Gravity-Driven Viscous Fluid Dilution System for Hydraulic Fracturing
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Solution Overview
Problem
Current hydraulic fracturing processes face inefficiencies in mixing and delivering fracturing fluids, particularly in achieving the required viscosity and maintaining it during transportation, which affects the effectiveness of fracture propagation and fluid flow in boreholes.
Innovation Solution
A dilution system that includes a hydration unit, dilution manifold, and gravity-driven viscous fluid line to hydrate and dilute viscosifying polymers on-site, eliminating the need for pumps and allowing for precise control of additive concentrations, thereby ensuring efficient mixing and delivery of fracturing fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If viscous fracturing fluid is pumped through conventional systems, then the fluid can be delivered to the fracture zone, but the shear-sensitive polymers are degraded and viscosity is lost
Solution Approach 1:
The system divides the fluid delivery process into separate gravity-driven flow paths for viscous fluid and diluent, avoiding mechanical pumping of the polymer-containing viscous fluid while still enabling efficient delivery through controlled gravity flow and dilution
Solution Approach 2:
A diluent stream is introduced as an intermediary substance that mixes with the viscous fluid in the fracture zone, reducing viscosity and improving flow without requiring the viscous fluid to be pumped under high shear conditions
2Manufacturing precision
If polymers are pre-hydrated before transportation, then viscosity is achieved, but shear degradation occurs during pumping
Solution Approach 1:
The system performs preliminary hydration of polymers into dry powder form that can be stored and transported without degradation, then completes the hydration process in-situ at the fracture zone where gravity-driven flow avoids shear damage
Solution Approach 2:
The system replaces mechanical pumping with gravity-driven flow to deliver both the viscous fluid and diluent, eliminating shear stress from mechanical pumps and protecting the polymer structure while maintaining delivery efficiency
3Ease of manufacture
If dry powder additives are used, then delivery cost and footprint are reduced, but precise viscosity control becomes difficult
Solution Approach 1:
The system incorporates flow meters and control valves that monitor and adjust the flow rates of both viscous fluid and diluent streams, providing real-time feedback control to achieve precise viscosity and concentration in the final fracturing fluid mixture
Solution Approach 2:
The system controls viscosity by adjusting the flow rate parameters of the diluent stream relative to the viscous fluid stream, allowing precise viscosity control through parameter adjustment rather than requiring pre-mixed solutions
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 system enables efficient hydration and dilution of fracturing fluids, reducing costs and preserving shear-sensitive polymers, ensuring effective fracture propagation and fluid flow by maintaining optimal viscosity during transportation and application.
Implementation Method 1
a gravity-driven viscous fluid line connecting an exit of the hydration tank to the dilution manifold
Data Source
AI summary
A dilution system for a hydraulic fracturing fluid includes a dilution manifold, a hydration unit configured to provide a source of liquid, a diluent line connecting the hydration unit to the dilution manifold, a diluent flow control valve on the diluent line, a hydration tank configured to hydrate a mixed additive, a gravity-driven viscous fluid line connecting an exit of the hydration tank to the dilution manifold, a viscous fluid flow meter on the viscous fluid line, and a viscous fluid control valve on the viscous fluid line.