Drag Reducing Latex Additives Prevent Pump Head Film Formation
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Solution Overview
Problem
Existing drag reducing agents (DRAs) for hydrocarbons often form films when injected through pump heads, leading to clogging and requiring specialized equipment, and their high viscosity limits maximum polymer concentration, resulting in inefficient transportation and increased costs.
Innovation Solution
A drag reducing latex formulation produced by emulsion polymerization with solid particles dispersed in an aqueous medium and an additive, such as ester derivatives, is used to reduce film formation by 50% or more when injected through a pump head, eliminating the need for special equipment and minimizing inert material transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If ground polymer particles are used as DRA, then the polymer can be pumpable in liquid media, but the particles form films when they come in mutual contact, leading to pump head clogging
Solution Approach 1:
The patent introduces suspension aids as intermediary substances that coat the polymer particles and prevent direct contact between them. These suspension aids act as mediators that maintain particle separation in the liquid carrier, preventing film formation on pump heads while preserving pumpability. The suspension aids include materials like stearic acid, stearamides, polyolefins, and other compounds that adsorb onto particle surfaces.
Solution Approach 2:
The patent modifies the surface properties of polymer particles by coating them with suspension aids, changing their surface chemistry from tacky to non-tacky. This parameter change in surface properties prevents film formation while maintaining the particles' ability to remain suspended and pumpable in the liquid carrier.
2Quantity of substance
If gel or solution DRAs are used, then the polymer concentration can be increased, but the high solution viscosity requires specialized injection equipment and pressurized delivery systems
Solution Approach 1:
The patent uses segmented or particulate polymer particles dispersed in a liquid carrier instead of continuous gel or solution phases. This segmentation allows the polymer to be delivered as pumpable particles that do not require specialized injection equipment, while still achieving effective drag reduction at the injection point.
Solution Approach 2:
The patent employs a liquid carrier system that allows standard hydraulic pumping methods to be used for delivering the DRA. The pumpable liquid suspension can be delivered through conventional equipment, eliminating the need for specialized pressurized delivery systems required by gel or solution DRAs.
3Object-generated harmful factors
If suspension aids are heated to reach maximum effectiveness, then film formation is reduced, but heating the process stream is economically disadvantageous
Solution Approach 1:
The patent selects suspension aids with optimized properties that provide maximum effectiveness at lower temperatures or without heating. By changing the parameters of the suspension aid selection (molecular structure, surface activity, thermal stability), the system achieves film prevention without requiring energy-intensive heating of the process stream.
4Volume of moving object
If emulsion polymerization is used to produce DRA particles, then small particles are created that can be dispersed in aqueous carrier, but the particles may still form films upon contact
Solution Approach 1:
The patent applies suspension aids as intermediary coatings on the emulsion polymerization-produced particles. These suspension aids prevent direct particle-to-particle contact and particle-to-surface contact, eliminating film formation while preserving the benefits of small particle size and aqueous dispersibility.
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 composition significantly reduces film formation during injection, preventing pump head clogging and allowing for higher polymer concentrations without increasing viscosity, thereby enhancing the efficiency and cost-effectiveness of hydrocarbon transportation.
Implementation Method 1
The use of polyalpha-olefins or copolymers thereof to reduce the drag of a hydrocarbon flowing through a conduit, and hence the energy requirements for such fluid hydrocarbon transportation
Implementation Method 2
produced by emulsion polymerization whereby the monomer(s) are dispersed with a large quantity of surfactant in a continuous liquid carrier prior to polymerization
Implementation Method 3
The use of the composition results in a decrease of film formation while injected through a pump head
Data Source
AI summary
A composition comprising a drag reducing latex formulation produced by emulsion polymerization to create solid particles dispersed in an aqueous medium and an additive. The use of the composition results in a decrease of film formation while injected through a pump head when compared to the drag reducing latex formulation injected through the pump head.