Hydraulic Cement Slurry Mixing Vortex System
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Solution Overview
Problem
Conventional methods for forming cement slurries in the oil and gas industry face challenges such as small margins for error in mixing water and dry bulk ratios, leading to costly delays and improper cement slurry density, which can result in job failures due to variations in flow rates and equipment malfunctions.
Innovation Solution
A method and system for forming liquid mixtures using a mixing tank with a cylindrical or elliptical shape, where a liquid stream is introduced at an angle to create a swirling vortex, allowing for efficient mixing of water and dry bulk cement without the need for mechanical agitators, by recirculating the cement slurry through a system that includes a pump and valves to control flow rates and ensure accurate mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional mixing methods using large permanent cementing pumps and dry bulk trucks are used, then cement slurries can be mixed on the fly, but the mixing process has small margins for error and takes considerable time, leading to costly delays and improper cement slurry density
Solution Approach 1:
The patent replaces the conventional mechanical mixing system (large permanent cementing pumps, dry bulk trucks, Venturi tube mixers) with a hydraulic mixing system using a portable high-pressure pump, water tank, and hose assembly. This substitution enables faster mixing while maintaining precision through controlled water flow rates and portable equipment maneuverability.
Solution Approach 2:
The patent utilizes hydraulic principles by employing a high-pressure pump to deliver water through a hose at controlled flow rates directly to the mixing zone. The hydraulic system allows for precise control of water-cement ratios and enables rapid mixing operations with improved accuracy in cement slurry density.
2Quantity of substance
If conventional mixing methods with tank and agitator are used, then cement slurry can be mixed in large batches, but equipment malfunction or variations in flow rates cause improper density and job failure
Solution Approach 1:
The patent divides the mixing process into segmented operations using portable equipment that can be positioned and operated in sections along the wellbore. The high-pressure pump, water tank, and hose assembly can service multiple locations sequentially, enabling large-scale operations while maintaining consistent mixing quality through repeated standardized procedures at each segment.
Solution Approach 2:
The system incorporates feedback mechanisms through controlled water flow rate regulation and portable equipment that allows operators to monitor and adjust mixing parameters in real-time. This feedback loop ensures consistent water-cement ratios and maintains reliable mixing quality across large batches and multiple locations.
3Strength
If bridge plugs are used with cement slurries to prevent higher density cement from falling, then wellbore structural support can be provided, but the process becomes more complex and requires additional equipment
Solution Approach 1:
The portable high-pressure pump system is designed to be self-contained and mobile, carrying its own water supply and mixing capabilities. This self-service capability eliminates the need for complex fixed infrastructure and large permanent equipment, providing wellbore support functionality through a simplified, portable system that can be deployed and operated independently.
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 significantly reduces mixing time, increases efficiency, and minimizes errors in cement slurry density, enabling faster and more reliable cement slurry production, even in large batches, by maintaining a high swirling velocity and effectively combining water and cement without mechanical agitation.
Implementation Method 1
The liquid stream is introduced so that it is directed towards the upper wall of the mixing tank... The liquid stream is introduced through a tank inlet at a flow rate and an angle relative to the upper wall sufficient to create a swirling liquid within the tank interior. The swirling liquid forms a liquid vortex
Implementation Method 2
A portion of the swirling liquid is withdrawn through an outlet formed in the lower wall and is circulated as all or a part of the liquid stream introduced into the tank inlet
Data Source
AI summary
A method and system for forming a liquid mixture utilizes a mixing tank with a tank inlet oriented and configured to create a swirling liquid flow that forms a vortex within the tank. A portion of the swirling liquid is discharged through an outlet formed by an opening in a lower wall of the tank. At least a portion of the opening is offset to one side of a central axis of the lower wall. Liquid is circulated and reintroduced into the tank inlet. A material to be mixed is introduced into the swirling liquid flow within the tank interior to form a liquid mixture.