Waterless Foam Generator for Shale Fracturing
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Solution Overview
Problem
Conventional fracturing technologies face challenges in forming effective waterless foam fracturing fluids for shale oil and gas reservoirs due to the unique properties of liquid CO2 and N2, which require specialized foaming agents and temperature control, and struggle with proppant distribution and resilience against abrasion.
Innovation Solution
A waterless foam generator system comprising a proppant storage tank, high-pressure gas-liquid-solid mixer, and multiple shakers with specific designs for efficient mixing and temperature control, utilizing hydraulic sealing gates and wear-resistant materials to produce uniform and dense waterless foam fracturing fluids with controlled proppant concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional water-based foam generators are used for waterless foam generation, then device complexity is reduced, but manufacturing precision and foam uniformity deteriorate due to the different physical properties of liquid CO2/N2 compared to water-based systems
Solution Approach 1:
The patent modifies key operational parameters including temperature control (maintaining liquid CO2 at -10°C to 0°C), pressure settings (5-20 MPa for liquid CO2, 15-30 MPa for N2), and flow rate ratios to achieve proper foam formation with liquid CO2 and N2, which have fundamentally different physical properties from water-based systems
Solution Approach 2:
The patent introduces specialized components as intermediaries: a heat exchanger to control liquid CO2 temperature, a hydraulic sealing gate to regulate flow, and a high-pressure mixing chamber to facilitate uniform mixing, thereby bridging the gap between simple device structure and precise foam generation
2Manufacturing precision
If stronger mixing capacity is used to achieve uniform waterless foam, then foam uniformity improves, but device complexity and energy consumption increase
Solution Approach 1:
The patent employs a shaker component that generates mechanical vibrations to enhance mixing efficiency. The vibration frequency and amplitude are controlled to optimize the dispersion of N2 gas bubbles in liquid CO2, achieving uniform foam structure without requiring overly complex mixing mechanisms
Solution Approach 2:
The patent utilizes hydraulic principles through the hydraulic sealing gate system to control liquid CO2 flow, and pneumatic principles through high-pressure N2 injection, creating a balanced mixing system that achieves uniform foam through fluid dynamics rather than mechanical complexity
3Manufacturing precision
If temperature control capability is added to the foam generator, then foam generation quality improves, but device complexity increases
Solution Approach 1:
The patent introduces a heat exchanger as an intermediary component that efficiently controls liquid CO2 temperature. The heat exchanger uses a simple but effective heat transfer mechanism to maintain liquid CO2 within the optimal temperature range of -10°C to 0°C, ensuring proper viscosity and foam generation quality without requiring complex temperature control systems
Solution Approach 2:
The system leverages the inherent thermal properties of liquid CO2 and the ambient environment, using the heat exchanger to passively maintain temperature through controlled heat exchange rather than active heating or cooling systems, thereby reducing overall device complexity
4Reliability
If the foam generator must withstand strong proppant abrasion, then reliability improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent specifies the use of wear-resistant composite materials for components exposed to proppant abrasion, particularly the high-pressure gas-liquid-solid mixer and discharge components. These composite materials combine hardness for abrasion resistance with toughness to withstand impact, achieving high reliability without requiring overly complex structural designs
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
The system effectively generates waterless foam fracturing fluids with uniform N2 dispersion in liquid CO2, ensuring efficient proppant distribution and reduced damage to shale formations, while minimizing water consumption and environmental impact.
Implementation Method 1
a high-pressure gas-liquid-solid mixer, configured to mix the liquid CO2, the N2 and the proppant to form the waterless foam fracturing fluid
Implementation Method 2
a first shaker of waterless foam fracturing fluid, a second shaker of waterless foam fracturing fluid and a third shaker of waterless foam fracturing fluid
Implementation Method 3
where a thermal insulation layer is wrapped around an outer surface of the foam generator
Data Source
AI summary
The present disclosure discloses a waterless foam generator for fracturing shale oil and gas reservoirs and use thereof. The structure of the waterless foam generator includes: a top of the proppant storage tank is provided with a proppant inlet, a second feed port of liquid CO2 and a safety valve, and a bottom of the proppant storage tank is connected to the high-pressure gas-liquid-solid mixer, a side wall of the high-pressure gas-liquid-solid mixer is provided with a first feed port of liquid CO2, an feed port of N2 and an feed port of waterless foam foaming agent, and the high-pressure gas-liquid-solid mixer is connected to the first shaker of waterless foam fracturing fluid, the first shaker of waterless foam fracturing fluid, the second shaker of waterless foam fracturing fluid and the third shaker of waterless foam fracturing fluid are connected in sequence.