Biomass Rheology Modifier Production via Refining and Homogenizing
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Solution Overview
Problem
Current methods for drilling and hydraulic fracturing in the oil and gas industry face challenges in minimizing environmental impact and costs, with a lack of economical processes for using cellulose-based materials with adjustable properties in drilling and fracturing fluids.
Innovation Solution
A process is developed to produce a biomass-derived rheology modifier from cellulosic biomass, involving digestion with steam and/or hot water, refining, washing, gelling, and homogenizing to create a high-viscosity compound that can be used as a gelling agent or rheology modifier in drilling and fracturing fluids, offering adjustable properties and biodegradability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional drilling and fracturing fluids are used, then operational effectiveness is maintained, but environmental impact increases and costs rise
Solution Approach 1:
The patent changes the chemical composition parameters of drilling and fracturing fluids by replacing conventional synthetic polymers with biomass-derived rheology modifiers. This substitution maintains operational effectiveness while reducing environmental impact through biodegradability and use of renewable resources.
Solution Approach 2:
The patent employs biodegradable rheology modifiers that can be naturally decomposed after use, replacing persistent conventional additives. This allows for environmentally friendly disposal while maintaining functional performance during the operational lifecycle.
2Adaptability or versatility
If cellulose-based materials are used as rheology modifiers, then biodegradability and renewable resource utilization are improved, but economical production processes are lacking
Solution Approach 1:
The patent segments the cellulose processing into distinct stages: pretreatment to remove lignin and hemicellulose, followed by controlled refining to achieve desired molecular weight and viscosity. This segmentation enables economical production by optimizing each stage independently and using readily available equipment.
Solution Approach 2:
The patent utilizes autohydrolysis where steam and hot water naturally decompose hemicellulose and extract lignin without requiring additional chemical reagents. This self-service approach reduces production costs while maintaining biodegradability and renewable resource utilization.
3Reliability
If high-intensity refining is applied to cellulose-rich solids, then rheology modifier performance is improved, but processing complexity increases
Solution Approach 1:
The patent employs a refiner that performs multiple functions: mechanical fibrillation of cellulose, heat treatment for controlled degradation, and water circulation for temperature control and hemicellulose extraction. This multi-functionality improves rheology modifier performance while avoiding the need for separate processing equipment.
Solution Approach 2:
The patent implements continuous refining where cellulose-rich solids are continuously fed through the refiner with constant steam injection and water circulation. This continuous operation maintains optimal processing conditions, improves product consistency, and reduces the complexity of batch-to-batch transitions.
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 process results in a biodegradable, high-viscosity rheology modifier that enhances the performance of drilling and fracturing fluids by providing strong shear thinning, thixotropic qualities, and thermal stability, reducing environmental impact and operational costs.
Implementation Method 1
digesting the feedstock with a reaction solution including steam and/or hot water in a digestor under effective reaction conditions to produce a digested stream containing cellulose-rich solids, hemicellulose oligomers, and lignin
Implementation Method 2
refining the cellulose-rich solids in a first high-intensity refining unit, thereby generating refined cellulose solids
Implementation Method 3
homogenizing the gelled cellulose solids in a high-shear homogenizer, thereby generating a biomass-derived rheology modifier
Data Source
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AI summary
A process is provided for producing a biomass-derived rheology modifier, comprising: providing a pretreated feedstock comprising cellulose-rich solids; refining the cellulose-rich solids in a first high-intensity refining unit, generating refined cellulose solids; gelling the refined cellulose solids in a second high-intensity refining unit, thereby generating gelled cellulose solids; and homogenizing the gelled cellulose solids in a high-shear homogenizer, thereby generating a biomass-derived rheology modifier. The pretreated feedstock may include kraft pulp, sulfite pulp, AVAP® pulp, soda pulp, mechanical pulp, thermomechanical pulp, and/or chemimechanical pulp, derived from wood or lignocellulosic biomass. The pretreated feedstock may be GP3+® pulp, obtained from steam or hot-water extraction of lignocellulosic biomass. These rheology modifiers may be utilized in a wide variety of applications, including water-based or oil-based hydraulic fracturing fluid formulations, as gelling agents. These rheology modifiers are biodegradable, and their production does not directly involve chemicals other than biomass and water.