Dynamic Wetting Head Prevents Polymer Deposition
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Solution Overview
Problem
Current polymer wetting units face issues with polymer deposition on metal surfaces, leading to blockages and equipment damage, especially at higher polymer concentrations, which increases maintenance costs and requires redundant systems.
Innovation Solution
A dynamic wetting head with a prewetting unit and mixing unit featuring a feed spigot with reduced relative roughness materials, spray nozzles arranged to spray water in the flow direction, and cleaning nozzles to create a vortex, along with a nitrogen feed and mixer with a multistage toothed rim rotor and stator, to prevent polymer deposition and facilitate efficient mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polymer concentration is increased to reduce downstream equipment size and cost, then equipment cost is reduced, but polymer deposition on metal surfaces increases causing blockages and damage
Solution Approach 1:
The invention changes the surface roughness parameter of the feed spigot from standard metal surface roughness to a reduced relative roughness surface. This parameter change prevents polymer deposition by eliminating nucleation sites, allowing the system to operate at higher polymer concentrations (above 1.5 wt%) without the harmful deposition effects that would otherwise force the system to use lower concentrations and larger downstream equipment
Solution Approach 2:
The invention segments the wetting unit into distinct functional zones: a prewetting zone with the modified feed spigot for initial polymer-water contact, and a mixing zone with dynamic mixing elements. This segmentation allows the critical deposition-prevention function to be localized at the feed spigot while maintaining efficient mixing downstream, enabling high-concentration operation without throughout the system
2Productivity
If spray nozzles are used to wet polymer powder, then wetting efficiency is improved, but polymer deposits form hard crystals blocking nozzles and rotating mechanisms
Solution Approach 1:
The invention changes the surface roughness parameter of the feed spigot to reduced relative roughness, which prevents polymer deposition and crystal formation. This parameter change maintains wetting efficiency while eliminating the reliability problems of nozzle and mechanism blockages
Solution Approach 2:
The invention implements self-cleaning functionality where water spray continuously rinses the feed spigot and internal surfaces during operation. This self-service cleaning mechanism prevents polymer accumulation and crystal formation, maintaining equipment reliability without requiring external intervention or shutdown for maintenance
3Ease of repair
If cleaning nozzles are added to prevent polymer buildup, then maintenance frequency is reduced, but device complexity increases
Solution Approach 1:
The invention makes the process water serve multiple functions: it acts as the wetting agent for polymer dissolution, the mixing medium for solution preparation, and the cleaning agent for preventing polymer deposition on surfaces. This multi-functionality eliminates the need for separate cleaning systems, maintaining reduced maintenance frequency without increasing device complexity
Solution Approach 2:
The system performs self-cleaning through the continuous flow of process water that rinses internal surfaces during normal operation. This self-service approach eliminates dedicated cleaning equipment and complex cleaning mechanisms, achieving reduced maintenance frequency while keeping the device simple
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 prevents polymer deposition, reduces maintenance needs, and allows for polymer concentrations exceeding 1.5 wt %, minimizing equipment damage and operational expenses while maintaining efficient polymer wetting and mixing.
Implementation Method 1
Surfaces of a portion of the feed spigot projecting into the wetting chamber may have a reduced relative roughness
Implementation Method 2
at least a first spray nozzle projecting into the wetting chamber provided for operatively spraying water from a source of water into the wetting chamber
Implementation Method 3
cleaning nozzles to create a vortex
Implementation Method 4
mixer with a multistage toothed rim rotor and stator
Implementation Method 5
The wetted polymer is known to degrade in the presence of oxygen. Therefore, an inert atmosphere (typically nitrogen) is applied to equipment that sees wetted polymer
Data Source
AI summary
A dynamic wetting head with which polymers are prewetted and mixed. The prewetted and mixed polymers are typically used in the process of polymer flooding during chemical enhanced oil recovery. The dynamic wetting head comprises a prewetting unit and a mixing unit. The prewetting unit has a feed spigot provided in communication with a source of powder and projecting at least partially into a wetting chamber of the prewetting unit. The feed spigot feeds polymer powder into the wetting chamber. Furthermore, at least a first spray nozzle sprays water into the wetting chamber. The mixing unit comprises a mixing chamber with an inlet provided in communication with the wetting chamber outlet, a feed water inlet, and an outlet. A mixer is furthermore arranged within the mixing chamber.