Hydraulic Fracturing Polymer Dispersion System
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Solution Overview
Problem
Existing polymer dispersion systems for hydraulic fracturing in the oil and gas industry face frequent equipment breakdowns and long 'down' periods due to mechanical wear and tear, leading to operational delays and revenue losses, despite advancements in eductor mixing devices which still suffer from energy inefficiencies and noise issues.
Innovation Solution
A polymer dispersion system comprising an eductor mixing device with a tank assembly and transfer sub-systems, controlled by a programmable logic controller, which minimizes mechanical components and includes backup systems to ensure continuous operation by diverting flow to redundant pumps and filters, reducing downtime and increasing polymer concentration processing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a polymer slicing unit with mechanical components is used, then polymer can be ground and mixed into solvent, but the mechanical parts suffer from wear and tear and frequent breakdown requiring replacement
Solution Approach 1:
The patent replaces the mechanical polymer slicing unit with a jet mixing system that uses high-velocity fluid jets to atomize and mix polymer particles with solvent. This eliminates mechanical contact between moving parts and polymer, eliminating wear and tear on mechanical components while maintaining effective polymer dissolution capability
Solution Approach 2:
The invention uses hydraulic jet mixing where high-pressure fluid jets create intense turbulence and shear forces to break down and mix polymer particles with solvent. This hydraulic approach replaces mechanical grinding and slicing operations, achieving polymer dissolution without mechanical wear
2Reliability
If eductor mixing devices are used to replace polymer slicing units, then mechanical breakdown is reduced, but energy consumption increases and noise levels become excessive
Solution Approach 1:
The patent optimizes the jet mixing parameters including fluid pressure, jet velocity, and nozzle configuration to achieve effective polymer mixing at lower energy consumption levels. By carefully controlling these parameters, the system maintains reliability benefits while reducing excessive energy use and noise generation associated with conventional eductor devices
3Productivity
If polymer slicing units are used, then polymer can be processed, but the amount of polymer that can be liquefied is limited by mechanical limitations of the unit
Solution Approach 1:
By replacing the mechanically limited slicing unit with a jet mixing system, the patent removes the mechanical constraints on polymer processing capacity. The jet mixing system can handle higher polymer concentrations and larger volumes without the mechanical wear and size limitations that constrain traditional slicing units
4Ease of manufacture
If polymer dissolution equipment with mechanical components is used, then polymer hydraulic fracturing fluid can be prepared, but long down periods occur when components malfunction or require maintenance
Solution Approach 1:
The patent replaces mechanical dissolution equipment with a jet mixing system that has no mechanical parts in contact with the polymer-solvent mixture. This eliminates mechanical failures and extended downtime associated with malfunctioning components, enabling continuous operation and rapid preparation of fracturing fluids without maintenance interruptions
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 significantly reduces equipment downtime, maintains high polymer concentration processing, and optimizes energy use by employing redundant components and smart flow management, enhancing operational efficiency and reducing maintenance needs.
Implementation Method 1
The eductor mixing device is capable of generating a negative pressure for drawing the liquid medium and the particulate material into the eductor mixing device
Implementation Method 2
The eductor mixing device is used for mixing the liquid medium and the particulate material by vortex to form a mother solution
Data Source
AI summary
A polymer dispersion system for use in a hydraulic fracturing operation is disclosed. The system comprises (a) a tank assembly comprising an ingress, an egress, and an interior volume for collecting mother solution; (b) a first transfer pump coupled with the egress of the tank assembly: and (c) a second transfer pump coupled with the egress of the tank assembly. The first transfer pump is configured for coupling to a missile unit and a blender unit downstream thereof, but in fluid communication with only one of such units at any given time when coupled. A method of operating said polymer dispersion system is also disclosed.