Core-shell flow improver reduces pressure loss
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Solution Overview
Problem
Existing flow improvers for pipelines, particularly those using polymeric drag reducing agents, suffer from surfactant shearing and agglomeration issues, leading to reduced pipeline efficiency and increased maintenance costs due to polymeric film formation on equipment.
Innovation Solution
A core-shell flow improver is developed, comprising a polymeric core and a shell formed by emulsion polymerization with hydrophobic and amphiphilic monomers, which reduces pressure loss and enhances pumping stability by minimizing agglomeration and film formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If latex flow improver is introduced into pipelines via high pressure injection pump, then fluid throughput is improved, but surfactant molecules are sheared off causing polymeric film formation on pump internals and downstream equipment
Solution Approach 1:
The flow improver composition is segmented into discrete polymeric particles with controlled size distribution (0.1-10 micrometers), preventing agglomeration and film formation while maintaining individual particle integrity during high-pressure pumping
Solution Approach 2:
The invention changes the physical and chemical parameters of the flow improver by creating crosslinked polymeric particles with specific glass transition temperatures and molecular weights, enhancing pumping stability and preventing surfactant shearing at high pressures
2Loss of energy
If polymeric drag reducing agents are used to reduce friction losses, then fluid flow rate increases at constant pumping pressure, but polymeric film forms on pipeline equipment requiring maintenance
Solution Approach 1:
The invention uses low concentrations of polymeric particles (5-500 ppm) that function as disposable drag reducers, providing energy efficiency benefits without forming persistent films that require maintenance, effectively replacing long-lived but maintenance-intensive polymeric coatings
3Stability of the object's composition
If surfactant molecules are associated with polymeric latex particles, then particles remain dispersed in aqueous phase, but shear forces in injection pump cause surfactant removal and particle agglomeration
Solution Approach 1:
The invention creates composite polymeric particles combining hydrophobic drag-reducing polymer cores with hydrophilic outer layers or surface modifications, achieving both aqueous dispersion stability and resistance to shear-induced agglomeration during high-pressure pumping
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 core-shell flow improver demonstrates improved pumping stability and reduced maintenance costs by effectively reducing pressure loss and preventing polymeric film buildup in pipeline equipment, extending operational periods and maintaining throughput.
Implementation Method 1
the shell comprises a shell copolymer having repeat units of a hydrophobic compound and repeat units of an amphiphilic compound
Implementation Method 2
The polymeric particles comprise a core and a shell at least partly surrounding the core. The core comprises a drag reducing polymer formed by emulsion polymerization. The shell is formed around the core by emulsion polymerizing at least one hydrophobic monomer and at least one polymerizable surfactant in the presence of the core.
Data Source
AI summary
A flow improver comprising a plurality of core-shell particles that can be formed by emulsion polymerization. The core of the core-shell particles can include a drag reducing polymer, while the shell of the particles can include repeat units of a hydrophobic compound and an amphiphilic compound. The flow improver can demonstrate increased pumping stability over conventionally prepared latex flow improvers.