Continuous Gel Hydration for Compact Well Fracturing Systems
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Solution Overview
Problem
Existing hydration systems for high viscosity fluid mixtures used in subterranean well treatment operations require large tanks with long residence times, which are cumbersome to transport and difficult to handle, and gravity-flow tanks cannot handle high concentration mixtures effectively.
Innovation Solution
A method and apparatus that involves continuously mixing hydratable material with hydrating fluid to form a concentrated stream, allowing hydration to occur within an enclosed system, followed by dilution to achieve a lower concentration stream suitable for well fracturing operations, utilizing a mixer, enclosed hydrator, and diluter to manage viscosity and concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large volume tanks are used to provide sufficient residence time for hydration, then the hydration level and viscosity of the fluid mixture are improved, but the equipment footprint and transportability deteriorate
Solution Approach 1:
The hydration system is divided into multiple smaller tanks (first hydration tank, second hydration tank, third hydration tank) rather than using a single large tank. Each tank provides a portion of the total residence time needed for hydration, achieving the same overall hydration level while reducing the footprint of any single stationary object and improving transportability.
2Duration of action of moving object
If long residence time is provided in hydration tanks, then the viscosity and hydration of the fluid mixture are improved, but the tank volume and complexity increase
Solution Approach 1:
The total residence time requirement is segmented across multiple smaller tanks connected in series. The fluid mixture passes through each tank sequentially, accumulating the required residence time without requiring any single tank to be excessively large or complex.
Solution Approach 2:
Multiple tanks perform the same hydration function in sequence, with each tank contributing to the overall hydration process. This multi-functional arrangement achieves the required residence time while maintaining modular, manageable tank sizes.
3Device complexity
If gravity-flow tanks are used for hydration, then the system simplicity is improved, but the ability to handle high concentration fluid mixtures deteriorates
Solution Approach 1:
The system uses multiple smaller tanks instead of a single gravity-flow tank. This segmentation allows the system to handle high concentration fluid mixtures that would be too viscous for effective gravity flow in a single large tank, while maintaining operational simplicity through the series configuration.
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
This approach enables efficient hydration and viscosity increase in a compact system, reducing equipment footprint and facilitating transport, while ensuring the fluid mixture meets the requirements for well fracturing operations.
Implementation Method 1
Hydration is a process by which the hydratable material solvates, absorbs, and/or otherwise reacts with hydrating fluid to create the high viscosity fluid mixture
Implementation Method 2
Hydration is a process by which the hydratable material solvates, absorbs, and/or otherwise reacts with hydrating fluid
Implementation Method 3
A mixer is operable to receive and mix hydratable material and hydrating fluid
Implementation Method 4
The first substantially continuous stream may be communicated through an enclosed hydrator to form a second substantially continuous stream. The second substantially continuous stream may include gel having the first concentration of hydratable material and a second viscosity that is substantially greater than the first viscosity
Implementation Method 5
A diluter may be operable to dilute the substantially continuous supply of increased viscosity gel having the second hydratable material concentration to substantially continuously supply gel having the first hydratable material concentration
Data Source
AI summary
A substantially continuous stream of aqueous fluid and a substantially continuous stream of gel having a first concentration are combined to form a substantially continuous stream of gel having a second concentration. The second concentration is substantially lower than the first concentration. The gel having the second concentration may thereafter be utilized in conjunction with a well fracturing operation.