Blender Impeller Blocking Ledges for Slurry Leakage
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Solution Overview
Problem
Existing impeller designs for blending liquids and solids in downhole fracking operations face challenges in minimizing energy expenditure, wear, and preventing slurry leakage back into the impeller eye, while maintaining optimal blending conditions across varying flow rates and particle densities.
Innovation Solution
The design incorporates three-sided impeller vanes with converging sides and blocking ledges to redirect counterflow back into the annular space, along with an expeller to accelerate sand delivery and maintain uniform flow, minimizing energy consumption and wear by blocking counterflow close to its origin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional impeller vanes are used to blend liquids and solids, then blending function is achieved, but energy expenditure increases and wear occurs due to counterflow of slurry back into the impeller eye
Solution Approach 1:
The impeller vane is divided into multiple functional segments: a leading face for initial slurry engagement, a blocking ledge positioned radially outward to intercept counterflow, and a trailing face for discharge. This segmentation allows each portion to perform its specific function efficiently, with the blocking ledge specifically dedicated to preventing slurry from returning to the impeller eye, thereby reducing energy loss and wear.
Solution Approach 2:
The blocking ledge is positioned radially outward on the vane to intercept and redirect counterflowing slurry before it can reach the impeller eye. By taking preliminary action to block the counterflow path, the design prevents the harmful effect of slurry re-entering the impeller center, which would otherwise cause energy expenditure and wear on the impeller components.
2Productivity
If impeller speed is increased to maintain blending at higher flow rates, then productivity increases, but wear and energy consumption increase
Solution Approach 1:
The design changes the geometric parameters of the impeller vane, specifically adding a blocking ledge at a predetermined radial position. This geometric modification allows the impeller to maintain effective blending across a wider range of flow rates and speeds without proportionally increasing energy expenditure, as the blocking ledge ensures efficient slurry direction regardless of operating conditions.
3Productivity
If more vanes are added to increase flow capacity, then productivity increases, but device complexity and manufacturing cost increase
Solution Approach 1:
Each impeller vane is designed as a multi-functional component: the leading face engages and directs slurry outward, the blocking ledge intercepts and redirects counterflow, and the trailing face completes the discharge function. This multi-functionality allows each vane to contribute maximally to both productivity and efficiency, reducing the need for additional vanes or components to achieve the desired flow capacity.
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 solution effectively reduces energy consumption and wear, prevents slurry leakage, and maintains optimal blending conditions by redirecting counterflow efficiently, ensuring continuous high-volume mixing with reduced part replacement needs.
Implementation Method 1
the vanes were designed to balance the point at which the solids and liquids were intermixed between the outer space surrounding the impeller vanes and the center of the impeller assembly
Implementation Method 2
blocking vanes in the spaces between the primary vanes in order to keep the eye of the impeller dry and to regulate the balance point between the solids and slurry
Implementation Method 3
there is disclosed an arrangement or configuration of vanes in which the liquid would follow a path between the primary vanes toward the center of the impeller, until it reached the next vane which would cause it to reverse and flow away from the center
Data Source
AI summary
A method and apparatus for blending liquids and granular materials in which an impeller assembly is mounted for rotation within a housing at a lower end of a particles inlet and characterized in particular by circumferentially spaced impeller vanes in outer concentric relation to a series of expeller vanes surrounding the particles inlet and which together propel the solid particles outwardly to intermix with the liquid introduced into the annulus surrounding the impeller assembly, and different selected vane configurations are provided with circumferential portions protruding into the path of counterflow of the slurry from the annulus in order to keep the eye or central area of the impeller assembly dry.