Aqueous Polymer Slurry Stability via Supersaturated Salt
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Solution Overview
Problem
Current aqueous-based polymer slurry systems for water-soluble polymers face challenges such as hydration issues, short shelf-life, and instability, particularly in high-temperature conditions, which affect viscosity and processability, leading to economic and operational inefficiencies in industries like oil and gas.
Innovation Solution
Aqueous-based water-soluble polymer slurry systems comprising a liquid phase with water, salts, and water-soluble organic solvents, and a solid phase with water-soluble polymer powders, where the salt concentration exceeds its maximum solubility in water, preventing polymer hydration and maintaining stability, with specific compositions that include 10-55% polymer, 10-53% water, and 1-85% organic solvent by weight, ensuring long-term stability and pumpability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If water-soluble polymer powders are slurred into an oil-based suspension fluid, then handling and operational convenience are improved, but cost structure deteriorates when mineral oil prices are high
Solution Approach 1:
The patent changes the base fluid parameter from oil-based to aqueous-based, creating a water-soluble polymer slurry system that maintains handling convenience while eliminating dependence on mineral oil prices. The system uses water as the continuous phase with specific additives to prevent polymer hydration and maintain stability.
Solution Approach 2:
The patent creates a composite aqueous-based slurry system combining water, water-soluble polymer powders, and specific additives (including water-miscible solvents and surfactants) to achieve both operational convenience and cost-effectiveness, replacing the simple oil-based slurry approach.
2Stability of the object's composition
If aqueous-based suspensions use calcium chloride solution with low molecular weight polymer and alcohol, then polymer solubility is reduced, but flash point, shelf-life, and stability deteriorate
Solution Approach 1:
The patent modifies the aqueous-based suspension by replacing calcium chloride with sodium chloride and changing the alcohol component to a water-miscible solvent with specific physical properties (flash point above 100°C, viscosity 1-100 cP). These parameter changes simultaneously achieve polymer solubility control and improved stability with extended shelf-life.
Solution Approach 2:
The patent uses common, inexpensive materials like sodium chloride and water-miscible solvents that are readily available and stable, replacing the more specialized calcium chloride system. This approach achieves the desired polymer solubility control while using more stable, longer-lasting components.
3Quantity of substance
If aqueous-based suspensions are formulated, then cost control is improved, but polymer hydration occurs leading to viscosity changes and processability issues
Solution Approach 1:
The patent introduces water-miscible solvents and surfactants as intermediary substances that mediate between water and polymer powder, preventing direct hydration of the polymer while maintaining cost-effectiveness. These intermediaries create a stable slurry system where polymer particles remain suspended without dissolving or aggregating.
Solution Approach 2:
The patent replicates the successful oil-based slurry approach using aqueous-based components, copying the slurry formulation strategy while adapting to water-based chemistry. This allows cost control benefits of aqueous systems while maintaining the stability and viscosity characteristics of proven slurry systems.
4Stability of the object's composition
If polymer concentration is increased to affect rheology, then viscosity control is improved, but pumpability and handling deteriorate
Solution Approach 1:
The patent uses water-miscible solvents and surfactants as intermediaries that allow polymer particles to remain suspended at lower concentrations while maintaining effective rheology control. The intermediaries prevent polymer aggregation and ensure uniform distribution, achieving viscosity control without the handling difficulties of concentrated solutions.
Solution Approach 2:
The patent changes the physical parameters of the suspension system by using water-miscible solvents with specific viscosity ranges (1-100 cP) and incorporating surfactants, enabling effective polymer concentration (10-50%) that balances rheology control with pumpability and handling convenience.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed system significantly prevents polymer hydration, maintaining viscosity and processability over 30 days at elevated temperatures, enhancing shelf-life and economic viability by avoiding separation and consolidation, thus overcoming previous limitations.
Implementation Method 1
a liquid phase which provides sufficient suspension and significantly prevents the solid phase from hydrating into solution
Implementation Method 2
the salts are present in the liquid phase in an amount that is higher than its maximum solubility in water
Implementation Method 3
a water-soluble organic solvent or a mixture of water-soluble organic solvents... significantly prevents the solid phase from hydrating into solution
Data Source
AI summary
Systems and methods for forming aqueous based, water-soluble polymer slurry systems may include (1) a liquid phase which may be a suspension comprised of salt, water, and a water-soluble organic solvent and (2) a solid phase which may comprise a water-soluble polymer powder. The aqueous based, water-soluble polymer slurry systems may optimize processing of the suspension package so that it may slurry in low and high salt tolerance polymers, and the finished product can survive over 30 days at an approximately 120-degree Fahrenheit aging temperature, thereby overcoming economic performance and stability challenges through its high flash point, long shelf-life, high-temperature tolerance, and low cost.