Particulate Drag Reducing Agent via Sealed Container Polymerization

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Solution Overview

Problem

Current methods for manufacturing drag reducing agents for heavy crude oils are inefficient and require improvement, particularly in terms of process efficiency and the need for alternative formulations that can effectively reduce frictional energy losses in pipelines.

Innovation Solution

A process involving the formation of a temporary container for radical polymerization, where unsaturated monomers and radical polymerization components are introduced and sealed, allowing polymerization to occur, followed by grinding to produce particulate drag reducing agents with specific molecular weights and particle sizes, using materials like polyethylene and polypropylene, and optionally incorporating anti-agglomerating agents, viscosifiers, and surfactants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If commercial drag reducing agents are manufactured via emulsion polymerization, then the produced drag reducing agents are micron-sized particles that can be used directly without grinding, but the process efficiency needs improvement

Engineering Contradiction:

Improvemanufacturing process efficiencyVSAvoidprocess efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent employs disposable sealed containers for radical polymerization reactions. These containers are used once and then discarded, eliminating the need for cleaning and preparation of conventional reactors. This approach significantly improves process efficiency and reduces manufacturing costs while maintaining the ability to produce drag reducing agents with desired molecular weights and particle sizes

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the polymerization method from emulsion polymerization to radical polymerization in sealed containers. This parameter change allows for better control over molecular weight (1 million to 50 million gram/mol) and particle size (1 to 1,500 microns), improving both process efficiency and product performance

Inventive Principle:

Principle #35Parameter changes

2Temperature

If conventional reactors are used for polymerization, then the reaction can proceed, but heat transfer and temperature control are problematic

Engineering Contradiction:

Improvetemperature controlVSAvoidheat transfer efficiency

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent divides the polymerization process into small, isolated sealed containers rather than using a single large conventional reactor. This segmentation provides a large surface-area-to-volume ratio, enabling efficient heat transfer and precise temperature control during the radical polymerization reaction, thereby reducing energy loss and improving thermal management

Inventive Principle:

Principle #1Segmentation

3Reliability

If drag reducing agents are produced with molecular weight of 1 million to 50 million gram/mol, then the friction reduction effectiveness is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvefriction reduction effectivenessVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The use of disposable sealed containers simplifies the manufacturing process for producing high molecular weight drag reducing agents. The containers are prepared in advance, filled with monomers and initiators, sealed, and then subjected to radical polymerization. This eliminates the need for complex in-process monitoring and control systems required in conventional continuous processes, reducing manufacturing complexity while ensuring consistent product quality with molecular weights of 1 million to 50 million gram/mol

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 process enhances the efficiency of drag reducing agent production, allowing for better heat transfer and temperature control, reducing costs associated with conventional reactors, and producing particles that effectively reduce friction in pipelines.

Implementation Method 1

allowing the unsaturated monomer component to polymerize in the sealed temporary container to form the drag reducing agent via a radical polymerization reaction

Methodology Applied

Scientific EffectRadical polymerization: Photopolymerisation

Data Source

PatentUS11814458B2Drag reducing agent and process of manufacture thereof

Publication Date: 2023.11.14 BAKER HUGHES OILFIELD OPERATIONS LLC

AI summary

A process of manufacturing a composition comprises a particulate drag reducing agent is disclosed. The process comprising: continuously forming a temporary container; introducing an unsaturated monomer component and a radical polymerization component into the temporary container; sealing the temporary container to form a sealed temporary container; allowing the unsaturated monomer component to polymerize in the sealed temporary container to form the drag reducing agent via a radical polymerization reaction, the drag reducing agent having a molecular weight of about 1 million gram/mol to about 50 million gram/mol; and grinding the drag reducing agent to form a composition comprising a particulate drag reducing agent, the particulate drag reducing agent having a particle size of about 1 to about 1,500 microns.