Pressure Exchanger Fluid Plug for Fracturing Efficiency
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Solution Overview
Problem
Existing pressure exchangers used in hydraulic fracturing operations suffer from significant mixing of clean fluids and proppant slurries, leading to reduced efficiency and limited utilization of stroke length, resulting in lower volumetric efficiency and increased wear and tear.
Innovation Solution
The implementation of a fluid plug within the hydraulic energy transfer system, formed by increasing the viscosity of the proppant slurry, which separates the clean fluid and proppant slurry, preventing mixing and allowing for greater stroke length utilization and increased efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If clean fluid and proppant slurry are allowed to interact in the pressure exchanger, then pressure transfer occurs, but mixing occurs which reduces output volume and utilization of stroke length
Solution Approach 1:
The pressure exchanger channel is segmented into distinct zones: a clean fluid zone, a proppant slurry zone, and a fluid plug zone separating them. This segmentation prevents mixing while allowing pressure transfer through the reciprocating motion of the fluid plug, resolving the contradiction between pressure transfer efficiency and volumetric efficiency.
Solution Approach 2:
A fluid plug acts as an intermediary between the clean fluid and proppant slurry. This intermediary transfers pressure from the clean fluid to the proppant slurry through its reciprocating motion without allowing direct mixing, thereby maintaining both pressure transfer efficiency and volumetric efficiency.
2Productivity
If the stroke length of channels is fully utilized, then productivity increases, but mixing of fluids occurs reducing efficiency
Solution Approach 1:
The channel is segmented into distinct zones with the fluid plug creating clear boundaries. This segmentation allows the full stroke length to be utilized for productive pressure transfer while preventing harmful mixing, as the fluid plug maintains separation throughout the reciprocating motion.
Solution Approach 2:
The fluid plug serves as a movable intermediary that traverses the full stroke length of the channel, enabling complete utilization of the channel volume for pressure transfer while maintaining fluid separation and preventing mixing losses.
3Power
If clean fluid and proppant slurry mix, then pressure transfer occurs, but filtration systems are required increasing device complexity
Solution Approach 1:
The fluid plug acts as a continuous intermediary barrier that prevents mixing between clean fluid and proppant slurry throughout the pressure transfer process. This eliminates the need for filtration systems while maintaining effective pressure transfer, thereby reducing device complexity.
Solution Approach 2:
The fluid plug self-regulates the separation of clean fluid and proppant slurry through its reciprocating motion, creating a self-contained separation mechanism that eliminates the need for external filtration systems and reduces overall device complexity.
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 solution enhances the volumetric efficiency of the pressure exchanger, reduces wear and tear, and minimizes the need for filtration systems by effectively isolating the clean fluid and proppant slurry, thereby improving the overall performance and longevity of the equipment.
Implementation Method 1
the portion of the proppant slurry to be retained in the hydraulic energy transfer system is crosslinked to increase a viscosity of the portion
Data Source
AI summary
A method includes introducing a proppant slurry into a first end of a hydraulic energy transfer system, introducing a clean fluid into a second end of the hydraulic energy transfer system opposite the first end, operating the hydraulic energy transfer system to retain a portion of the proppant slurry in the hydraulic energy transfer system while transferring pressure of the clean fluid to the proppant slurry, and forming a fluid plug that separates the proppant slurry and the clean fluid, the fluid plug being formed by increasing a viscosity of the portion of the proppant slurry to be higher than a viscosity of the clean fluid and a viscosity of the proppant slurry in the hydraulic energy transfer system.