Venturi Mixing for Fiber Emulsion Injection
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Solution Overview
Problem
Current methods for injecting fibers into wellbores to seal off high permeability 'thief zones' are inefficient and pose safety risks due to pressure buildup and lack of real-time quality control, leading to potential equipment damage and ineffective plugging of formations.
Innovation Solution
A system that mixes fibers with an emulsion using a venturi while the emulsion is moving through surface tubing, and then injects the pressurized mixture into a wellbore using a combination of pumps and pressure boosters, or conveys the emulsion and fiber suspension downhole where they mix at specific nozzles, allowing for real-time monitoring and control of the mixture quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If fibers are mixed with base fluid prior to injection using batch mixing, then the fibers can be uniformly distributed, but the mixture cannot be monitored in real-time and quality control is limited to visual inspection
Solution Approach 1:
The patent implements real-time quality control by monitoring the fiber dispersion and flocculation process during injection. Sensors detect parameters such as fluid viscosity, fiber concentration, and mixture homogeneity, providing feedback that allows operators to adjust injection rates and mixing conditions dynamically to ensure optimal plug formation while preventing equipment damage.
Solution Approach 2:
The patent replaces traditional mechanical mixing equipment with an injection system that utilizes the fluid flow itself to drive mixing. By injecting the fiber-emulsion mixture through controlled nozzles and using the formation pressure gradient, the system achieves effective mixing without requiring complex mechanical mixers, thereby reducing device complexity while enabling real-time monitoring.
2Productivity
If high pressure pumps are used to inject the fiber mixture, then the mixture can be delivered to the wellbore, but pressure buildup may damage equipment
Solution Approach 1:
The patent performs preliminary mixing of fibers with emulsion on the surface before injection, ensuring proper flocculation and cluster formation. This preliminary action allows the mixture to be optimized for injection, reducing the pressure required during delivery and preventing equipment damage while maintaining effective injection rates for thief zone plugging.
Solution Approach 2:
The patent controls injection parameters dynamically, including injection rate, pressure gradient, and fluid temperature, to optimize the balance between delivery efficiency and equipment safety. By adjusting these parameters in real-time based on monitoring data, the system achieves productive injection without causing harmful pressure buildup that could damage equipment or damage the formation.
3Ease of operation
If fibers are injected without real-time monitoring, then the injection process is simpler, but the operator has no indication of fiber interaction and placement success
Solution Approach 1:
The patent incorporates sensors and monitoring systems that provide real-time feedback on fiber dispersion, flocculation, and placement success. Operators receive information about mixture quality and interaction parameters, enabling them to make informed decisions about injection rate adjustment and mixture composition to ensure effective thief zone sealing while maintaining operational simplicity.
4Reliability
If early flocculation occurs, then the fibers can form effective plugs, but surface or downhole equipment may be plugged
Solution Approach 1:
The patent performs preliminary mixing and controlled flocculation of fibers with emulsion on the surface before injection. This preliminary action allows fibers to form appropriate clusters and flocs in a controlled environment, ensuring they are ready for effective plug formation in the formation while preventing premature flocculation that could clog surface or downhole equipment.
Solution Approach 2:
The patent carefully controls injection parameters such as injection rate, fluid viscosity, and pressure gradient to manage flocculation timing. By adjusting these parameters, the system ensures fibers flocculate at the appropriate depth and time to form effective plugs without causing equipment plugging, balancing plug effectiveness with equipment safety.
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 approach enhances the efficiency and safety of fiber-based stimulation fluid injection by ensuring proper mixing and placement, reducing the risk of equipment damage and improving the sealing of thief zones, thereby optimizing hydrocarbon production.
Implementation Method 1
A venturi is used to mix the fiber with the emulsion while the emulsion is moving through the tubing
Implementation Method 2
Pumps and pressure boosters may be used to move the fluid
Implementation Method 3
The fiber flocculation and the particle coagulation are known to be highly sensitive to the viscosity of the carrying fluid
Implementation Method 4
The fibers and/or particles are expected to interact with one another and form flocs and/or clusters to plug high permeability zones
Data Source
AI summary
An emulsion is mixed with fibers while the emulsion is moving through a surface tubing using a venturi. The fiber/emulsion mixture is injected into a pressurized tank and the pressurized fiber/emulsion mixture is injected from the pressurized tank into a desired location in a wellbore. Pumps and pressure boosters may be used to move the fluid.