High-Pressure Shear Mixing for Polymer Hydration
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Solution Overview
Problem
Conventional blending methods for fluids and chemicals used in well injection are time-consuming and inefficient, as they rely on low-pressure mixing and recirculation to achieve full hydration of polymers and chemicals, which can take several hours and result in incomplete mixing and shear stress on molecules.
Innovation Solution
An in-line, high-pressure shearing and blending device that uses a positive displacement process to introduce polymers and chemicals into a mixing chamber with a shear orifice and hydration passage, applying shear stress to molecules and achieving near-full hydration and mixing before injection into the well, utilizing existing high-pressure pumps and energies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional low-pressure blending systems are used, then the blending process can be performed with simple equipment, but the blending time is extended to several hours and the mixing homogeneity is insufficient
Solution Approach 1:
The invention changes the pressure parameter from conventional low-pressure (atmospheric) blending to high-pressure (250-10,000 psi) blending. This parameter change enables the fluid to pass through shear-producing elements that rapidly hydrate and mix polymer molecules, reducing blending time from hours to minutes while achieving homogeneous mixing.
Solution Approach 2:
The invention replaces conventional mechanical mixing systems (paddles, stirrers, recirculation pumps) with a pressure-driven shear mixing system. The high-pressure pump forces fluid through shear-producing elements (orifices, restrictors) that create intense shear stress to unravel and hydrate polymer molecules, eliminating the need for lengthy mechanical mixing cycles.
2Productivity
If conventional batch mixing tanks with recirculation are used, then the mixing process can be simplified, but the equipment footprint is large and the mixing efficiency is low
Solution Approach 1:
The invention merges the pumping, mixing, and hydrating functions into a single integrated in-line system. The high-pressure pump, shear-producing elements, and hydration passage are combined in one compact apparatus, eliminating the need for separate batch mixing tanks, recirculation piping, and storage vessels, thus dramatically reducing equipment footprint while maintaining high mixing efficiency.
Solution Approach 2:
The invention transitions from three-dimensional batch mixing in large tanks to a streamlined linear flow path through the in-line device. The compact apparatus processes fluid in a continuous linear sequence through shear zones and hydration passages, achieving thorough mixing in a fraction of the space required by conventional batch systems.
3Manufacturing precision
If low-pressure surface blending systems are used, then the system complexity is reduced, but the polymer hydration is incomplete and the fluid homogeneity is poor
Solution Approach 1:
The invention introduces shear-producing elements (orifices, restrictors, flow constrictions) as intermediaries between the high-pressure pump and the output. These elements create controlled zones of intense shear stress that act as mediators to unravel polymer molecules and promote complete hydration, achieving homogeneous mixing without requiring complex multi-component mixing systems.
4Productivity
If conventional blending procedures are used, then the process is simple to operate, but the total time to drill out wells is increased due to time-consuming blending
Solution Approach 1:
The invention performs polymer hydration and mixing in advance, immediately before the fluid is needed for well injection or drilling operations. The in-line high-pressure system prepares the fluid on-demand with rapid mixing, eliminating the need for lengthy pre-blending operations and allowing immediate deployment, thus reducing overall well completion time.
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 blending time, achieving near-instantaneous and homogeneous mixing of polymers and chemicals, producing a consistent and viscous fluid ready for injection, with a small footprint and minimal maintenance requirements, while utilizing existing wellsite energies.
Implementation Method 1
The shear device causes molecular unraveling of the polymeric additives via shear stressing, homogeneous mixing/blending
Implementation Method 2
The inlet of the mixing device is connected to the discharge of a positive displacement pump
Data Source
AI summary
A mixing device has an elongate shell, an inlet, an outlet and at least one shear orifice between the inlet and the outlet. A hydration passage is located between the shear orifice and the outlet. The hydration passage has a flow area greater than a total shear flow area of the shear orifice, greater than an inlet flow area of the inlet and greater than an outlet flow area of the outlet. During operation, a polymer is mixed in a fluid flow flowing to the intake of a positive displacement pump, which pumps the fluid through the mixing device and into an injection conduit leading into a well. The shear orifice produces high shear separation of molecules of the polymer. The hydration passage causes hydration under pressure of the various polymer molecules in addition to blending the various chemicals and/or gases with other components of the fluid flow stream.