Closed-Circuit Polymer Powder Dissolution With Cyclone Filtration
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Solution Overview
Problem
Existing installations face challenges in efficiently dissolving fine water-soluble polymers, particularly those with particle sizes less than 350 micrometers, which lead to bulk issues, safety concerns for operators, and increased maintenance due to agglomeration, hydroscopy, and filter clogging, especially in offshore applications.
Innovation Solution
A closed-circuit installation with a grinding device, cyclone, and filter assembly operates in a dry atmosphere to grind and separate polymer particles, ensuring optimal dissolution without maturation tanks, reducing exothermal phenomena, and maintaining safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If simple wetting means (ejectors, wetting shovels, nozzles) are used to dissolve polymer powder, then the dissolution process is simple to implement, but the flow rate is low and dissolution time is long (1 to 2 hours)
Solution Approach 1:
The dissolution process is segmented into distinct functional zones: a wetting cone for initial powder wetting, a grinding chamber with rotor-stator for mechanical dispersion, and a discharge zone. This segmentation allows each zone to perform its specific function efficiently, transforming the single-step simple wetting process into a multi-stage process that maintains simplicity while dramatically improving dissolution speed and flow rate.
2Productivity
If polymer powder with particle size less than 350 micrometers is used, then the polymer dissolves more efficiently, but the powder becomes more sensitive to hydroscopy causing flowability problems and filter clogging
Solution Approach 1:
The system performs preliminary classification of the polymer powder using a classifier before it enters the dissolution process. This preliminary action separates the powder into appropriate particle size fractions, ensuring that only suitably sized particles proceed to the wetting and dissolution stages, thereby preventing flowability problems and filter clogging that would occur with unsuitable fine particles.
Solution Approach 2:
Different zones of the dissolution system are designed with specific local qualities: the wetting cone has specific geometry and surface properties optimized for wetting, the grinding chamber has rotor-stator configuration optimized for mechanical dispersion, and the discharge zone is optimized for efficient particle transfer. This local optimization ensures that each stage handles the powder properties appropriately, maintaining flowability while achieving efficient dissolution.
3Volume of moving object
If grinding device is directly connected to wetting cone inlet, then the installation is compact, but rapid heating of constitutive elements causes technical damage and thermal degradation of polymer
Solution Approach 1:
An intermediary cooling system is introduced between the grinding device and the wetting cone. This intermediary element (cooling circuitry, cooling air passages, or thermal management components) absorbs and dissipates the heat generated during grinding, preventing thermal degradation of the polymer while maintaining the compact integrated design of the installation.
4Ease of operation
If fine polymer powder is handled in open environment, then operators can easily access the material, but significant quantity of powder disperses into atmosphere requiring complex safety equipment
Solution Approach 1:
The system employs enclosed housings with flexible seals and controlled access points that allow operators to interact with the polymer powder in a controlled manner. These enclosed structures prevent powder dispersion into the atmosphere while maintaining ease of operation through designed access mechanisms, eliminating the need for complex personal protective equipment.
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 installation achieves efficient polymer dissolution with reduced footprint, minimizing dust dispersion and mechanical breakdowns, while ensuring safe handling and operation, particularly suitable for offshore operations.
Implementation Method 1
a cyclone, having a bottom part and a top part, which is provided with a means for connection to the grinding device, the cyclone being capable of separating the polymer particles, such that the finest particles are located in the top part of the cyclone, while the coarsest particles are located in the bottom part of the cyclone
Implementation Method 2
a filter having a top part and a bottom part, the bottom part being connected to the top part of the cyclone, the filter being capable of performing a second separation of the polymer particles coming from the top part of the cyclone, such that the finest particles are located in the top part of the filter, while the coarsest particles are located in the bottom part of the filter
Implementation Method 3
an air extraction means connected to the top part of the filter, said extraction means being capable of suctioning air entering from the air inlet of the grinding device and circulating successively in the cyclone then in the filter
Implementation Method 4
a device for grinding polymer into powder provided with an air inlet and a means for connection to the transport device, said grinding device being configured to grind the polymer powder into particles of different sizes
Data Source
AI summary
Installation for dissolving water-soluble polymers in powder form, in particular for enhanced oil and/or gas recovery operations or for fracking operations, comprising a device (1) for transporting polymer in powder form, a grinding device (3), a cyclone (5), a filter (7), an air extraction means (9), a hopper (12), a metering device (13), a hydration device (14). Method for producing a water-soluble polymer solution implementing the installation. Enhanced oil and/or gas recovery method. Method for tracking an oil or gas reservoir.