Dry Polymer Powder for Friction Reduction in Hydraulic Fracturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current hydraulic fracturing operations face challenges in achieving rapid hydration of dry polymer powders for friction reduction, as existing methods require pre-hydration and are prone to particle aggregation and degradation, leading to inefficiencies and logistical issues.
Innovation Solution
A dry polymer powder with a specific particle size distribution, where at least 85% of particles are smaller than 40-mesh and 75% are greater than 200-mesh, allowing for direct on-the-fly injection into fracturing fluids without pre-hydration, achieving hydration times under 1 minute and preventing fisheye formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dry polymer powder is used for friction reduction in hydraulic fracturing, then storage and handling are simplified, but hydration time increases and particle aggregation occurs
Solution Approach 1:
The patent segments the polymer into ultrafine particles with specific size distribution (at least 85% smaller than 40-mesh and 75% greater than 200-mesh). This segmentation increases the surface area to volume ratio, enabling rapid hydration while maintaining storage stability. The segmented structure allows individual particles to hydrate quickly without requiring pre-hydration of bulk powder.
Solution Approach 2:
The patent changes the critical parameter of particle size to resolve the contradiction. By controlling the particle size distribution within specific mesh ranges, the polymer achieves both easy storage (as dry powder) and rapid hydration (under 1 minute). The parameter change from coarse to ultrafine particles transforms the hydration kinetics without compromising storage handling properties.
2Loss of time
If polymer particles are made smaller to increase surface area for faster hydration, then hydration time decreases, but particle aggregation and fisheye formation increase
Solution Approach 1:
The patent applies local quality by creating a specific particle size distribution where different size ranges serve different functions. The ultrafine particles (smaller than 40-mesh) provide rapid hydration, while the controlled presence of larger particles (greater than 200-mesh) prevents aggregation. This local differentiation in particle sizes creates a self-regulating system where finer particles hydrate quickly and coarser particles act as spacers to prevent fisheye formation.
Solution Approach 2:
The patent creates a composite particle size distribution system rather than using uniform particles. The combination of particles in different size ranges (at least 85% smaller than 40-mesh and 75% greater than 200-mesh) creates a composite structure that leverages the advantages of both fine and coarse particles: rapid hydration from fine particles and aggregation prevention from coarser particles.
3Stability of the object's composition
If pre-hydration is used to ensure complete polymer dissolution, then hydration completeness improves, but process complexity and logistical requirements increase
Solution Approach 1:
The patent performs preliminary action during the polymer manufacturing stage by controlling the particle size distribution before the polymer is used. The ultrafine particles are pre-prepared with high surface area and controlled morphology, which enables complete dissolution without requiring pre-hydration equipment or procedures. This preliminary sizing action eliminates the need for complex pre-hydration processes while ensuring complete polymer dissolution.
Solution Approach 2:
The polymer particles are designed to self-hydrate completely when introduced to water, without requiring external pre-hydration equipment or processes. The specific particle size distribution (at least 85% smaller than 40-mesh and 75% greater than 200-mesh) enables the particles to self-dissolve rapidly and completely through their own surface area characteristics, eliminating the need for pre-hydration infrastructure.
4Stability of the object's composition
If larger polymer particles are used to maintain structural integrity, then polymer stability improves, but hydration rate decreases
Solution Approach 1:
The patent segments the polymer into controlled particle size ranges that balance stability and hydration rate. By segmenting into specific mesh ranges (at least 85% smaller than 40-mesh and 75% greater than 200-mesh), the polymer achieves sufficient surface area for rapid hydration while maintaining adequate particle size for structural stability. The segmentation creates optimal surface area to volume ratio without compromising integrity.
Solution Approach 2:
The patent optimizes the particle size parameter to achieve the optimal balance between stability and hydration rate. The specific parameter range (at least 85% smaller than 40-mesh and 75% greater than 200-mesh) represents the critical threshold where hydration rate increases sufficiently while structural integrity is maintained. This parameter optimization resolves the trade-off between stability and speed.
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 approach enables cost-effective and efficient friction reduction in hydraulic fracturing, maintaining performance under high-shear conditions and reducing logistical complexities, while avoiding the need for additional additives and equipment.
Implementation Method 1
direct contact of friction reducers with water should be avoided... after being synthesized, polymers are separated from solution, dried, purified and often ground into powdered products
Data Source
AI summary
A dry polymer powder for use in enhanced petroleum recovery without being prehydrated before being added to water or brine to be introduced into a wellhead. The dry polymer powder consisting of at least one of a polyacrylamide, a copolymer of acrylamide and acrylic acid, a galactomannan, or cellulosic polymer or derivatives thereof, and the polymer can be crosslinked or not crosslinked, provided that if they are homo- or co-polymers of acrylic acid, they are not crosslinked. The dry polymer powder has a polymer size range distribution of 6.6%<40 mesh and 85.4% of 40 to 200 mesh and 8%>200 mesh, and wherein the polymer size range ensures that the dry polymer powder will efficiently hydrate in the water or brine within about one minute without forming fisheyes.