Parallel Tube Flow Control Valve for Low-Shear Polymer Injection
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Solution Overview
Problem
Existing flow control valves cause significant mechanical degradation of polymer solutions during their passage, which is detrimental in Enhanced Oil Recovery (EOR) processes due to high elongational shearing, leading to viscosity loss and reduced effectiveness of polymer solutions used to enhance oil recovery.
Innovation Solution
A flow control valve design featuring a plurality of fluid transport pipes with geometrically variable cross-sections arranged in parallel, minimizing elongation and degradation by maximizing viscous dissipation and allowing continuous regulation of flow loss through a bundle of pipes, reducing attrition and maintaining polymer solution viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional flow control valve is used to control polymer solution flow, then flow regulation is achieved, but mechanical degradation of the polymer solution occurs due to high elongational shearing
Solution Approach 1:
The valve divides the flow control function into multiple parallel capillary tubes instead of using a single restricted opening. This segmentation distributes the polymer solution flow across many small channels, reducing the elongational shearing stress on polymer chains in each individual tube while maintaining overall flow control capability through the collective effect of all tubes.
Solution Approach 2:
The capillary tubes are designed with specific dimensional characteristics (small diameter, controlled length) that create local flow conditions favorable for minimizing polymer degradation. The local geometry of each tube is optimized to reduce elongational shearing while the aggregate of all tubes provides the required flow regulation function.
2Manufacturing precision
If the valve opening is decreased to increase loss of load for flow control, then flow regulation precision improves, but polymer solution viscosity decreases due to increased mechanical degradation
Solution Approach 1:
By segmenting the flow control into multiple parallel capillary tubes, the valve achieves precise flow regulation through the collective resistance of many small channels. Each tube operates at low shearing conditions that preserve polymer viscosity, while the aggregate effect provides the necessary flow control precision equivalent to or better than a single restricted opening.
Solution Approach 2:
The invention changes the geometric parameters of the flow restriction from a single large opening or few large holes to many small capillary tubes with specific diameter and length ratios. This parameter change allows achieving the required loss of load and flow control precision while maintaining polymer solution viscosity by operating in a different geometric regime that reduces elongational shearing.
3Productivity
If a single injection line supplies multiple wells with flow control valves, then distribution efficiency improves, but wells farther from the start experience insufficient head pressure for effective injection
Solution Approach 1:
The capillary valve design with specific tube dimensions (diameter, length, number of tubes) provides high flow resistance in a compact device, enabling effective flow control and head pressure regulation at each well head. This allows the single injection line to effectively serve multiple wells at different distances by providing local pressure regulation at each well.
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 solution effectively reduces polymer solution degradation to less than 25%, enabling efficient and prolonged use of polymer solutions in EOR processes while maintaining control over flow and viscosity, thus enhancing oil recovery and reducing operational and capital expenses.
Implementation Method 1
minimizing elongation and degradation by maximizing viscous dissipation
Data Source
AI summary
The present invention relates to a flow control valve to be connected to a pipe. The valve includes: a plurality of fluid transport tubes having a geometrically variable cross-section and placed in parallel with each other; and a means for connecting to the pipe and located at one end of the fluid transport tubes.