Atmospheric Proppant Addition System for Frac Fluid
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Solution Overview
Problem
Conventional proppant addition systems for well fracturing require expensive and costly high-pressure equipment, and balancing multiple frac pressure pumps to mix proppant with frac fluids, which can reduce the effectiveness of liquefied petroleum gas (LPG) usage and complicate clean-up processes.
Innovation Solution
A system using a frac pressure pump, a frac fluid source, and a proppant supply source with a positive displacement pump to mix proppant with liquid hydrocarbons, allowing the mixture to be pumped into a stream of frac fluid at atmospheric pressure, eliminating the need for a pressure vessel and enabling more control over proppant addition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional high-pressure proppant addition systems are used with multiple frac pressure pumps, then proppant can be mixed with frac fluid under pressure, but the system becomes expensive, complex to operate, and difficult to control
Solution Approach 1:
The system separates the proppant addition function from the high-pressure frac fluid pumping function. A dedicated positive displacement pump operates at atmospheric pressure to add proppant to the frac fluid stream, while the frac pressure pump handles only the frac fluid. This segmentation eliminates the need for multiple high-pressure pumps and complex balancing systems.
Solution Approach 2:
The patent introduces an intermediary atmospheric pressure proppant addition system that connects to the high-pressure frac fluid stream. The positive displacement pump serves as an intermediary device that injects proppant into the frac fluid without requiring high-pressure containment, using the existing high-pressure stream as the medium for proppant delivery.
2Manufacturing precision
If multiple frac pressure pumps are used to balance outlet pressures, then proppant mixing can be achieved, but the pumping becomes difficult to control and operational costs increase
Solution Approach 1:
The system divides the pumping functions into two independent parts: a positive displacement pump for precise proppant metering at atmospheric pressure, and a frac pressure pump for high-pressure fluid delivery. This eliminates the need to balance multiple high-pressure pumps while maintaining precise proppant addition control.
Solution Approach 2:
The invention changes the operating pressure parameter of the proppant addition system from high-pressure to atmospheric pressure. This parameter change allows the use of a positive displacement pump with precise flow control capabilities, eliminating the complexity of pressure balancing while maintaining mixing precision.
3Ease of manufacture
If proppant is mixed with substantial amounts of low vapor pressure frac oils, then proppant can be pumped, but the positive effects of LPG frac fluid are reduced and clean-up becomes more difficult
Solution Approach 1:
The patent uses liquid hydrocarbons as an intermediary carrier fluid to transport proppant through the positive displacement pump at atmospheric pressure. This intermediary allows proppant to be pumped without requiring high-pressure containment or substantial amounts of traditional frac oils, minimizing contamination of the LPG frac fluid stream.
Solution Approach 2:
The invention changes the pressure parameter from high-pressure to atmospheric pressure for proppant addition, and changes the carrier fluid from substantial amounts of low vapor pressure frac oils to minimal liquid hydrocarbon. This reduces the harmful effects on LPG frac fluid effectiveness and simplifies clean-up procedures.
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
This solution reduces operational costs, simplifies the pumping process, and maintains the effectiveness of LPG frac fluids by allowing proppant to be added at atmospheric pressure, improving control over fracturing and reducing clean-up challenges.
Implementation Method 1
The positive displacement pump is connected to pump proppant into the stream of frac fluid before the frac pressure pump
Data Source
AI summary
An apparatus and related method for fracturing a formation penetrated by a well comprises a frac pressure pump, a frac fluid source, and a proppant supply source. The frac pressure pump is connected to the well. The frac fluid source is connected to supply a stream of frac fluid to the frac pressure pump. The proppant supply source has a proppant receiver, a positive displacement pump, and at least an inlet into the proppant supply source. The at least an inlet is connected to one or more liquid hydrocarbon sources to supply liquid hydrocarbons to proppant in the proppant supply source. The positive displacement pump is connected to pump proppant into the stream of frac fluid before the frac pressure pump. Fluid lines connecting the frac pressure pump, the well, and the frac fluid source have isolation valves spaced so that the volume of fluid containable between any set of neighboring isolation valves is less than or equal to 500 L.