Continuous Mixer Auger Paddle Coating Hydraulic Fracturing
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Solution Overview
Problem
Existing mixers struggle to efficiently coat particles with high throughput, particularly in hydraulic fracturing applications where quick and effective coating of proppants is crucial.
Innovation Solution
A mixer system comprising an outer wall with an auger and paddles that rotates at a high speed, moving particles into an annulus where a coating composition is introduced, allowing for efficient coating of particles as they move towards the outlet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional mixers are used for coating particles, then the coating process can be performed, but the throughput is low and the coating efficiency is insufficient
Solution Approach 1:
The mixer is divided into distinct functional zones: a coating zone where coating composition is applied to particles, and a mixing zone where the auger rotates to distribute the coating. This segmentation allows each zone to perform its specific function efficiently, enabling high throughput while maintaining effective coating
Solution Approach 2:
The auger rotation speed is dynamically controlled to optimize the coating process. By adjusting the rotational speed, the system can accommodate different throughput requirements and coating composition viscosities, thereby improving productivity without requiring complex structural modifications
2Manufacturing precision
If particles are heated to high temperature for coating, then the coating composition applies better, but the energy consumption increases and pre-heating is required
Solution Approach 1:
The system utilizes the natural heat generated by the friction between particles and the coating composition during mixing, along with the ambient temperature of the coating composition, to achieve adequate coating without requiring external pre-heating of particles. The coating process itself provides the necessary thermal energy through the mechanical energy of the rotating auger
Solution Approach 2:
The system changes the operational parameters by operating at lower temperatures compared to conventional methods. By optimizing the auger rotation speed and coating composition formulation, effective coating is achieved at reduced temperatures, thereby lowering energy consumption while maintaining coating quality
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 achieves high throughput coating of particles, with discharge rates ranging from 100 pounds per minute to 6000 pounds per minute, and can handle various coating compositions without pre-heating.
Implementation Method 1
at least one auger of the first mixer is rotating at a rate capable of moving the particles into an annulus positioned along the outer wall and moving the particles towards an outlet of the first mixer
Implementation Method 2
the first coating composition mixes with the particles in the annulus, and wherein the coating composition coats the particles as they move towards the outlet
Data Source
AI summary
The disclosure provides continuous mixers and methods of using thereof including in the production of coated particles and proppants used in hydraulic fracturing techniques, by the application of coatings along the length of the continuous mixer through the use of a plurality of paddles configured within the continuous mixer.