Polymer Hydration System Using Split Fluid Streams
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Solution Overview
Problem
In subterranean well treatment operations, heating all the hydrating fluid before mixing with hydratable materials is costly due to high energy requirements, and ambient temperature hydration results in poor polymer performance and waste, especially in cold climates.
Innovation Solution
A process where only a minor portion of the hydrating fluid is heated, introduced at ambient temperature, and split into two streams, with the heated stream mixed with the hydratable material to form a concentrated hydration mixture, which is then combined with the remaining ambient temperature hydrating fluid to achieve efficient hydration and reduce energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all hydrating fluid is heated before mixing with hydratable materials, then polymer hydration performance is improved, but energy consumption increases significantly
Solution Approach 1:
The hydrating fluid is divided into two separate streams: a first stream that is heated to elevated temperature and a second stream that remains at ambient temperature. This segmentation allows the system to achieve effective polymer hydration through the heated stream while avoiding the high energy cost of heating the entire fluid volume, thus resolving the contradiction between hydration performance and energy consumption.
Solution Approach 2:
Heating is applied locally only to the portion of hydrating fluid that directly contacts the hydratable material (the first stream), rather than heating the entire hydrating fluid system. This localized heating approach provides sufficient thermal energy for effective polymer hydration at the mixing point while minimizing overall energy consumption by leaving the majority of the fluid unheated.
2Use of energy by moving object
If ambient temperature hydrating fluid is used, then energy consumption is reduced, but polymer performance deteriorates and waste increases
Solution Approach 1:
By segmenting the hydrating fluid into heated and unheated streams, the invention enables the system to operate at low energy consumption levels (using ambient temperature for the majority of fluid) while still achieving reliable polymer performance through the localized heated stream that contacts the hydratable material.
Solution Approach 2:
Instead of heating the entire hydrating fluid (excessive action), the invention applies heating partially only to the necessary portion that will contact the hydratable material. This partial heating provides sufficient thermal energy for effective polymer hydration without the excessive energy expenditure of heating all fluid, thus resolving the contradiction between energy savings and polymer performance.
3Use of energy by stationary object
If hydratable material is mixed with ambient temperature fluid, then energy costs are reduced, but hydration rate decreases and viscosity rise is delayed
Solution Approach 1:
The hydrating fluid is segmented into a heated first stream and an ambient temperature second stream. The heated first stream provides rapid hydration and immediate viscosity rise when contacting the hydratable material, while the ambient temperature second stream can be added subsequently without delaying the initial hydration response, thus achieving both energy cost reduction and maintained hydration rate.
Solution Approach 2:
The first stream of hydrating fluid is pre-heated before mixing with the hydratable material, creating a ready-to-react thermal environment that immediately promotes rapid hydration and viscosity development. This preliminary heating action ensures fast hydration rate while the overall system energy costs are reduced by not heating the entire fluid volume.
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 significantly reduces energy usage while achieving rapid hydration and optimal polymer gel formation, similar to full heating, but with substantial energy savings, and minimizes polymer waste by using a fraction of the energy typically needed.
Implementation Method 1
a first stream of hydrating fluid is heated so as to elevate its temperature
Implementation Method 2
Hydration is a process by which a hydratable polymer chemically combines with water to create a viscous gel
Data Source
AI summary
A system and method for hydrating a hydratable material are provided in which a first hydration fluid is heated prior to mixing with the hydratable material to produce a hydration mixture. The hydration mixture is subsequently mixed with a second hydration fluid to produce a well injection fluid having a hydrated hydratable material. Generally, the first hydration fluid will be at about ambient temperature before it is heated and the second hydration fluid will be at about at about ambient temperature when it is mixed with the hydration mixture. Typically, the first hydration fluid will be a minor part of the hydration fluid content of the well injection fluid and the second hydration fluid will be a major part of the hydration fluid content of the well injection fluid.