Blending Produced Fluids with Fresh Water for Hydraulic Fracturing

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Solution Overview

Problem

Hydraulic fracturing in oil and gas wells requires large volumes of water, and existing methods for reusing produced fluids in gel-based fracture fluids have been ineffective.

Innovation Solution

A system and process for blending fresh water with produced formation fluids, using on-site measurements and Potassium Chloride Equivalency calculations to control clay stabilization and cross-linking times, allowing for real-time adjustments in volumetric ratios to optimize gel-based hydraulic fracturing operations, thereby reducing the need for clay stabilizer chemicals and improving water usage efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If produced fluids are reused in gel-based fracture fluids, then water scarcity is addressed and water usage efficiency is improved, but gel cross-linking and clay stabilization are compromised

Engineering Contradiction:

Improvewater usage efficiencyVSAvoidgel cross-linking and clay stabilization

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent changes the chemical parameters of produced fluids by adding potassium chloride (KCl) to achieve clay stabilization and adjusting boron levels to enable gel cross-linking. This transforms produced fluids from unsuitable to suitable for gel-based fracturing by modifying their chemical composition

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces KCl and boron compounds as intermediary substances that mediate between produced fluids and gel chemistry. These intermediaries enable the produced fluids to function as effective fracturing fluids by facilitating proper gel cross-linking and clay stabilization

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If clay stabilizer chemicals are used to stabilize formation clays, then clay stabilization is improved, but chemical usage and environmental impact increase

Engineering Contradiction:

Improveclay stabilizationVSAvoidchemical usage

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent changes the approach to clay stabilization by using KCl to modify the ionic environment and produced fluid chemistry rather than adding dedicated clay stabilizer chemicals. This reduces chemical usage while achieving the same stabilization effect

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent enables produced fluids to self-stabilize clays through their inherent chemistry when supplemented with KCl and boron, eliminating the need for additional clay stabilizer chemicals. The system uses the produced fluids' own properties to achieve stabilization

Inventive Principle:

Principle #25Self-service

3Reliability

If fresh water is blended with produced fluids, then water quality is improved, but real-time monitoring and control complexity increase

Engineering Contradiction:

Improvewater qualityVSAvoidblending and monitoring system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements real-time monitoring of blend ratios, boron levels, and chloride concentrations with feedback control to maintain optimal water quality. This ensures proper gel cross-linking and clay stabilization while managing the complexity of the blending process

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent creates a multi-functional blending system that simultaneously controls water quality, gel cross-linking chemistry, and clay stabilization through a single integrated process. This consolidates multiple functions into one system, managing complexity while achieving multiple objectives

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables efficient use of produced fluids in hydraulic fracturing by ensuring adequate gel cross-linking and clay stabilization, reducing chemical usage, and providing real-time monitoring for maintaining water quality and pump performance.

Implementation Method 1

cross-linked gel-based hydraulic fracturing

Methodology Applied

Scientific EffectGel cross-linking: Chemical Bonding

Implementation Method 2

Potassium Chloride (KCl) Equivalency calculation, to provide feedback on water constituent adjustments

Methodology Applied

Scientific EffectIon exchange: Ion Exchange

Data Source

PatentUS10406492B1Process or using subterranean produced fluids for hydraulic fracturing with cross-linked gels while providing elimination or reduction of formation clay stabilizer chemicals

Publication Date: 2019.09.10 HYDROZONIX LLC

AI summary

A system and process for defining, blending and monitoring fresh water with subterranean produced formation fluids, with particular constituents of the blended waters being controlled for proper use in gel-type hydraulic fracturing operations. On-site measurements and calculations of clay stabilization replacement, through a Potassium Chloride (KCl) Equivalency calculation, provide feedback on water constituent adjustments that may be needed just prior to the gel-based hydraulic fracturing process. This assures adequate gel cross-linking times, delayed gel cross-linking times, and clay stabilization in the formation to be fractured.