Wellsite Mixing Unit for Fracturing Fluid Hydration
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Solution Overview
Problem
Current subterranean well treatment operations face inefficiencies due to the need for large, cumbersome hydration tanks and separate equipment for gelling and blending, leading to transportation challenges, equipment complexity, safety concerns, and increased manual control requirements.
Innovation Solution
A mobile wellsite system with a mixing unit that includes a rheology control portion and a high-volume solids blending portion, allowing for the efficient mixing and blending of fracturing fluids using a centralized system with metering and transfer mechanisms, reducing the need for multiple tanks and equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If large volume hydration tanks are used to provide sufficient residence time for hydration, then the hydration level and viscosity of the fluid mixture are improved, but the tank footprint and transportation difficulty increase significantly
Solution Approach 1:
The patent changes the key parameter from tank volume to residence time through continuous flow. By controlling the flow rate and tank configuration, sufficient hydration is achieved without requiring large tank volumes, thus reducing footprint while maintaining hydration quality
Solution Approach 2:
The system transitions from static large tanks to dynamic continuous flow tanks where fluid constantly moves through the system. This dynamic approach allows sufficient residence time for hydration while maintaining compact tank dimensions through optimized flow paths and rates
2Reliability
If separate equipment is used for gelling and blending operations, then each function can be performed with specialized equipment, but the overall system complexity and equipment quantity increase
Solution Approach 1:
The patent combines gelling and blending operations into a single integrated continuous flow system. The mixing unit performs both hydration (gelling) and blending functions sequentially in one continuous process, eliminating the need for separate equipment while maintaining functional reliability through dedicated mixing zones
Solution Approach 2:
The mixing unit is designed as a multi-functional device that performs both gelling and blending operations. By incorporating multiple mixing zones and flexible configuration, a single piece of equipment accomplishes what previously required separate specialized equipment
3Duration of action of moving object
If delivery vehicles repeatedly arrive at the wellsite to supply materials, then material supply continuity is maintained, but vehicle congestion and wellsite organization complexity increase
Solution Approach 1:
The system uses large bulk storage containers that are filled in advance and can supply materials continuously without requiring repeated delivery vehicle arrivals. This preliminary stocking approach maintains supply continuity while significantly reducing the frequency of vehicle trips and associated organizational complexity
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 simplifies the process, reduces equipment complexity, enhances safety, and improves control over the fracturing fluid formation, enabling more efficient and reliable subterranean well treatment operations.
Implementation Method 1
Hydration is a process by which the hydratable material solvates, absorbs, and/or otherwise reacts with hydrating fluid to create the high viscosity fluid mixture
Implementation Method 2
a dispersing and/or mixing system... The dispersing and/or mixing system is operable to disperse and/or mix the metered first material with a fluid to form a first fluid mixture
Implementation Method 3
a solids blending system... The solids blending system is operable to blend the metered second material with the first fluid mixture to form a second fluid mixture
Data Source
AI summary
A mixing unit comprising a frame, a rheology control portion, and a high-volume solids blending portion. The rheology control portion comprises means for receiving a first material from a first transfer mechanism, a dispersing/mixing system connected with the frame, and a first metering system to meter the first material from the first material receiving means to the dispersing/mixing system. The dispersing/mixing system disperses/mixes the metered first material with a fluid to form a first fluid mixture. The high-volume solids blending portion comprises means for receiving a second material from a second transfer mechanism, a solids blending system connected with the frame, and a second metering system to meter the second material from the second material receiving means to the solids blending system. The solids blending system blends the metered second material with the first fluid mixture to form a second fluid mixture.