Inversion Device for Polymer Latex Dilution
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Solution Overview
Problem
Current methods for inverting water-in-oil polymer lattices in enhanced oil recovery (EOR) face challenges in achieving rapid and efficient inversion, especially in conditions with high total dissolved solids and elevated temperatures, leading to slow hydration and equipment issues such as coagulation and phase separation.
Innovation Solution
A single-step inversion device with a pressure differential of 2 psi to 150 psi, designed to handle high molecular weight polymers, facilitates continuous inversion of w/o lattices with 10 wt % to 80 wt % polymer solids and 2 wt % to 5 wt % surfactant, resulting in a dilute latex with less than 10,000 ppm polymer solids within 5 minutes, characterized by a Filter Ratio of 1.5 or less.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional w/o latex inversion methods are used, then polymer solution formation occurs, but inversion time is excessively long (5-180 minutes) and complete inversion at target concentrations below 1 wt% cannot be achieved
Solution Approach 1:
The patent applies preliminary action by pre-forming invertible lattices with specific surfactant combinations (HLB 2-8 and HLB 14-18) and stabilizers incorporated during latex manufacturing. This preliminary preparation enables rapid inversion upon water contact, reducing inversion time from 5-180 minutes to significantly shorter durations while achieving complete inversion at target concentrations below 1 wt%
Solution Approach 2:
The patent employs parameter changes by modifying the chemical composition parameters of the latex formulation, specifically incorporating surfactants with specific HLB ranges (2-8 and 14-18) and stabilizers at controlled concentrations (0.1-5.0 wt%). These compositional parameter changes fundamentally alter the inversion kinetics, enabling rapid and complete inversion that conventional formulations cannot achieve
2Ease of operation
If w/o latex is diluted with water source, then polymer inversion occurs, but coagulation and phase separation occur leading to equipment plugging
Solution Approach 1:
The patent applies the intermediary principle by incorporating stabilizers (polymers with different functionality than the EOR polymer) that act as mediators between the hydrophobic polymer particles and the aqueous environment. These stabilizers prevent coagulation and phase separation during inversion by providing steric or electrostatic stabilization, ensuring solution stability while maintaining ease of operation in single-step dilution processes
Solution Approach 2:
The patent employs composite materials by creating a multi-component system comprising the EOR polymer, surfactants with specific HLB ranges, and stabilizers formulated together in the invertible latex. This composite formulation works synergistically to enable rapid inversion while preventing coagulation and phase separation, resolving the contradiction between operational simplicity and solution stability
3Productivity
If higher HLB surfactant is added as destabilizer, then latex inversion is facilitated, but polymer molecular weight loss and viscosity loss increase
Solution Approach 1:
The patent applies parameter changes by precisely controlling the HLB parameters of surfactants used during latex formulation (before inversion) versus those acting as destabilizers during inversion. By selecting surfactants with specific HLB ranges (2-8 and 14-18) and controlling their concentrations, the patent achieves rapid inversion while minimizing polymer degradation and maintaining molecular weight, thus resolving the contradiction between inversion speed and substance loss
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 enables rapid and complete inversion of polymer lattices, reducing polymer molecular weight loss and viscosity loss, achieving efficient polymer solution formation without additional mixing steps, suitable for harsh field conditions.
Implementation Method 1
an inversion device, or mixing pump, designed and adapted to provide a pressure differential (or pressure drop) of at about 2 psi to 150 psi between the inlet and outlet of the device
Implementation Method 2
a surfactant having a hydrophilic-lipophilic balance (HLB) of about 2 to 8
Implementation Method 3
mixing the two phases using techniques that result in a water-in-oil emulsion or latex
Implementation Method 4
subsequent dissolution of the concentrated polymer particles to full hydrodynamic volume and maximum solution viscosity
Data Source
AI summary
Disclosed herein are inversion systems and methods of diluting w/o lattices including about 10 wt % to 80 wt % of a water soluble polymer. Using the inversion systems and methods described herein, dilution of w/o lattices is carried out in a single step to form dilute lattices having 10,000 ppm or less polymer; the dilute lattices form polymer solutions with no further addition of mixing force or water. The solution viscosities of the polymer solutions obtained using the systems and methods of the invention are at least about 80% of solution viscosity expected in the absence of shear.