Vortex Mixing Apparatus for Clump-Free Gel Hydration
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Solution Overview
Problem
Current methods for mixing dry hydratable agents with base fluids in the oil industry face challenges such as clumping, uneven mixing, and high costs, particularly in remote or large-volume applications, which hinder the efficiency of forming homogeneous high viscosity fluids for fracturing operations.
Innovation Solution
A vortex mixing apparatus that pre-wets and partially hydrates dry compositions in a mixing chamber before sweeping them into a larger portion of base fluid, creating a clump-free and hydrated concentrate, which can then be injected into a well for fracturing, using a low-cost, efficient system that eliminates the need for complex and costly mixers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dry gel additives are mixed directly with water at the job site, then the process is simple and equipment requirements are minimal, but clumping and uneven mixing occur resulting in poor hydration quality
Solution Approach 1:
The mixing process is segmented into two distinct stages: (1) pre-wetting stage where dry gel particles are contacted with a limited amount of water to form a slurry, and (2) hydration stage where the slurry is mixed with the remaining water. This segmentation prevents clumping by controlling the sequence of water addition and mixing intensity at each stage.
Solution Approach 2:
The pre-wetting step is performed as a preliminary action before full hydration. Dry gel particles are first contacted with a portion of water to form a uniform slurry, which then serves as the basis for subsequent mixing with the remaining water. This preliminary action ensures uniform distribution of gel particles before complete hydration occurs.
2Manufacturing precision
If liquid gel concentrate is used instead of dry additives, then clumping is reduced and mixing efficiency improves, but equipment complexity and capital costs increase
Solution Approach 1:
The system uses the energy and flow characteristics of the fracturing fluid itself to perform the mixing function. The high-velocity fluid stream creates turbulence and shear forces that automatically mix and hydrate the gel particles without requiring separate mixing equipment. The fluid serves both as the processing medium and the mixing mechanism.
Solution Approach 2:
Traditional mechanical mixing equipment (mixers, agitators, pumps) is replaced with a fluid-mechanics-based mixing system. The kinetic energy of the fracturing fluid stream provides the mixing action through turbulence and shear, eliminating the need for complex mechanical mixing devices while achieving superior mixing efficiency.
3Quantity of substance
If hydrocarbon-based liquid gel concentrate is used, then higher quantities of solids can be suspended, but environmental impact and material costs increase
Solution Approach 1:
The system changes the physical parameters of the fracturing fluid (velocity, pressure, turbulence intensity) to achieve enhanced solids suspension capacity. By optimizing the fluid flow regime and mixing intensity, the system can suspend and hydrate dry gel particles effectively using water-based fluids, eliminating the need for hydrocarbon carriers while maintaining or improving suspension capacity.
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 allows for on-demand, efficient, and cost-effective production of clump-free, high viscosity fracturing fluids, reducing capital costs and environmental impact while ensuring effective hydration and dispersion of gelling agents, thereby enhancing the efficiency of fracturing operations.
Implementation Method 1
A second portion of the base fluid is directed through a nozzle to form a vacuum zone, which sucks or sweeps the partially hydrated fluid exiting the vortex mixing chamber into the second portion of the base fluid
Implementation Method 2
A dry composition is fed into the vortex mixing chamber, while a first portion of the base fluid is fed radially into the vortex mixing chamber to form a partially hydrated, substantially clump and/or fish-eye free fluid
Data Source
AI summary
Apparatus, methods and systems for preparing a polymer concentrate for treating a formation with slick water systems viscous fluid or a gelled viscous fluid are disclosed. The method includes directing a powdered gel into a vortex mixing chamber, while directing a first portion of a base fluid into the vortex mixing chamber to form partially hydrated fluid concentrate. The partially hydrated fluid concentrate is then sucked or sweep into a main portion of base fluid for form the slick water systems viscous fluid or gelled viscous fluid.