Polymer Dispersion Friction Reducer via Controlled Radical Polymerization
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Solution Overview
Problem
Existing polymer dispersions used in oil and gas field fracturing operations face stability issues and environmental concerns due to the use of hydrocarbon solvents, and there is a need for a friction reducer that is both effective and easy to prepare.
Innovation Solution
A process involving controlled living polymerization to create a copolymer with a block of ionic charged polymeric dispersant and a block of nonionic monomers, which is then used to formulate a polymer dispersion comprising water-soluble copolymer, salt, and polyol, providing improved stability and friction reduction capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional free radical polymerization is used to prepare polymer dispersion, then the manufacturing process is simple, but the stability of the polymer mixture is poor
Solution Approach 1:
The patent combines the polymeric dispersant synthesis and the copolymer synthesis into a single controlled radical polymerization process. The polymeric dispersant and copolymer are formed simultaneously in the same reaction medium, creating a unified system where the dispersant stabilizes the copolymer particles in situ, eliminating the stability issues of physical mixtures from separate synthesis steps.
Solution Approach 2:
The invention creates a composite polymer system where a polymeric dispersant (formed from monomers like acrylic acid or its salts) is integrated with the copolymer matrix (containing acrylamide and other monomers). This composite structure provides both the friction reduction functionality of the copolymer and the stabilization functionality of the dispersant within a single material system.
2Ease of manufacture
If hydrocarbon solvent is used to emulsify and disperse the aqueous phase, then the polymer dispersion can be formed, but environmental safety hazards occur
Solution Approach 1:
The patent removes the hydrocarbon solvent component from the emulsion system entirely. Instead of using oil-based continuous phase, the invention employs purely aqueous-based dispersion medium, extracting the harmful element while maintaining the dispersion functionality through water-soluble polymeric dispersants and surfactants.
Solution Approach 2:
The invention changes the fundamental parameter of the continuous phase from hydrocarbon-based to water-based. This parameter change transforms the system from an oil-in-water or water-in-oil emulsion to a water-based polymer dispersion, eliminating environmental hazards while achieving the desired polymer dispersion through controlled radical polymerization in aqueous medium.
3Manufacturing precision
If two-step synthesis with separate polymeric dispersant and copolymer production is used, then each component can be optimized, but the final product requires additional pre-dissolution process
Solution Approach 1:
The patent merges the dispersant synthesis and copolymer synthesis into a single integrated controlled radical polymerization process. Both components are formed simultaneously in the same reaction vessel, and the dispersant remains associated with the copolymer particles throughout, eliminating the need for separate pre-dissolution steps before use.
Solution Approach 2:
The polymeric dispersant is formed in advance during the polymerization process itself, before the copolymer particles are fully formed and stabilized. This preliminary formation of the dispersant ensures it is already positioned to stabilize the growing polymer particles, eliminating the need for subsequent pre-dissolution or separate addition steps.
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 polymer dispersion exhibits excellent friction reducing capacity and stability, with the ability to effectively reduce friction in turbulent flow within aqueous fracturing fluids, while being environmentally friendly and easy to prepare.
Implementation Method 1
The copolymer obtained is a single polymer since the living polymer obtained in the first step reacts and forms covalent bond with subsequently loaded monomers
Implementation Method 2
U.S. Pat. Nos. 5,837,775 and 6,787,506 disclose the preparation of nonionic and anionically charged acrylamide-acrylic acid copolymer via conventional radical polymerization in aqueous media
Implementation Method 3
anionic charged polymeric dispersant is prepared from at least an anionic monomer in the presence of a radical polymerization control agent
Data Source
AI summary
A polymer dispersion may include a water soluble copolymer, a water soluble salt, a polyol, and water. A method of preparing a polymer dispersion may include controlled radical polymerization. A method of using the polymer dispersion as a friction reducer in oil field processes.