Hydration System with Compartmentalized Batch and Continuous Processing
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Solution Overview
Problem
Current hydraulic fracturing processes face inefficiencies in hydrating additives, particularly in achieving optimal viscosity and delivery costs, due to limitations in existing hydration systems that cannot selectively switch between batch and continuous processing based on the specific requirements of different polymers.
Innovation Solution
A hydration system with multiple compartments that allows for both batch and continuous processing, capable of calibrating feeders to meter various dry powders and incorporating a mixer to disperse and grind powders, enabling efficient hydration of viscosifying agents like polysaccharides and synthetic polymers, and allowing for continuous dilution processes to achieve the required viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single hydration system is used for all additives, then device complexity is reduced, but adaptability to different polymer requirements deteriorates
Solution Approach 1:
The hydration system is divided into multiple compartments (first compartment, second compartment, third compartment) within a single tank, allowing different zones to perform different functions simultaneously. This segmentation enables the system to handle both batch and continuous processes without requiring separate systems, thus reducing overall device complexity while maintaining adaptability to different polymer requirements.
Solution Approach 2:
The single hydration system is designed to perform multiple functions by incorporating both batch processing capability (first and second compartments) and continuous processing capability (third compartment with overflow outlet) within one device. This multi-functionality allows the system to adapt to different polymer hydration requirements without increasing device complexity.
2Ease of operation
If batch processing is used for all additives, then process control is simplified, but productivity deteriorates
Solution Approach 1:
The system segments processing into batch mode (first and second compartments for slow-hydrating polymers) and continuous mode (third compartment for fast-hydrating polymers). This segmentation allows each compartment to be optimized for its specific processing mode, maintaining simple process control for batch operations while achieving high productivity through continuous processing where applicable.
Solution Approach 2:
The system dynamically adapts its processing mode based on the specific polymer being hydrated. The control system can switch between batch and continuous processing modes, and adjust compartment utilization, to match the hydration characteristics of different polymers. This dynamic operation maintains ease of control while optimizing productivity for each specific case.
3Productivity
If continuous processing is used for all additives, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The system segments the hydration process into appropriate compartments based on polymer requirements. Fast-hydrating polymers are processed continuously in the third compartment to maximize productivity, while slow-hydrating polymers are processed in batch mode in the first and second compartments to ensure precise viscosity control. This segmentation allows each process mode to be applied where it is most effective.
Solution Approach 2:
Different compartments are assigned different processing qualities based on local requirements. The third compartment is optimized for continuous processing with high productivity, while the first and second compartments are optimized for batch processing with precise control. This local quality assignment ensures that each zone performs its specific function with the appropriate level of precision and speed.
4Loss of energy
If additives are provided as pre-hydrated slurry, then delivery cost is reduced, but device complexity and footprint increase
Solution Approach 1:
The system performs preliminary hydration actions within the fracturing fleet itself by incorporating the hydration system directly on the vessel. This allows dry polymer to be converted to hydrated slurry on-site, eliminating the need for extensive pre-hydrated storage facilities and reducing the footprint required for additive storage while maintaining delivery cost efficiency.
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 effectively hydrates additives to achieve the necessary viscosity for hydraulic fracturing fluids, reducing hydration time and costs by allowing precise control over processing methods, accommodating both natural and synthetic polymers, and enabling efficient delivery of fracturing fluids to boreholes.
Implementation Method 1
The additives can be provided as dry powders and subsequently hydrated at the fracturing site
Data Source
AI summary
A hydration system configured to selectively enable a continuous process or a batch process of an additive for a hydraulic fracturing fluid, the hydration system including a hydration tank having a plurality of compartments, wherein the hydration tank is configured to enable movement of a material through the plurality of compartments in the continuous process. The hydration tank is configured to substantially restrict movement of the material between the plurality of compartments in the batch process. Also included is a method of selectively hydrating an additive in a batch process or a continuous process using a hydration system configured to enable both the batch process and the continuous process.