Jet Pump Processing for Sub-Standard Frac Sand
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Solution Overview
Problem
Current methods for modifying sand into frac sand with desirable properties for fracking are costly, time-consuming, and often require non-contaminated sand, necessitating a cost-effective and efficient method to enhance the mechanical strength, sphericity, roundness, and turbidity of sub-standard frac sand.
Innovation Solution
The process involves passing sub-standard frac sand through a jet pump to remove contaminants and improve its properties, such as reducing cluster percentages, achieving specific sieve size distributions, and enhancing sphericity and roundness, thereby meeting API and ISO specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple steps are used to modify sand into frac sand with desirable properties, then the mechanical strength, sphericity, roundness, and turbidity are improved, but the cost and time to produce increase
Solution Approach 1:
The patent combines multiple modification steps into a single integrated jet pump processing stage. The jet pump simultaneously performs contaminant removal, particle shape improvement, and size sorting in one continuous operation, eliminating the need for separate processing steps while achieving the desired frac sand properties
Solution Approach 2:
The jet pump system is designed to perform multiple functions simultaneously: it removes contaminants, improves particle sphericity and roundness, sorts by size through the nozzle geometry, and achieves the desired turbidity and mechanical strength all in one processing stage, making the equipment universally effective for producing standard frac sand
2Reliability
If multiple steps are used to modify sand into frac sand with desirable properties, then the mechanical strength, sphericity, roundness, and turbidity are improved, but the production cost increases
Solution Approach 1:
The patent combines multiple modification steps into a single integrated jet pump processing stage. The jet pump simultaneously performs contaminant removal, particle shape improvement, and size sorting in one continuous operation, eliminating the need for separate processing steps while achieving the desired frac sand properties
Solution Approach 2:
The jet pump system uses the kinetic energy of the fluid stream itself to perform the modification work. The high-velocity fluid jet naturally erodes and rounds particles, removes contaminants through hydraulic action, and sorts them by size through the nozzle geometry, eliminating the need for external mechanical processing equipment
3Reliability
If conventional methods are used to modify sand, then desirable fracking properties are achieved, but the method requires non-contaminated sand as input
Solution Approach 1:
The jet pump system converts the presence of contaminants and sub-optimal particle shapes in the input sand into beneficial effects. The high-velocity fluid jet uses the contaminants and irregular particle shapes as material to be eroded and removed, transforming the harmful characteristics of the input sand into the mechanism for achieving the desired output properties
Solution Approach 2:
The system changes the physical parameters of the sand particles through hydraulic action. The high-velocity fluid jet modifies particle shape, removes contaminants, and sorts by size by changing the flow dynamics and mechanical interaction between the fluid and particles, transforming sub-standard input sand into standard frac sand
4Manufacturing precision
If sub-standard frac sand is processed through jet pump, then contaminant removal and property improvement are achieved, but the process requires specific process conditions
Solution Approach 1:
The system achieves precise control over the frac sand properties by adjusting key parameters of the jet pump operation, including fluid velocity, nozzle geometry, and processing time. These parameter adjustments allow precise control over particle shape, size distribution, and contaminant removal without requiring complex multi-step processing
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 method effectively converts sub-standard frac sand into standard frac sand with improved crush resistance, sphericity, roundness, and turbidity, making it suitable for fracking while reducing contamination levels and enabling the reuse of sand, thus lowering production costs and time.
Implementation Method 1
A jet pump is used to slurry and convey the material... The jet pump is configured to receive raw sub-standard frac sand... passing sub-standard frac sand at least one time through at least one jet pump under processes and conditions sufficient to remove at least one contaminant from the sub-standard frac sand and/or improve sub-standard frac sand into standard frac sand
Implementation Method 2
passing sub-standard frac sand at least one time through at least one jet pump under processes and conditions sufficient to remove at least one contaminant from the sub-standard frac sand
Data Source
AI summary
Methods for converting non-standard frac sand into sand with fracking properties using at least one jet pump.