Integrated Blender System for Slurry Consistency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current well service equipment lacks an efficient system for integrating dry chemicals into wellbore fluids during drilling, completion, and production operations, which affects the consistency and quality of the slurry used in operations like hydraulic fracturing.
Innovation Solution
An integrated blender system with a skid-mounted blender assembly, including a dry product additive system that utilizes a hopper, feeder system, eductor assembly, and supply pump to effectively mix dry chemicals with base fluids, ensuring uniform distribution and transportation of the slurry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dry chemicals are added to wellbore fluids using conventional methods, then the slurry consistency and quality are compromised, but the system complexity and integration level remain low
Solution Approach 1:
The patent combines multiple previously separate systems (blender, friction reducer system, proppant feed system) into a single integrated blender system. The blender assembly includes an eductor assembly with suction pump and friction reducer reservoir, and a proppant feed system with hopper and feeder, all integrated with the main blender tub and drive system. This integration ensures consistent slurry quality while managing system complexity through unified design.
2Manufacturing precision
If an integrated blender system with multiple components is implemented, then mixing precision is improved, but the device complexity increases
Solution Approach 1:
The integrated blender system is divided into distinct functional modules: a blender tub with mixing paddle, an eductor assembly with suction pump for friction reducer, a proppant feed system with hopper and feeder, and a drive system. Each module operates independently but is coordinated through the control system, allowing precise mixing while managing complexity through modular segmentation.
Solution Approach 2:
The blender assembly serves multiple functions: mixing base fluid and chemicals, feeding friction reducer via eductor, delivering proppant through the feeder system, and circulating slurry through pumps. This multi-functionality improves mixing precision by coordinating all additive delivery systems within a single integrated platform.
3Adaptability or versatility
If portable skid-mounted blender assembly is used, then operational flexibility is improved, but the system complexity increases
Solution Approach 1:
The blender assembly is mounted on a skid, making it mobile and adaptable to different wellsite locations. The skid-mounted design allows the entire integrated system to be transported and repositioned as needed, providing operational flexibility while containing the complexity within a self-contained mobile unit rather than a fixed installation.
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 ensures precise and efficient mixing of dry chemicals with base fluids, enhancing the quality and consistency of the slurry used in wellbore operations, such as hydraulic fracturing, by providing a portable and operatively coupled solution for on-site use.
Implementation Method 1
a suction pump positioned to draw base fluid from the base fluid tank
Implementation Method 2
an eductor assembly including a suction inlet, a motive inlet, and an outlet
Implementation Method 3
a discharge pump positioned to receive the mixed fluid and proppant from the blender tub
Data Source
AI summary
An integrated blender system includes a skid. The integrated blender system includes a blender assembly, including a blender tub including an outlet, a supply pipe coupled between a suction pump and the blender tub, and an outlet pipe coupled to the outlet of the blender tub. The integrated blender assembly includes a dry product additive system. The dry product additive system includes a skid, a hopper, a pickup funnel, a feeder system, a supply pump, and an eductor assembly. The feeder system may be configured to transport product from the hopper to the pickup funnel. The eductor assembly including a suction inlet, a motive inlet, and an outlet. The suction inlet may be coupled to the pickup funnel by a suction hose. The motive inlet may be coupled to the supply pump by a motive fluid hose. The outlet nozzle is positioned to eject fluid and product into the blender tub.