Tubless Proppant Blending System for On-the-Fly Slurry Preparation
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Solution Overview
Problem
Existing fracturing systems for subterranean operations require large mix tanks and significant horsepower for agitators, which occupy valuable space and pose maintenance and operational consistency challenges due to the need for premixing solids with a carrier fluid before pumping.
Innovation Solution
A solids pump, preferably of the Posimetric® style, delivers solids directly into the fluid pipeline, eliminating the need for a mix tank and agitators, and can inject solids either before or after the triplex pump, allowing for on-the-fly slurry preparation and reduced horsepower requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a mix tank with agitators is used to prepare slurry, then solids can be premixed with carrier fluid, but significant space is occupied and maintenance issues arise
Solution Approach 1:
The invention extracts and eliminates the mix tank and agitator system from the slurry preparation process. Instead of premixing solids with carrier fluid in a large tank, the system delivers solids directly into the fluid pipeline using a solids pump, removing the need for the mixing equipment and the space it occupies.
Solution Approach 2:
The slurry preparation process is segmented into separate functions: solids are delivered independently via a solids pump, and fluid is delivered via a fluid pump, with mixing occurring in-line within the pipeline rather than in a separate tank. This segmentation eliminates the need for a large stationary mix tank.
2Stability of the object's composition
If agitators are used to maintain slurry consistency, then uniform slurry can be achieved, but significant horsepower is required
Solution Approach 1:
The invention extracts and eliminates the high-horsepower agitator system from the slurry preparation process. Instead of using mechanical agitation to maintain consistency, the system relies on the flow dynamics within the pipeline and the proper sequencing of solids and fluid delivery to achieve uniform slurry without requiring significant power input.
Solution Approach 2:
The invention replaces the mechanical agitator system with a fluid dynamics-based mixing approach. By controlling the delivery of solids and fluid through properly sized pipelines and pumps, and by utilizing the kinetic energy of the flowing fluid, the system achieves slurry mixing without mechanical agitation, thereby eliminating the need for high horsepower.
3Productivity
If solids are delivered into high pressure discharge line, then on-the-fly mixing is achieved, but solids pump horsepower requirement increases substantially
Solution Approach 1:
The invention applies preliminary action by delivering solids to an intermediate pressure line before the high-pressure discharge. The solids are first delivered to a lower pressure line where they mix with fluid, and then the combined slurry is pressurized to the required high pressure for fracturing operations. This sequencing avoids the need to deliver solids directly into the high-pressure line.
Solution Approach 2:
The pressure delivery process is segmented into two stages: first, solids are delivered to an intermediate pressure line at lower pressure where mixing occurs; second, the mixed slurry is then pressurized to the final high pressure required for fracturing. This segmentation of the pressure-building process reduces the horsepower requirement for the solids pump.
4Device complexity
If one or both pumps are eliminated by delivering solids downstream, then system complexity is reduced, but solids pump horsepower must be increased
Solution Approach 1:
The invention applies preliminary action by delivering solids to an intermediate pressure line before the high-pressure discharge. The solids are first delivered to a lower pressure line where they mix with fluid, and then the combined slurry is pressurized to the required high pressure for fracturing operations. This sequencing avoids the need to deliver solids directly into the high-pressure line.
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 reduces space and maintenance needs, enhances operational reliability, and allows for efficient slurry preparation by eliminating the need for premixing, while also enabling the use of alternative fluids and solid materials.
Implementation Method 1
A solids pump, preferably of the Posimetric® style, delivers solids directly into the fluid pipeline
Implementation Method 2
pumping large volumes at high pressure into a formation to initiate and extend fractures
Implementation Method 3
The material that is pumped is invariably water with a small percentage by weight of solids such as proppants that are used to create and hold open the produced fractures with the high pressure associated with the slurry flow
Data Source
AI summary
Fracturing slurries are prepared on the fly using a solids pump to feed the solid such as a gel into a liquid stream of normally water for pumping downhole with a large capacity triplex pump. The solids pump is preferably a Posimetric® style which delivers the solid into the fluid pipeline in a manner that keeps fluid from backing into the solids hopper above the solids pump. A separate fluid tank is connected to a fluid pump to pressurize a suction line to a boost pump before reaching the triplex pump and pumping into the subterranean formation. The solids pump can deliver between the fluid and boost pumps in which case the solids go through the triplex pump or alternatively the solids can be delivered into the higher pressure discharge line of the triplex pump.