial projection 424a extends longitudinally between the intermediate ring portion 411 and the lower ring portion 409, along the entire length of the corresponding lower rib 410a. The projection defines a parabolically curved lower surface 425a that extends generally upward and inward (defining a substantially parabolic curve) from the lower ring portion 409 to the central node 413a. Similarly, each upper radial projection 424b extends longitudinally between the upper ring portion 407 and the intermediate ring portion 411 , along the entire length of the corresponding upper rib 410b. Each upper radial projection 424b defines a respective parabolically curved lower surface 425b that extends generally upward and inward (defining a substantially parabolic curve) from the lower ring portion 409 to the central node 413a. The side walls of the radial projections 424a and 424b have a helical orientation similar to the ribs 410a and 410b, and the radial projections 424a and 424b may thus also contribute to the corresponding vortex flows. In some embodiments, the lower surfaces 425a and 425b of the projections 424a and 424b mayhave a pitch angle similar to a propellor blade for contributing to inducement of the corresponding vortex flows.

[0077] The radial projections 424a and 424b may not extend the entire length of the corresponding ribs 410a and 410b in other embodiments. The length, parabolic curvature, etc. may vary in other embodiments. Non-parabolic curvature (e.g. spherical) may also be used in other embodiments.

[0078] FIG. 6F is a cross sectional view of the apparatus 400 taken along the line B-B in FIG. 6B, showing the lower radial projections 424a.

[0079] FIGs. 7A and 7B illustrate yet another example apparatus 500 according to some embodiments. FIGs. 7A and 7B are side and inlet end views of the apparatus 500 respectively. The apparatus 500 is similar in form and function to the example apparatus 400 in FIGs. 6A to 6F. The example apparatus 500 is provided with wider beams 524a and 524b and may have other dimensional differences from the example apparatus 400 of FIGs. 6A to 6F. The beams 524a in this example also have parabolically curved lower surfaces.

[0080] The apparatuses 100, 200, 300, 400 and 500 in FIGs. 1A to 1 D and 3 to 7B are examples of structure that may be included in tubing to create first and second intertwined helical flows. The apparatuses 100, 200, 300, 400 and / or 500 may create and induce a sustained dual helical vortex that may reduce or substantially eliminate friction effects in pipe or other forms of tubing. The structure of the apparatuses 100, 200, 300, 400 and / or 500 may have modifications or otherwise different structural details in other embodiments.

[0081] In some implementations, two or more of the apparatuses described herein (or variations thereof) may be installed in a tubing system. Each apparatus that is downstream of another may in effect be a “repeater” point in the flow inducing a dual helical flow pattern that may persist over a significant distance and time to reduce the frictional effects normally encountered when transporting fluid through tubing.

[0082] The apparatuses in the form of inserts described herein may be positioned in a section or joint of tubing, such as but not limited to a “pup” joint which has connectingthreads or flanges on either end to allow it to be placed in line with existing pipe or tubing through which fluids will be flowing.

[0083] FIG. 8 is a flowchart of a method 800 according to some embodiments. At block 802, the apparatus of any of the embodiments shown in FIGs. 1 to 1 D and 3 to 7B is inserted into a section of a conduit such as tubing. At block 804, a fluid stream is flowed through the conduit and the apparatus, which may generate a dual helical vortex flow as described herein.

[0084] Dual helical vortex flow (DHVF) presents an innovative approach to reduce friction in tubing systems. Research and development has defined its design and validated its practical benefits. Implementing DHVF can lead to more energy-efficient and cost-effective fluid transport across various industries. The DHVF induced by the apparatuses described herein may be sustained to greater distances as flow rate and possibly pressure are increased. The DVHF principles and apparatuses discussed herein may be applied in high flow rate and / or pressure applications. By way of nonlimiting example, the flow rates may be in the range of approximately 50 to 150 BPM (approximately 11 k L / min to 25k L / min), and pressures may be in the range of approximately 0 - 15,000 psig or more (approximately 0 to 100,000,000 Pa or more). The principles discussed herein may also be applied in lower flow rate applications such as medical devices (e.g. blood flow, low injection rate waterflooding, enhanced fluid recovery and other applications.

[0085] In testing, a fluid stream was flowed through an embodiment of the apparatus described herein positioned in tubing with a 100 foot flow loop and the apparatus 100 of FIGs. 1 and 2 inserted within the tubing. Using bubbles in the flow to visually indicate flow patterns, dual helical flow has been observed.

[0086] In an experiment, a fluid stream was flowed through an embodiment of the apparatus 100 described herein and shown in FIG. 1A. Figures 9A shows four still two- dimensional (2D) images captured at four times (t1 to t4) separated by intervals of approximately 1 second downstream from the apparatus 100 positioned in substantially transparent tubing. The fluid flow includes bubbles that were observed for indications of flow patterns in the fluid stream. Dots 502a to 502d are used to illustrate the approximate positions of one or more bubbles in the flow at the respective image capture times. Figure10B illustrates these approximate positions overlayed in 2D to indicate an estimated partial flow path. The overlayed dots 502a to 502d are believed to follow an approximate first helical vortex flow pattern projected in 2D (whereas the flow would be three- dimensional (3D) in reality). Figure 10A shows the same four still images of Figure 9A (at times t1 to t4), but with dots 602a to 602d illustrating the approximate positions of other bubbles in the flow. Figure 10B illustrates these approximate positions overlayed to indicate a second estimated partial flow path. The overlayed dots 602a to 602d are believed to follow an approximate second helical vortex flow pattern projected in 2D (whereas the flow would be three-dimensional (3D) in reality).

[0087] In some embodiments, multiple tubing insert apparatuses as described herein may be positioned within tubing. FIG. 11 is a side view of an example system including first and second apparatuses 500a and 500b positioned in a tubing section 129. Each apparatus 500a and 500b is of the form of the example tubing insert apparatus 500 shown in FIGs. 7A and 7B. However, other forms of tubing insert apparatuses, such as (but not limited to) those shown in FIGs. 1 A to 1 D and 4A to 6F may also be placed within the tubing section 129. Multiple dual helical flows may be induced by the multiple apparatuses.

[0088] In some embodiments, a tubing joint may include one or more of the apparatuses of FIGs. 1A to 1 D and 4A to 7B positioned within a section of tubing. The tubing joint may be interconnected between two other sections of tubing.

[0089] As described above, the principles, apparatuses and methods described herein may be beneficial to a wide array of industrial and technical applications. Example applications and possible benefits include, but are not limited to:

[0090] Oil and gas applications: Reduced friction may improve the efficiency of transporting crude oil, natural gas, refined products, water (e.g. including fracturing additives or treatment additives) leading to lower energy costs and reduced wear on pumping equipment.

[0091] Mining applications: Low-friction pipes may be beneficial for slurry transport, maintaining flow rates and minimizing energy consumption.

[0092] Chemical processing applications: Efficient movement of chemicals may be enhanced by low friction, reducing pressure drops and facilitating consistent flow rates in processing plants.

[0093] Water management: Low-friction pipes may improve the efficiency of water transport, reducing pumping costs and energy use.

[0094] Medical and pharmaceutical applications: In medical applications like catheter design and drug delivery systems, low-friction materials may reduce patient discomfort and facilitate smooth fluid delivery.

[0095] Food and beverage applications: Low-friction surfaces aid in transporting liquids and semi-liquids, ensuring consistent flow and minimizing residue buildup.

[0096] Pulp and paper applications: In pulp slurry transport, low friction may help maintain efficient flow and reduce energy consumption.

[0097] Power generation applications: In cooling systems of power plants, low- friction conduits maintain efficient flow rates and reduce energy needed for pumping cooling water.

[0098] HVAC (Heating, Ventilation, and Air Conditioning) applications: Low-friction ducts and conduits may improve the efficiency of air and fluid flow, enhancing energy performance.

[0099] Pharmaceutical manufacturing applications: Low-friction flow of active ingredients and solvents may help maintain product integrity and consistency.

[0100] Aerospace applications: Low-friction conduits may be beneficial in fuel and hydraulic systems in aircraft and may facilitate efficiency and reliability.

[0101] Agriculture applications: In irrigation systems, low-friction pipes may efficiently transport water over long distances, and may thereby reduce pumping energy and improve crop yields.

[0102] Vehicle applications: Low-friction conduits may be used in fluid systems like fuel lines, brake systems, and coolant systems, and may improve performance.

[0103] Pharmaceutical packaging: Low-friction surfaces in conduits may help in the smooth movement of products during packaging and may help prevent damage.

[0104] Biotechnology applications: In biotechnology, low-friction pipes transport sensitive biological fluids while maintaining smooth flow and material integrity.

[0105] Renewable energy (wind, solar): Low-friction conduits in renewable energy installations may assist in cooling systems and fluid transport for maintaining efficiency.

[0106] Semiconductor manufacturing applications: Low-friction piping may be beneficial for providing precise and clean transport of chemicals and ultra-pure water in semiconductor production.

[0107] Textile manufacturing applications: Low-friction pipes may be used to transport dyes and chemicals, and may contribute to consistent flow rates and reducing energy costs.

[0108] Pharmaceutical research and development: Low-friction conduits in R&D labs transport chemicals, reagents, and other substances with high precision and minimal loss.

[0109] Electronics manufacturing applications: Low-friction conduits may be used to transport fluids in electronics production, and may assist with providing precision and reducing waste.

[0110] Cement and concrete applications: Low-friction pipes in cement slurry transport may help maintain flow rates and reduce clogging risks in large construction projects.

[0111] Hydropower applications: Low-friction conduits in hydropower plants may efficiently transport water, crucial for electricity generation with minimal energy loss.

[0112] Nuclear power applications: In nuclear power plants, low-friction pipes may be used in coolant systems and may help provide efficient heat exchange and reduce pressure loss.

[0113] Gas distribution networks: Low-friction pipelines in natural gas distribution may reduce energy consumption and help provide consistent flow rates over long distances.

[0114] Mixing applications: applications in which multiple components in a fluid stream may be mixed may benefit from the apparatuses, systems, and methods disclosed herein.

[0115] It is to be understood that a combination of more than one of the approaches described above may be implemented. Embodiments are not limited to any particular one or more of the approaches, methods or apparatuses disclosed herein. One skilled in the art will appreciate that variations, alterations of the embodiments described herein may be made in various implementations without departing from the scope of the claims.

Claims

CLAIMS:1 . An apparatus for receiving a fluid stream therethrough, the apparatus comprising: a body having an inlet end and an outlet end and defining a passage axially therethrough from the inlet end to the outlet end, the body comprising: a first portion comprising first helical angle elements for inducing a first vortex flow component in the fluid stream; and a second portion comprising second helical angle elements for inducing a second vortex flow component in the fluid stream, wherein the first helical angle elements have one of a left-handed orientation or a right-handed orientation, and the second helical elements have the other of the lefthanded orientation or the right-handed orientation.

2. The apparatus of claim 1 , wherein the apparatus is a tubing insert.

3. The apparatus of claim 1 or 2, wherein the first vortex flow component is a lefthanded vortex flow component and the second vortex flow component is a right-handed vortex flow component.

4. The apparatus of claim 1 or 2, wherein the first vortex flow component is a right- handed vortex flow component and the second vortex flow component is a left-handed vortex flow component.

5. The apparatus of any one of claims 1 to 4, wherein the second portion is positioned downstream of the first portion.

6. The apparatus of claim 5, wherein: wherein the body is a hollow cylindrical body having an inner body surface and an outer body surface; wherein the first helical angle elements of the first portion comprise a first plurality of helically-oriented side channels extending radially through the hollow cylindrical body from the inner surface to the outer surface; andwherein the second helical angle elements of the first portion comprise a second plurality of helically-oriented side channels extending radially through the hollow cylindrical body from the inner surface to the outer surface.

7. The apparatus of claim 6, wherein the hollow cylindrical body comprises: an upper ring portion at the outlet end; a lower ring portion at the inlet end; an intermediate ring portion positioned intermediate the lower and upper ring portions; lower helically-oriented ribs interconnecting the intermediate ring portion and the lower ring portion, wherein the lower ribs, the lower ring portion and the intermediate ring portion collectively define the first plurality of helically-oriented side channels; and upper helically-oriented ribs interconnecting the intermediate ring portion and the upper ring portion, wherein the upper ribs, the upper ring portion and the intermediate ring portion collectively define the second plurality of helically-oriented side channels.

8. The apparatus of claim 7, wherein the first portion further comprises first projections extending from the inner surface of the cylindrical body to a first central node; and the second portion further comprises second projections extending from the inner surface of the cylindrical body to a second central node.

9. The apparatus of claim 8, wherein each of the first projections and each of the second projections comprises a respective beam.

10. The apparatus of claim 8, wherein each of the first projections has a respective lower face, the lower have defining a parabolic curvature.

11. The apparatus of any one of claims 8 to 10, wherein each of the second projections has a respective lower face, the lower have defining a parabolic curvature.

12. The apparatus of anyone of claims 8 to 11 , wherein each of the first projections is aligned with a respective one of the lower helically-oriented ribs.

13. The apparatus of anyone of claims 8 to 12, wherein each of the second projections is aligned with a respective one of the upper helically-oriented ribs.

14. The apparatus of any one of claims 8 to 13, wherein each of the lower helically- oriented ribs has a respective upper end aligned with a respective lower end of one of the upper helically-oriented ribs.

15. The apparatus of claim 2, wherein the first portion is a first insert section, the second portion is a second insert section, and the first and second insert sections are joined in an axially stacked configuration.

16. The apparatus of any one of claims 1 to 14, wherein the apparatus is formed as a single unitary piece of material.

17. A system comprising: a conduit section; and the apparatus of any one of claims 1 to 16 positioned within the the conduit section to receive a fluid stream therethrough.

18. The system of claim 17, further comprising one or more additional apparatuses according to claims 1 to 16 positioned within the section of tubing.

19. A method comprising: positioning the apparatus of any one of claims 1 to 16 within a conduit section; and flowing a fluid stream through the conduit section and the apparatus.

20. An apparatus for receiving a fluid stream therethrough and comprising: a first section for inducing a first vortex flow component in the fluid stream; and a second section for inducing a second vortex flow component in the fluid stream.

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