Acid Mixing Flow Control With Integrated Flush and Vapor Recovery
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Solution Overview
Problem
Conventional systems for mixing water, acid, and other chemicals in hydrocarbon formation fracturing operations are complex, leading to job-site safety concerns, inefficiency, and inconsistency.
Innovation Solution
A system comprising a tank for holding acid, an acid pump, acid flow meter, acid control valve, a water pump, water flow meter, water control valve, a flush valve, and a controller to monitor flow meters and control pumps and valves, allowing for precise acid concentration control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional systems are used to mix water, acid, and chemicals, then mixing capability is provided, but system complexity increases leading to safety concerns and inefficiency
Solution Approach 1:
The patent combines multiple mixing functions into a single integrated system that includes a tank, pump, flow meter, control valve, and vapor recovery unit. This consolidation reduces the number of separate components and connections needed, thereby reducing overall system complexity while maintaining reliable acid mixing capability and improving job-site safety.
Solution Approach 2:
The system integrates multiple functions into one apparatus: acid storage, pumping, flow measurement, flow control, mixing, and vapor recovery. This multi-functionality eliminates the need for separate systems for each operation, reducing complexity and potential failure points while enhancing safety and reliability.
2Productivity
If conventional mixing systems are used, then acid mixing is achieved, but consistency and efficiency decrease due to operational complexity
Solution Approach 1:
The system incorporates a flow meter that provides feedback on acid flow rate to a controller, which automatically adjusts the control valve to maintain the desired flow rate. This closed-loop control ensures consistent mixing ratios and improves efficiency by eliminating manual adjustments and reducing setup complexity.
Solution Approach 2:
The system is designed to automatically regulate its own operation through the controller that monitors flow meter readings and adjusts the control valve accordingly. This self-regulating capability reduces the need for operator intervention, simplifying operation and improving consistency while maintaining high efficiency.
3Quantity of substance
If acid mixing operations are performed, then fracturing fluid is produced, but environmental emissions increase from acid vapors
Solution Approach 1:
The vapor recovery unit captures harmful acid vapors that would otherwise be emitted into the environment and redirects them back into the mixing system or storage tank. This converts the harmful emission into a beneficial recycling process, maintaining full acid/water mixture output while eliminating environmental pollution.
Solution Approach 2:
The vapor recovery unit creates a controlled environment that prevents acid vapors from escaping to the atmosphere. By containing and recirculating the vapors within an enclosed system, the harmful emissions are eliminated while the acid mixing and production process continues uninterrupted.
Data Source
AI summary
A system for mixing acid and water can include a tank for holding acid, an acid pump for pumping acid out of the tank, an acid control valve, a water pump for pumping water, a water control valve, a flush valve to selectively flush the system with water, and a controller to control the pumps and the valves. The acid control valve and/or the water control valve can be an electronically controlled valve. The flush valve can be an electronically controlled valve to selectively permit water to flow from downstream of the water pump to upstream of the acid pump. The acid control valve, the water control valve, the flush valve, or any combination thereof can be throttled by the controller to control flow therethrough.