Blender Tub Overflow Catch System for Fracturing Fluid Recycling
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Solution Overview
Problem
Fracturing fluid blenders often experience overflow during blending operations, leading to fluid spillage onto the ground, which is both environmentally hazardous and inefficient, as the excess fluid is not effectively contained or recycled.
Innovation Solution
A system comprising a first tub and a secondary tub, where the secondary tub is designed to circumvent the outside diameter of the first tub and is equipped with valves and routing pipes to redirect overflow fluid back into the first tub once its capacity is determined to be sufficient, utilizing sensors to manage fluid levels and flow rates for efficient recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a single tub is used for blending fracturing fluid, then the device structure is simple, but the fluid overflows and spills onto the ground causing environmental contamination
Solution Approach 1:
The patent implements a nested tub configuration where a second tub is positioned inside or around the first tub. The second tub acts as an inner containment vessel that can receive and hold overflow fluid from the first tub, preventing environmental contamination while maintaining a relatively compact overall structure.
Solution Approach 2:
The patent introduces an intermediary overflow management system including overflow ports, routing pipes, and valves that mediate between the first tub and the environment. This intermediary structure captures overflow fluid and redirects it back into the first tub through the routing pipes, eliminating direct spillage onto the ground.
2Loss of substance
If overflow fluid is discharged directly onto the ground, then the system operation is simple, but the fluid is wasted and not recycled
Solution Approach 1:
The patent implements a feedback mechanism where overflow fluid that exits the first tub through overflow ports is captured and redirected back into the first tub via routing pipes. This creates a closed-loop system that continuously recycles fluid, minimizing loss and waste while maintaining operational simplicity through automatic fluid return.
Solution Approach 2:
Instead of discarding overflow fluid onto the ground, the patent recovers it through the second tub and routing pipe system. The overflow fluid is captured, transported back through the routing pipes, and returned to the first tub, effectively recovering the substance that would otherwise be wasted.
3Reliability
If the tub capacity is increased to prevent overflow, then the fluid containment is improved, but the device occupies more space and has greater mass
Solution Approach 1:
The patent divides the fluid containment function into two separate tubs: the first tub for primary blending and the second tub for overflow management. This segmentation allows the first tub to maintain its original size and weight while the second tub handles overflow, achieving reliable containment without increasing the mass of the primary blending vessel.
Solution Approach 2:
The patent addresses overflow containment by adding a vertical or radial dimension through the nested tub configuration. Instead of increasing the size of the first tub in all dimensions, the second tub is positioned to catch overflow in a different spatial arrangement, maintaining compact overall dimensions while improving containment reliability.
Data Source
AI summary
In at least one embodiment, a system for a blender tub overflow catch is disclosed for fracturing operations using a fracturing fluid blender. In at least one embodiment, the system includes a first tub that may be a blender tub and a second tub forming a blender tub overflow catch that is adapted to circumvent an outside diameter of the first tub to catch overflow fluid from the first tub so that it can be directed back into the first tub upon a determination that the first tub has a capacity to handle the overflow fluid.