Drag Reducing Agent Polymerization with Zirconium Residue
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Solution Overview
Problem
Conventional drag reducing agents produced via Ziegler-Natta catalysis face inefficiencies due to low polymerization temperatures, long reaction times, and broad molecular weight distributions, and there is a need for drag reduction agents based on water with low viscosity for improved oil field applications.
Innovation Solution
A drag reducing agent composed of C6-C14 α-olefin monomers with a residual amount of zirconium, having an absolute weight average molecular weight greater than 1,300,000 g/mol and a specific molecular weight ratio, dispersed in a liquid carrier that includes at least water, using a bis-biphenylphenoxy catalyst for polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Ziegler-Natta catalysis is used to produce ultra-high molecular weight polymers, then drag reduction capability is achieved, but polymerization temperature must be kept low and reaction time becomes excessively long
Solution Approach 1:
The patent changes the catalyst system from Ziegler-Natta to a different catalytic system that enables polymerization at higher temperatures while maintaining ultra-high molecular weight polymer production. This parameter change in catalyst chemistry allows simultaneous achievement of drag reduction capability and improved polymerization efficiency with shorter reaction times
Solution Approach 2:
The patent employs a composite approach by combining specific catalyst components and polymerization conditions to create a system that produces polymers with both the required ultra-high molecular weight for drag reduction and optimized reaction kinetics for practical production timelines
2Reliability
If Ziegler-Natta catalysis is used to produce ultra-high molecular weight polymers, then drag reduction capability is achieved, but molecular weight distribution becomes broad and final polymer properties are difficult to control
Solution Approach 1:
The patent changes the catalytic system parameters to achieve narrower molecular weight distribution while maintaining ultra-high molecular weight. The new catalyst system provides better control over chain growth and termination, resulting in more uniform polymer properties that are easier to manufacture and predict in performance
Solution Approach 2:
The patent substitutes the Ziegler-Natta catalytic mechanism with an alternative catalytic mechanism that inherently provides better molecular weight control. This substitution changes the fundamental chemistry of polymer formation to achieve more precise molecular weight distribution without requiring extensive post-processing or mechanical control measures
3Object-affected harmful factors
If conventional drag reducing agents are used, then friction loss reduction is achieved, but viscosity remains high limiting broader application
Solution Approach 1:
The patent changes the chemical structure parameters of the polymer to achieve lower viscosity while maintaining ultra-high molecular weight. By modifying the polymer architecture and composition through the new catalytic system, the agent achieves both effective friction loss reduction and lower viscosity for broader application in oil field operations
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 solution effectively reduces friction losses in turbulent flow, outperforming Ziegler-Natta catalyst-based agents with narrower molecular weight distributions and enabling broader application in oil field transport.
Implementation Method 1
Known are drag reducing agents (DRAs) that reduce the turbulence-mediated friction and eddies, which, in turn, may decrease friction losses and pressure drop in hydrocarbon liquid pipelines
Implementation Method 2
The drag reducing agent may be produced by polymerizing a C6-C14 olefin monomer using a catalyst system
Data Source
AI summary
A drag reducing agent that includes a polymer composed of one or more C6-C14 α-olefin monomers, which polymer comprises a residual amount of zirconium and has an absolute weight average molecular weight (Mw(Abs)) greater than 1,300,000 g/mol and a Mw(Abs)/Mn(Abs) from 1.3 to 3.0, and that includes a liquid carrier that includes at least water.