Blender Tub Flow Channel for Low-Air Fracturing Fluid Mixing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing blender systems for mixing fracturing fluids face inefficiencies due to air entrainment, which affects the performance and operational life of discharge pumps, particularly when unmixed materials are introduced above the fluid surface.
Innovation Solution
A blender system design featuring a blender tub with an open top, shroud, and flow surface that encourages turbulent flow, reducing air entrainment by allowing unmixed materials to enter below the fluid surface, combined with paddle-driven mixing to enhance proppant suspension and slurry efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If unmixed materials are introduced above the fluid surface in existing blender systems, then the blending process can accommodate various material inputs, but air entrainment occurs which reduces pump efficiency and operational life
Solution Approach 1:
The patent introduces a vertical flow channel dimension that guides materials downward through the blender tub. By creating a controlled vertical flow path from the top opening through the fluid surface to the discharge point, the system ensures materials enter below the fluid surface level, eliminating air entrainment while maintaining versatile material input capability
Solution Approach 2:
The flow channel acts as an intermediary structure between the material input point and the discharge point. It mediates the flow by directing materials through a controlled path that passes below the fluid surface, preventing direct contact with air and eliminating the harmful air entrainment effect
2Productivity
If paddle-driven mixing is used to enhance proppant suspension, then slurry mixing efficiency improves, but device complexity increases
Solution Approach 1:
The paddle assembly serves multiple functions simultaneously: it mixes the slurry, suspends proppant particles, and works in conjunction with the flow channel to control material flow. By making the paddle system multi-functional, the patent achieves enhanced mixing efficiency without proportionally increasing device complexity
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 design reduces air entrainment, enhancing the efficiency and operational life of discharge pumps by ensuring they handle only designed materials, thereby improving the overall performance and reliability of the blending process.
Implementation Method 1
The blender system design features a blender tub with an open top, shroud, and flow surface that encourages turbulent flow, reducing air entrainment
Implementation Method 2
paddle-driven mixing to enhance proppant suspension and slurry efficiency
Data Source
AI summary
A blender system may include a blender assembly, the blender assembly including a blender tub, the blender tub having a mixing chamber and an open top. The blender assembly may also include one or more paddles, the paddles positioned within the mixing chamber and a tub paddle motor, the tub paddle motor adapted to rotatably drive the one or more paddles. The blender assembly may also include an upper lip, the upper lip positioned within the blender tub and a shroud, the shroud extending from the upper lip. In addition, the blender system may include a flow surface, the flow surface positioned below the shroud forming a flow channel between the shroud and the flow surface.