Cement Slurry Mixing System with Recirculation and Vortex Air Separation
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Solution Overview
Problem
In downhole cementing operations, the quality and consistency of cement slurries are affected by the handling and delivery of powder cement blends and slurry fluids, leading to issues with air separation and solids fraction monitoring, particularly in applications where the cement slurry is close to or lighter than water.
Innovation Solution
A system comprising a conical tank with a powder cement blend inlet and a mixing liquid inlet, combined with a mixing assembly driven by a shaft, creates a vortex for enhanced mixing and air separation, and includes a recirculation system to improve the accuracy of solids fraction monitoring by reintroducing mixed slurry back into the mixer, allowing for better control and monitoring of the cement slurry composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional mixing systems are used to mix cement slurry, then the mixing process can be completed, but air separation is insufficient and solids fraction monitoring accuracy deteriorates
Solution Approach 1:
The patent extracts air from the cement slurry using a dedicated air separation chamber positioned above the mixing assembly. The vortex created by the mixing assembly naturally separates air bubbles from the slurry, and the air separation chamber provides a controlled environment for complete air removal before the slurry is discharged. This extraction principle directly addresses the harmful effect of air contamination while improving measurement accuracy.
Solution Approach 2:
The system performs preliminary air separation and density stabilization before the cement slurry reaches the monitoring and pumping stages. The conical tank and air separation chamber are designed to remove air and stabilize the slurry density in advance, ensuring accurate solids fraction monitoring and preventing issues during downhole injection.
2Stability of the object's composition
If recirculation system is implemented to improve mixing quality, then mixing consistency is improved, but system complexity increases
Solution Approach 1:
The patent combines multiple functions into integrated components. The mixing assembly serves both as a mixing device and an air separation mechanism through vortex creation. The conical tank structure integrates storage, mixing, and air separation functions. The recirculation system is simplified by using the existing mixing assembly and tank geometry to achieve both mixing enhancement and air removal simultaneously, reducing overall system complexity while improving slurry consistency.
3Object-affected harmful factors
If vortex mixing is used to enhance air separation, then air removal is improved, but mixing assembly design complexity increases
Solution Approach 1:
The patent employs a conical tank geometry with curved surfaces to facilitate vortex formation and air separation. The conical shape naturally guides the slurry flow to create a vortex pattern that effectively separates air bubbles from the cement slurry. This geometric approach achieves superior air separation without requiring complex mechanical mixing assemblies with multiple moving parts.
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 system ensures a cement slurry substantially free of air, enhancing the accuracy of solids fraction monitoring and optimizing the delivery of constituents, leading to improved mixing quality and consistency, even in challenging density measurement scenarios.
Implementation Method 1
creates a vortex for enhanced mixing and air separation
Implementation Method 2
creates a vortex for enhanced mixing and air separation
Data Source
AI summary
A technique facilitates mixing of cement slurry for use in a cementing application. At least one cement mixer is provided with a tank, e.g. a conical tank, having a powder cement blend inlet and a mixing liquid inlet. A cement slurry discharge may be positioned generally beneath the tank. A mixing assembly also is positioned below the tank and driven by a shaft. The mixing assembly is exposed to an interior of the tank and is used to mix the cement slurry when rotated by the shaft and to direct the cement slurry out through the cement slurry discharge. Additionally, a recirculation system comprises an inlet positioned to receive a portion of the cement slurry mixed in the mixing assembly. The recirculation system also comprises an outlet positioned to direct the portion back into the mixer to enhance mixing effects.