U.S. patent application number 13/689873 was filed with the patent office on 2014-06-05 for apparatus and method of delivering a fluid using direct proppant injection.
This patent application is currently assigned to GENERAL ELECTRIC COMPANY. The applicant listed for this patent is GENERAL ELECTRIC COMPANY. Invention is credited to Jason Paul Mortzheim, Stephen Duane Sanborn, Tiffany Elizabeth Pinard Westendorf.
Application Number | 20140151049 13/689873 |
Document ID | / |
Family ID | 49641856 |
Filed Date | 2014-06-05 |
United States Patent
Application |
20140151049 |
Kind Code |
A1 |
Sanborn; Stephen Duane ; et
al. |
June 5, 2014 |
APPARATUS AND METHOD OF DELIVERING A FLUID USING DIRECT PROPPANT
INJECTION
Abstract
An apparatus and method for delivering a fluid mixture using
direct injection to a mixing apparatus. The apparatus including a
proppant storage vessel configured to contain therein a proppant
material and output a proppant output flow at ambient pressure to a
solid feed pump assembly. The apparatus further including a
fracturing fluid storage vessel configured to contain therein a
fracturing fluid and output a fracturing fluid output flow at a
fracture fluid blending pressure. The solid feed pump assembly
configured to output to a mixing apparatus, a proppant output flow
at the fracture fluid blending pressure. The mixing apparatus
configured to output a fluid mixture of the proppant and the
fracturing fluid at the fracture fluid blending pressure. The
mixing apparatus coupled to a high pressure pump assembly and
configured to deliver the fluid mixture therein to a downstream
component at an injection pressure.
Inventors: |
Sanborn; Stephen Duane;
(Copake, NY) ; Mortzheim; Jason Paul;
(Gloversville, NY) ; Westendorf; Tiffany Elizabeth
Pinard; (Troy, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GENERAL ELECTRIC COMPANY |
Schenectady |
NY |
US |
|
|
Assignee: |
GENERAL ELECTRIC COMPANY
Schenectady
NY
|
Family ID: |
49641856 |
Appl. No.: |
13/689873 |
Filed: |
November 30, 2012 |
Current U.S.
Class: |
166/305.1 ;
166/75.15 |
Current CPC
Class: |
E21B 43/267 20130101;
E21B 21/062 20130101 |
Class at
Publication: |
166/305.1 ;
166/75.15 |
International
Class: |
E21B 43/25 20060101
E21B043/25 |
Claims
1. An apparatus for delivering a fluid mixture comprising: a
proppant storage vessel configured to contain therein a proppant
material and output a proppant output flow at ambient pressure; a
solid feed pump assembly coupled to the proppant storage vessel,
the solid feed pump assembly including a proppant inlet in fluidic
communication with the proppant storage vessel proppant output
flow, the solid feed pump assembly configured to output a proppant
output flow at a discharge pressure, wherein the discharge pressure
is greater than the ambient pressure; a fracturing fluid storage
vessel configured to contain therein a fracturing fluid and output
a fracturing fluid output flow at a fracture fluid blending
pressure, wherein the fracture fluid blending pressure is greater
than the ambient pressure; a pressurized mixing apparatus coupled
to the solid feed pump assembly, the pressurized mixing apparatus
including a proppant inlet in fluidic communication with the solid
feed pump assembly proppant output flow and a fracturing fluid
inlet in fluidic communication with the fracturing fluid output
flow, the pressurized mixing apparatus configured to mix the
proppant output flow and the fracturing fluid output flow therein
and output a fluid mixture of proppant and fracturing fluid,
wherein the fracturing fluid of the fluid mixture of proppant and
fracturing fluid is at the fracture fluid blending pressure; and a
pump assembly coupled to the pressurized mixing chamber and
configured to deliver the fluid mixture of proppant and fracturing
fluid therein to a downstream component at an injection pressure,
wherein the injection pressure is greater than the fracture fluid
blending pressure.
2. The apparatus of claim 1, wherein the solid feed pump assembly
is a solid feed pump assembly set forth by the Posimetric.RTM.
standard.
3. The apparatus of claim 1, wherein the solid feed pump assembly
is an eductor pump assembly.
4. The apparatus of claim 1, wherein the solid feed pump assembly
is a rotary positive displacement pump assembly.
5. The apparatus of claim 1, wherein the fracture fluid blending
pressure is in a range of 200-400 psi.
6. The apparatus of claim 5, wherein the fracture fluid blending
pressure is approximately 300 psi.
7. The apparatus of claim 1, wherein the injection pressure is in a
range of 5000-12,000 psi or higher.
8. The apparatus of claim 1, wherein the injection pressure is
approximately 10,000 psi.
9. The apparatus of claim 1, wherein the proppant material is
sand.
10. The apparatus of claim 1, wherein the fracturing fluid is at
least one of liquid CO.sub.2 or liquid propane.
11. The apparatus of claim 1, wherein the solid feed pump assembly
is configured to receive a continual supply of proppant material
and output a continuous proppant output flow.
12. An apparatus for delivering a fluid mixture comprising: a
proppant storage vessel configured to contain therein a proppant
material and output a proppant output flow at ambient pressure; a
solid feed pump assembly coupled to the proppant storage vessel,
the solid feed pump assembly including a proppant inlet in fluidic
communication with the proppant storage vessel proppant output
flow, the solid feed pump assembly configured to output a proppant
output flow at a discharge pressure, wherein the discharge pressure
is greater than the ambient pressure, wherein the solid feed pump
assembly is one of a solid feed pump assembly set forth by the
Posimetric.RTM. standard, an eductor pump assembly or a rotary
positive displacement pump assembly; a fracturing fluid storage
vessel configured to contain therein a fracturing fluid and output
a fracturing fluid output flow at a fracture fluid blending
pressure, wherein the fracture fluid blending pressure is greater
than the ambient pressure; a mixing apparatus coupled to the solid
feed pump assembly, the mixing apparatus including a proppant inlet
in fluidic communication with the solid feed pump assembly proppant
output flow and a fracturing fluid inlet in fluidic communication
with the fracturing fluid output flow, the mixing apparatus
configured to mix the proppant output flow and the fracturing fluid
output flow therein and output a fluid mixture of proppant and
fracturing fluid, wherein the fracturing fluid is at the fracture
fluid blending pressure; and a pump assembly coupled to the mixing
chamber and configured to deliver the fluid mixture therein to a
downstream component at an injection pressure, wherein the
injection pressure is greater than the fracture fluid blending
pressure.
13. The apparatus of claim 12, wherein the fracture fluid blending
pressure is in a range of 200-400 psi.
14. The apparatus of claim 13, wherein the fracture fluid blending
pressure is approximately 300 psi.
15. The apparatus of claim 12, wherein the injection pressure is in
a range of 5000-12,000 psi.
16. The apparatus of claim 12, wherein the proppant material is
sand and the fracturing fluid is at least one of liquid CO.sub.2 or
liquid propane.
17. The apparatus of claim 12, wherein the solid feed pump assembly
is a solid feed pump assembly set forth by the Posimetric.RTM.
standard coupled to the proppant storage vessel, the solid feed
pump assembly comprising: a consolidation section configured to
cause the proppant material to compact and act as a solid mass; a
rotating section configured to increase the pressure of the
proppant material therein; and a discharge section configured to
discharge the proppant material at the increased discharge
pressure.
18. The apparatus of claim 12, wherein the solid feed pump assembly
is an eductor pump assembly coupled to the proppant storage vessel
and the fracturing fluid storage vessel, the eductor pump assembly
comprising: a suction chamber in fluidic communication with the
proppant output flow, the fracture fluid output flow and a motive
fluid flow, the suction chamber configured to output a fluid
mixture to a mixing chamber; and an expansion feature coupled to
the mixing chamber and configured to expand the fluid mixture
therein for delivery to a downstream component.
19. The apparatus of claim 12, wherein the solid feed pump assembly
is rotary positive displacement pump assembly coupled to the
proppant storage vessel, the rotary positive displacement pump
assembly comprising: a pump body, including a feed inlet at a first
end and a discharge point at a second end; a feed mechanism
disposed within the pump body and configured to move the proppant
material from the feed inlet to the discharge point while
increasing a pressure of the proppant material from an ambient
pressure to the discharge pressure.
20. An apparatus for delivering a fluid mixture comprising: a
proppant storage vessel configured to output a proppant output flow
at ambient pressure; a solid feed pump in fluidic communication
with the proppant storage vessel, the solid feed pump assembly
configured to output a proppant output flow at a discharge
pressure, wherein the discharge pressure is greater than the
ambient pressure; a fracturing fluid storage vessel configured to
contain therein a fracturing fluid at a fracture fluid blending
pressure, wherein the fracture fluid blending pressure is greater
than the ambient pressure; a mixing apparatus coupled to the solid
feed pump assembly and the fracturing fluid storage vessel, the
mixing apparatus configured to output a fluid mixture of proppant
and fracturing fluid, wherein the fracturing fluid is at the
fracture fluid blending pressure; and a pump assembly coupled to
the mixing chamber and configured to output a fluid mixture to a
downstream component at an injection pressure, wherein the
injection pressure is greater than the fracture fluid blending
pressure.
21. A method of delivering a fluid mixture, comprising: providing
an input of a proppant material at ambient pressure to a proppant
storage vessel, the proppant storage vessel configured to output a
proppant output flow at ambient pressure; providing an input of a
fracture fluid at a fracture fluid blending pressure to a fracture
fluid storage vessel, the fracture fluid storage vessel configured
to output a fracture fluid output flow at the a fracture fluid
blending pressure; inputting the proppant output flow at ambient
pressure from the proppant storage vessel into a solid feed pump
assembly wherein the pressure of the proppant output flow is
increased to a discharge pressure; inputting the proppant output
flow at the discharge pressure and a fracture fluid output flow at
the fracture fluid blending pressure into a mixing apparatus;
mixing the proppant output flow and the fracturing fluid output
flow therein the mixing apparatus and outputting a fluid mixture of
proppant and fracturing fluid, wherein the fracturing fluid is at
the fracture fluid blending pressure; increasing the pressure of
the output fluid mixture in a pump to output an increased pressure
fluid mixture; and delivering the increased pressure fluid mixture
to one or more downstream components.
Description
BACKGROUND
[0001] Embodiments disclosed herein relate generally to an
apparatus and method of delivering a fluid mixture into a
wellbore.
[0002] Hydraulic fracturing, commonly known as hydrofracking, or
simply fracking, is a technique used to release petroleum, natural
gas or other substances for extraction from underground reservoir
rock formations. A wellbore is drilled into the reservoir rock
formation, and a treatment fluid is pumped which causes fractures
and allows for the release of trapped substances produced from
these subterranean natural reservoirs. Current wellhead fracking
systems utilize a process wherein a slurry of fracturing fluid and
proppant (e.g. sand) is created and then pumped into the well at
high pressure. When water-based fracturing fluids are used, the
proppant, water and appropriate chemicals can be mixed at
atmospheric pressure and then pumped up to a higher pressure for
injection into the well. However, if fluids other than water (e.g.
liquid CO.sub.2 or liquid propane) are used as the fracturing
fluid, then these fluids must be kept at a sufficient pressure
throughout the hydraulic fracturing system to avoid undesired
vaporization. As a result, the blending of these fluids with
proppant, chemicals, etc. must also be accomplished while the
fluids are kept under a sufficiently high pressure. Current
pressurized blenders exist for this purpose.
[0003] Known pressurized blenders capable of blending these
vaporizing fracturing fluids with the proppant at a suitably high
pressure utilize a pressurized proppant storage vessel arrangement
to feed and meter the proppant into the pressurized fracturing
fluid. These known lock-hopper based pressurized blenders require
pre-loading with the proppant to be utilized during a given
fracture stage. The pressurized proppant storage vessels used
typically have a capacity in the range of 20-40 tons of proppant
(e.g., sand). The limited volume capacity of the proppant storage
vessel system provides for limited amounts of proppant to be
blended with the fracturing fluid. If the fracturing design
requires more sand, then multiple blenders must be used. In
addition, these known pressurized blenders require an undesirably
long elapsed time to reload them with proppant for the next
fracture stage. In some instances, some pressurized blender
operations require the blender unit be moved off-site to another
location for the purpose of reloading with proppant, also requiring
an undesirably long time and potentially adding to the truck
traffic associated with fracturing operations. In many instances,
the limited capacity requires specialized logistics and on-pad (or
off-pad) proppant handling equipment to be used in conjunction with
the proppant storage vessel based pressurized blenders.
[0004] Accordingly, there is a need for an improved pumping system
and method for delivering treatment fluid into a wellbore that will
enable the blending and pumping of essentially unlimited quantities
of proppant and fracturing fluid to form the fluid mixture. The
ability to deliver unlimited quantities will provide for continuous
operation of the pressurized blender and sand feeding equipment,
enable fracture plans to be based upon reservoir stimulation
requirements without imposing equipment constraints, and therefore
providing overall a more efficient system.
BRIEF SUMMARY
[0005] These and other shortcomings of the prior art are addressed
by the present disclosure, which provides an apparatus and method
of delivering a fluid using direct proppant injection to a
pressurized blender.
[0006] In accordance with an embodiment, provided is an apparatus
for delivering a fluid mixture comprising: a proppant storage
vessel, a solid feed pump assembly, a fracturing fluid storage
vessel, a mixing apparatus and a high pressure pump assembly. The
proppant storage vessel is configured to contain therein a proppant
material and output a proppant output flow at ambient pressure. The
solid feed pump assembly is coupled to the proppant storage vessel.
The solid feed pump assembly including a proppant inlet in fluidic
communication with the proppant storage vessel proppant output
flow. The solid feed pump assembly is configured to output a
proppant output flow at or above a fracture fluid blending
pressure, wherein the fracture fluid blending pressure is greater
than the ambient pressure. The fracturing fluid storage vessel is
configured to contain therein a fracturing fluid and output a
fracturing fluid output flow at the fracture fluid blending
pressure. The mixing apparatus is coupled to the solid feed pump
assembly. The mixing apparatus including a proppant inlet in
fluidic communication with the solid feed pump assembly proppant
output flow and a fracturing fluid inlet in fluidic communication
with the fracturing fluid output flow. The mixing apparatus is
configured to mix the proppant output flow and the fracturing fluid
output flow therein and output a fluid mixture of proppant and
fracturing fluid at the fracture fluid blending pressure. The high
pressure pump assembly is coupled to the mixing chamber and
configured to deliver the fluid mixture therein to a downstream
component at an injection pressure, wherein the injection pressure
is greater than the fracture fluid blending pressure.
[0007] In accordance with another embodiment, provided is an
apparatus for delivering a fluid mixture comprising: a proppant
storage vessel, a solid feed pump assembly, wherein the solid feed
pump assembly is one of a Posimetric.RTM. pump assembly, an eductor
pump assembly or a rotary positive displacement pump assembly, a
fracturing fluid storage vessel, a mixing apparatus and a high
pressure pump assembly. The proppant storage vessel is configured
to contain therein a proppant material and output a proppant output
flow at ambient pressure. The solid feed pump assembly is coupled
to the proppant storage vessel and including a proppant inlet in
fluidic communication with the proppant storage vessel proppant
output flow. The solid feed pump assembly is configured to output a
proppant output flow at a fracture fluid blending pressure, wherein
the fracture fluid blending pressure is greater than the ambient
pressure. The fracturing fluid storage vessel is configured to
contain therein a fracturing fluid and output a fracturing fluid
output flow at the fracture fluid blending pressure. The mixing
apparatus is coupled to the solid feed pump assembly and including
a proppant inlet in fluidic communication with the solid feed pump
assembly proppant output flow and a fracturing fluid inlet in
fluidic communication with the fracturing fluid output flow. The
mixing apparatus is configured to mix the proppant output flow and
the fracturing fluid output flow therein and output a fluid mixture
of proppant and fracturing fluid at the fracture fluid blending
pressure. The high pressure pump assembly is coupled to the mixing
chamber and configured to deliver the fluid mixture therein to a
downstream component at an injection pressure, wherein the
injection pressure is greater than the fracture fluid blending
pressure.
[0008] In accordance with yet another embodiment, provided is a
method for delivering a fluid mixture, comprising: providing an
input of a proppant material at ambient pressure to a proppant
storage vessel, the proppant storage vessel configured to output a
proppant output flow at ambient pressure; providing an input of a
fracture fluid at a fracture fluid blending pressure to a fracture
fluid storage vessel, the fracture fluid storage vessel configured
to output a fracture fluid output flow at the fracture fluid
blending pressure; inputting the proppant output flow at ambient
pressure from the proppant storage vessel into a solid feed pump
assembly wherein the pressure of the proppant output flow is
increased to a fracture blending pressure; inputting the proppant
output flow at the fracture fluid blending pressure and a fracture
fluid output flow at a fracture fluid blending pressure into a
mixing apparatus; mixing the proppant output flow and the
fracturing fluid output flow therein the mixing apparatus and
outputting a fluid mixture of proppant and fracturing fluid at the
fracture fluid blending pressure; increasing the pressure of the
output fluid mixture in a high pressure pump; and delivering the
high pressure fluid mixture to one or more downstream
components.
[0009] Other objects and advantages of the present disclosure will
become apparent upon reading the following detailed description and
the appended claims with reference to the accompanying
drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0010] The above and other features, aspects, and advantages of the
present disclosure will become better understood when the following
detailed description is read with reference to the accompanying
drawings in which like characters represent like parts throughout
the drawings, wherein
[0011] FIG. 1 is a schematic diagram of an apparatus for delivering
a fluid mixture using a solid feed pump assembly for direct
proppant injection to a pressurized mixing apparatus constructed in
accordance with an embodiment;
[0012] FIG. 2 is a schematic diagram of an apparatus for delivering
a fluid mixture using a Posimetric.RTM. pump assembly for direct
proppant injection to a pressurized mixing apparatus constructed in
accordance with another embodiment;
[0013] FIG. 3 is a schematic diagram of an apparatus for delivering
a fluid mixture using a eductor pump assembly direct proppant
injection to a pressurized mixing apparatus constructed in
accordance with still another embodiment;
[0014] FIG. 4 is a schematic diagram of an apparatus for delivering
a fluid mixture using a pressurized rotary positive displacement
pump assembly for direct proppant injection to a pressurized mixing
apparatus constructed in accordance with still another embodiment;
and
[0015] FIG. 5 is a schematic block diagram of a method of
delivering a fluid mixture using a direct proppant injection to a
pressurized mixing apparatus constructed in accordance with still
another embodiment.
DETAILED DESCRIPTION
[0016] This disclosure will be described for the purposes of
illustration only in connection with certain embodiments; however,
it is to be understood that other objects and advantages of the
present disclosure will be made apparent by the following
description of the drawings according to the disclosure. While
preferred embodiments are disclosed, they are not intended to be
limiting. Rather, the general principles set forth herein are
considered to be merely illustrative of the scope of the present
disclosure and it is to be further understood that numerous changes
may be made without straying from the scope of the present
disclosure.
[0017] Preferred embodiments of the present disclosure are
illustrated in the figures with like numerals being used to refer
to like and corresponding parts of the various drawings. It is also
understood that terms such as "top", "bottom", "outward", "inward",
and the like are words of convenience and are not to be construed
as limiting terms. It is to be noted that the terms "first,"
"second," and the like, as used herein do not denote any order,
quantity, or importance, but rather are used to distinguish one
element from another. The terms "a" and "an" do not denote a
limitation of quantity, but rather denote the presence of at least
one of the referenced item. The modifier "about" used in connection
with a quantity is inclusive of the stated value and has the
meaning dictated by the context (e.g., includes the degree of error
associated with measurement of the particular quantity).
[0018] As used herein, the process of forming of a fluid mixture
includes mixing a fluid with a powdered or particulate material,
such as proppant, a powdered dissolvable or a hydratable additive
(prior to hydration). In a continuous treatment or in a continuous
part of a well treatment, the fluids are handled as fluid
streams.
[0019] Referring to the drawings wherein, as previously stated,
identical reference numerals denote the same elements throughout
the various views, FIG. 1 depicts in a simplified block diagram,
elements of an apparatus for delivering a fluid mixture 100
including direct proppant injection to a pressurized blender, or
mixing apparatus, according to an embodiment. The apparatus 100
includes a proppant storage vessel 102 coupled to a solid feed pump
assembly 104. The proppant storage vessel 102 is coupled to the
solid feed pump assembly 104, at an inlet port 106 of the solid
feed pump assembly 104. More specifically, an outlet 108 of the
proppant storage vessel 102 is configured in fluidic communication
with the inlet 106 of the solid feed pump assembly 104. The
proppant storage vessel 102 is configured as a traditional
unpressurized storage type vessel and includes a body 110
configured to hold a proppant material 112 therein at atmospheric
pressure. The proppant storage vessel 102 may further include a
proppant material inlet 114 coupled to a proppant material loading
device 116 and a source of proppant material (not shown). In an
embodiment, the proppant material 112 may be comprised of a sand,
or other material commonly utilized as proppant in pumping
operations. The proppant storage vessel 102 provides adequate
storage and loading capabilities to allow for a continuous supply
of proppant material 112 to solid feed pump assembly 104.
[0020] During operation, the proppant storage vessel 102 may be
loaded by the material loading device 116, such as a screw auger,
conveyor, or any other low pressure means configured to move the
proppant material 112 from a proppant supply source (not shown) to
the proppant storage vessel 102. Alternate means for providing the
proppant material 112 to the proppant storage vessel 102 are
anticipated herein.
[0021] The solid feed pump assembly 104 includes a pump assembly
capable of receiving a proppant output flow 118 at atmospheric
pressure via outlet 108 and inlet 106 and then providing at solid
feed pump assembly outlet 120, a proppant output flow 122 at a
fracture fluid blending pressure, wherein the fracture fluid
blending pressure is greater than the ambient pressure. In an
embodiment, the fracture fluid blending pressure is in a range of
about 50 psi to 400 psi, and preferably at a pressure of
approximately 300 psi.
[0022] A pressurized blender, or mixing apparatus, 124 is
configured to receive the proppant output flow 122 via a proppant
inlet 126. A fracturing fluid storage vessel 128 is provided in
fluidic communication via an outlet 130 with the pressurized mixing
apparatus 124 via a fracturing fluid inlet 132. The fracturing
fluid storage vessel 128 is configured for storage of a fracturing
fluid 134 at a required temperature and storage pressure, and more
particularly at or above the fracture blending pressure. The
pressurized mixing apparatus 124 is configured to receive a
fracturing fluid output flow 136 at the fracture fluid blending
pressure via the inlet 132. In an embodiment, the fracturing fluid
storage vessel 128 is configured to permit a minimal amount of the
fracturing fluid output flow 136 to enter the solid feed pump
assembly 104 so as to provide for moistening of the proppant
material to accomplish pumping therethrough of the proppant
material 112. It should be understood that while anticipated is the
permitting of a minimal amount of fracturing fluid output flow 136
to enter the solid feed pump assembly 104, in contrast to previous
known pumping systems, the amount of fracturing fluid output flow
136 that is allowed to enter the solid feed pump assembly 104 is
not sufficient to provide for the formation of a dense
proppant/fluid slurry to be pumped through the pump assembly
104.
[0023] During operation, the proppant output flow 122 and the
fracturing fluid output flow 136 are blended, or mixed, within the
pressurized mixing apparatus 124 and delivered as a fluid mixture
output flow 138 via an outlet 140 of the pressurized mixing
apparatus 124 to a high pressure pump assembly 142. In alternate
embodiments, a fracture fluid booster pump 141 may be provided
inline between the mixing apparatus 124 and the high pressure pump
assembly 142, or alternatively provided as part of the
functionality of the high pressure pump assembly 142. The fluid
mixture output flow 138 is output at the fracture blending
pressure. The fluid mixture output flow 138 is received via a fluid
mixture inlet 144 of the high pressure pump assembly 142. The high
pressure pump assembly 142 is configured to deliver the fluid
mixture output flow 138 received therein to a downstream component
146 at an injection pressure, wherein the injection pressure is
greater than the fracture fluid blending pressure. More
specifically, in an embodiment, the high pressure pump assembly 142
is configured to deliver a high pressure fluid mixture output flow
148 via an outlet 150 of the high pressure pump assembly 142 to an
inlet 152 of the downstream component 146, such as a well head
154.
[0024] The inclusion of the solid feed pump assembly 104 in
apparatus 100 will allow unlimited amounts of the proppant material
112 to be blended with the fracture fluid 134, using conventional
sand logistics and on-pad handling equipment. Accordingly, the
solid feed pump assembly 104 is capable of operating continuously,
in contrast to semi-batch operating modes of the state of the art
lock hoppers.
[0025] Further embodiments of an apparatus for delivering a fluid
using direct injection of a proppant at ambient pressure to a
pressurized blender are illustrated in FIGS. 2-4. More
particularly, illustrated are alternate embodiments of the solid
feed pump assembly 104 as described in FIG. 1. Each of the
embodiments of FIGS. 2-4 addresses the direct delivery of a dry
proppant material, such as proppant material 112 of FIG. 1, to a
pump assembly for pressurization and subsequent mixing with the
fracture fluid 134 in a pressurized mixing apparatus 124. More
particularly, each of the embodiments of FIGS. 2-4 describes a pump
assembly that may be utilized for the solid feed pump assembly 104,
as described in FIG. 1. Accordingly, like numbers are used to
identify like elements throughout the described embodiments and in
an effort to provide a concise description of these embodiments,
like features and elements previously described will not be further
described.
[0026] Referring more specifically to FIG. 2, illustrated is an
embodiment of an apparatus for delivering a fluid mixture,
generally referenced 200. The apparatus 200 includes a proppant
storage vessel 102 configured to contain therein a proppant
material 112 and output a proppant output flow 118 at ambient
pressure. A solid feed pump assembly 104 is provided and coupled to
the proppant storage vessel 102. The solid feed pump assembly 104
includes a proppant inlet 106 in fluidic communication with the
proppant storage vessel proppant output flow 118. In this
particular embodiment, the solid feed pump assembly 104 is a
Posimetric.RTM. pump assembly 202. The Posimetric.RTM. pump
assembly 202 employs positive-displacement action to feed the
proppant material 112 into the pressurized blender without the need
for a pressurizing fluid. The Posimetric.RTM. pump assembly 202
does not employ screws, augers, belts or vibratory trays to convey
the proppant material 112, and in contrast employs at least one
vertical rotating spool 204 disposed within a pump body 208 to move
the proppant material 112 therein. The proppant output flow 118 is
initially input at an input duct 206 that is coupled to the pump
body 208. As the proppant output flow 118 enters and fills the pump
assembly 202, and more particularly the pump body 208, from above,
the material locks itself firmly into the confines of the rotating
spool 204 contained therein, which carries it through an arc of
approximately 180.degree.. More particularly, the proppant output
flow 118 is rotated within the rotating spool 204, housed within
the pump body 208, where it becomes "locked up" or compacted so as
to act as a solid mass, and discharged via an output duct 210 at
the outlet 120 as a proppant output flow 122. While within the pump
body 208, the proppant material 118 acts as a solid mass and a seal
against the high pressure outlet. At the time of discharge via the
outlet 120, the proppant material output flow 122 is output at an
increased pressure, and more particularly at a fracture blending
pressure that is higher than ambient pressure.
[0027] In a preferred embodiment, the Posimetric.RTM. pump assembly
202 includes a consolidation section 212, a rotating section 214
and a discharge section 216. During operation, the proppant
material 112 enters the pump assembly 202 and becomes consolidated
as the individual proppant material particles settle and come into
contact with each other as well as the sidewalls defining the pump
body 208, the particles become compacted and act as a solid mass
and form a seal against the high pressure outlet environment. As
the proppant material 112 rotates in the rotating spool 204 and
pump body 208, the pressure of the proppant material 112 is
increased to the fracture blending pressure. Discharge of the
proppant material 112 at the increased fracture blending pressure
occurs upon rotating of the rotating spool 204 to the outlet 120.
Exemplary pump assemblies are described in commonly assigned U.S.
Pat. No. 8,006,827, D. Aldred et al., "Transporting Particulate
Material", issued Aug. 3, 2011, which is incorporated by reference
herein in its entirety.
[0028] The Posimetric.RTM. pump assembly 202 is configured to
output the proppant output flow 122 at a fracture fluid blending
pressure, wherein the fracture fluid blending pressure is greater
than the ambient pressure. The apparatus 200 further includes a
fracturing fluid storage vessel 128 configured to contain therein a
fracturing fluid 134 and output a fracturing fluid output flow 136
at or above the fracture fluid blending pressure. A pressurized
blender, or mixing apparatus, 124 is coupled to the Posimetric.RTM.
pump assembly 202 to receive the discharged proppant output flow
122 therefrom and to the fracturing fluid storage vessel 128. The
mixing apparatus 124 is configured to mix the proppant output flow
122 and the fracturing fluid output flow 136 therein and output a
fluid mixture 138 of proppant and fracturing fluid at the fracture
fluid blending pressure. A fracturing fluid booster pump 141 and a
high pressure pump assembly 142 are coupled to the mixing apparatus
124 and configured to deliver a high pressure fluid mixture 148
therein to a downstream component 146 at an injection pressure,
wherein the injection pressure is greater than the fracture fluid
blending pressure.
[0029] Referring more specifically to FIG. 3, illustrated is
another embodiment of an apparatus for delivering a fluid mixture,
generally referenced 300. The apparatus 300 includes a proppant
storage vessel 102 configured to contain therein a proppant
material 112 and output a proppant output flow 118 at ambient
pressure. The apparatus 300 further includes a fracturing fluid
storage vessel 128 configured to contain therein a fracturing fluid
134 and output a fracturing fluid output flow 136 at or above a
fracture fluid blending pressure, wherein the fracture fluid
blending pressure is greater than the ambient pressure as
previously described. A solid feed pump assembly 104 is provided
and coupled to the proppant storage vessel 102 and the fracturing
fluid storage vessel 128. The solid feed pump assembly 104 includes
a proppant inlet 106 in fluidic communication with the proppant
storage vessel proppant output flow 118 and a fracture fluid inlet
324 in fluidic communication with at least a portion of the
fracturing fluid output flow 136. In this particular embodiment,
the solid feed pump assembly 104 is an eductor pump assembly 302.
During operation, the eductor pump assembly 302 employs the Venturi
effect of a converging-diverging nozzle to convert the pressure
energy of a motive fluid, and more particularly a portion of the
fracturing fluid output flow 136, to velocity energy to feed the
proppant material 112. Similar to the previously described
Posimetric.RTM. pump assembly 202, the eductor pump assembly 302
does not employ screws, augers, belts or vibratory trays to convey
the proppant material 112 within the pump assembly toward the
downstream components.
[0030] As illustrated in FIG. 3, the proppant output flow 118 is
initially input into the eductor pump assembly 302 via an input
duct 306 that is coupled to a pump body 308. The input of the
proppant storage vessel proppant output flow 118 may be metered by
a valve mechanism (not shown) disposed in the input duct 306. In an
embodiment, the eductor pump assembly 302 further includes a first
converging nozzle 310, a second converging nozzle 312, a mixing
chamber 314 and a diffuser, or expansion feature, 316.
[0031] In an embodiment, the eductor pump assembly 302 includes the
eductor body 308, and more particularly a suction chamber 318 that
is driven by the motive fluid, and more particularly at least a
portion of the fracturing fluid output flow 136 utilized as a
motive flow. In an embodiment, at least a portion of the fracturing
fluid output flow 136 is input directly into the mixing apparatus
124. The fracturing fluid output flow 136 is accelerated through
the first converging nozzle 310. As with traditional eductors,
accelerating a higher pressure fluid through the first converging
nozzle 310 drops the static pressure of a motive flow exiting
through the first converging nozzle 310, while simultaneously
decreasing the static pressure within the suction chamber 318. The
lower suction pressure in the suction chamber 318 draws in the
proppant output flow 118, as a suction flow via the inlet port 106
of the eductor pump assembly 302. Subsequently, a fluid mixture
320, comprised of a combination of the proppant output flow 118 and
the fracturing fluid output flow 136, is delivered to the second
converging nozzle 312 prior to reaching the mixing chamber 314.
Within the mixing chamber 314 the fluid mixture 320, comprised of
the proppant output flow 118 and the fracturing fluid output flow
136, is further mixed as the stratifications between the two fluids
is allowed to settle out and as the turbulent fluid structure is
reduced. The fluid mixture 320 exiting the mixing chamber 314 is
expanded in the expansion feature 316, prior to being delivered to
the downstream components that may ultimately be in fluidic
communication with a wellhead. The expansion feature 316 provides
an expansion of the fluid mixture 320 and provides a decrease in
the velocity of the fluid mixture 320 and recovery of the pressure
of the fluid mixture 320 allowing the fluid to be delivered to a
mixing apparatus 124 at a fracture blending pressure.
[0032] During operation of the apparatus 300, including the eductor
pump assembly 302, the eductor pump assembly 302 is placed in
operation by pressurizing the suction chamber 318. Subsequent to
the appropriate pressure condition being reached, an optional valve
mechanism or gate, 322, disposed between the proppant storage
vessel 102 and the inlet port 106 may be opened to allow the
proppant storage vessel 102 contents to enter the eductor pump
assembly 302, and more particularly the suction chamber 318. The
suction chamber 318 draws in the proppant output flow 118,
including the proppant material 112, as the suction flow, and
subsequently mixes with the motive flow, and more particularly, at
least a portion of the fracturing fluid output flow 136. Operation
of the apparatus may be continuous with continuous flow of the
proppant output flow 118 and the fracturing fluid output flow
136.
[0033] It should be noted that valve mechanism 322 is optional,
being required in an application where the desire is to allow the
eductor pump assembly 302 to remain at full pressure. As valves in
the direct path of the proppant output flow 118, and more
particularly proppant material 112, it will be subject to a harsh
abrasive environment, it is realized that valve mechanism 322 will
be subject to higher wear rates. As such, an embodiment eliminating
the valve mechanism 322 is anticipated.
[0034] The eductor pump assembly 302 is configured to output a
proppant output flow 122 at a fracture fluid blending pressure,
wherein the fracture fluid blending pressure is greater than the
ambient pressure. The apparatus 300 further includes a pressurized
blender, or mixing apparatus, 124 coupled to the eductor pump
assembly 302 to receive the discharged proppant output flow 122
therefrom and the fracturing fluid output flow 136. The mixing
apparatus is configured to mix the proppant output flow 122 and the
fracturing fluid output flow 136 therein and output a fluid mixture
output flow 138 of proppant and fracturing fluid at the fracture
fluid blending pressure. A fracturing fluid booster pump 141 and a
high pressure pump assembly 142 are coupled to the mixing apparatus
124 and configured to deliver the fluid mixture 138 therein to a
downstream component 146 as a high pressure fluid mixture output
flow 148 at an injection pressure, wherein the injection pressure
is greater than the fracture fluid blending pressure.
[0035] Accordingly, the inclusion of the eductor pump assembly 302,
as described in apparatus 300, provides for the pressurizing of the
fracturing fluid 134 in a conventional high pressure fluid pump and
then use that at least a portion of the flow of high-pressure
fracturing fluid 136 as the motive fluid flow through the eductor
pump assembly 302 to convey the proppant 112 and more particularly
the proppant output flow 118 into the flowing motive fluid.
[0036] Referring more specifically to FIG. 4, illustrated is
another embodiment of an apparatus for delivering a fluid mixture,
generally referenced 400. The apparatus 400 includes a proppant
storage vessel 102 configured to contain therein a proppant
material 112 and output a proppant output flow 118 at ambient
pressure. The apparatus 400 further includes a fracturing fluid
storage vessel 128 configured to contain therein a fracturing fluid
134 and output a fracturing fluid output flow 136 at or above a
fracture fluid blending pressure, wherein the fracture fluid
blending pressure is greater than the ambient pressure as
previously described. A solid feed pump assembly 104 is provided
and coupled to the proppant storage vessel 102 and the fracturing
fluid storage vessel 128. The solid feed pump assembly 104 includes
a proppant inlet 106 in fluidic communication with the proppant
storage vessel proppant output flow 118. In this particular
embodiment, the solid feed pump assembly 104 is positive
displacement pump, and more particularly a rotary-type positive
displacement pump, such as an internal gear, screw or auger type
pump assembly, referenced 402. The unique design of the positive,
displacement pump 402, ensures that the proppant material 112 is
constantly present at a feed inlet 404, while the controlled
rotation of a feed mechanism 406 moves the proppant material 112,
and more particularly the proppant output flow 118, from the feed
inlet 404 to a discharge point 408. In the illustrated embodiment,
the feed mechanism 406 comprises a screw mechanism 410 (a helical
surface surrounding a central cylindrical shaft) disposed inside a
hollow body 412.
[0037] As illustrated in FIG. 4, the proppant output flow 118 is
initially input into the rotary-type positive displacement pump 402
via the feed inlet 404. Similar to the previous embodiment, the
input of the proppant storage vessel proppant output flow 118 may
be metered by an optional valve mechanism (not shown). Similar to
the Posimetric.RTM. pump assembly 202 of FIG. 1, the positive
displacement pump assembly 402 employs positive-displacement action
to feed the proppant material 112 as a free-flowing material with a
uniform discharge in a linear volumetric fashion. In contrast to
the Posimetric.RTM. pump assembly 202, the positive displacement
pump assembly 402 employs screws, augers, belts or vibratory trays
to convey the proppant material 112 therein. The proppant output
flow 118 is initially input at the feed inlet 404 that is coupled
to the pump body 412. As the proppant output flow 118 enters and
fills the pump assembly 402, and more particularly the pump body
412, the material is carried by the feed mechanism 406 contained
therein, toward the discharge point 408. The proppant output flow
118 is rotated within the feed mechanism 406, housed within the
pump body 412 and discharged via an output duct 414 at the
discharge point 408 as a proppant output flow 122. At the time of
discharge via an outlet 120, the proppant material output flow 122
is output at an increased pressure, and more particularly at a
fracture blending pressure that is higher than ambient
pressure.
[0038] In a preferred embodiment, during operation, the proppant
material 112 enters the rotary-type positive displacement pump 402
at the feed inlet 404. As the proppant material 112 rotates in the
feed mechanism 410 and pump body 412, the pressure of the proppant
material 112 is increased to the fracture blending pressure.
Discharge of the proppant material 112 at the increased fracture
blending pressure occurs upon rotation of the feed mechanism 406 to
the outlet 120.
[0039] The rotary-type positive displacement pump 402 is configured
to output the proppant output flow 122 at a fracture fluid blending
pressure, wherein the fracture fluid blending pressure is greater
than the ambient pressure. The apparatus 400 further includes a
pressurized blender, or mixing apparatus, 124 coupled to the
rotary-type positive displacement pump 402 to receive the
discharged proppant output flow 122 therefrom and the fracturing
fluid output flow 136. The mixing apparatus 124 is configured to
mix the proppant output flow 122 and the fracturing fluid output
flow 134 therein and output a fluid mixture 138 of proppant
material 112 and fracturing fluid 134 at the fracture fluid
blending pressure. A high pressure pump assembly 142 coupled to the
mixing chamber 124 is configured to deliver a high pressure fluid
mixture 148 to a downstream component 146 at an injection pressure,
wherein the injection pressure is greater than the fracture fluid
blending pressure. In this particular embodiment, a separate
booster pump is not provided, and in in lieu of boosting of the
fracturing fluid pressure is provided as part of the functionality
of the high pressure pump assembly 142.
[0040] Accordingly, the inclusion of the rotary-type positive
displacement pump 402, as described in apparatus 400, provides for
the pressurizing of the fracturing fluid 134 in a conventional high
pressure fluid pump. The proppant 112 does not flow through a
conventional high pressure fluid pump, or pumps, thereby minimizing
degradation to these pumps that pumping the proppant 112 through
them would cause.
[0041] FIG. 5 is a schematic block diagram of a method 500 of
delivering a fluid mixture using direct proppant injection to a
pressurized blender using a solid feed pump assembly in an
apparatus 100, 200, 300 according to an embodiment disclosed
herein. Generally, the method involves providing an input of a
proppant material 112 to a proppant storage vessel 102, and
providing an input of a fracture fluid 134 to a fracture fluid
storage vessel 128, at a step 502. Next in step 504, a proppant
output flow 118 at ambient pressure from the proppant storage
vessel 102 is input into a solid feed pump assembly 104. As
previously described, the solid feed pump assembly 104 may be
configured as a positive displacement pump assembly, and more
particularly a Posimetric.RTM. pump assembly 202 (as best
illustrated in FIG. 2) or a rotary-type positive displacement pump
402 (as best illustrated in FIG. 4) or as an eductor pump assembly
304 (as best illustrated in FIG. 3). Next in step 506, the proppant
output flow 118 and a fracturing fluid output flow 136 are input to
a mixing apparatus 124. In an embodiment, the fracturing fluid
output flow 136 is input to the mixing apparatus 124 via an eductor
pump assembly. The mixing apparatus 124 is configured to mix the
proppant output flow 118 and the fracturing fluid output flow 136
therein and output a fluid mixture output flow 138 of the proppant
and fracturing fluid at the fracture fluid blending pressure, at
step 508. The pressure of the fluid mixture output flow 138 is next
increased in a high pressure pump 142, at step 510. Subsequently
the high pressure fluid mixture 148 is delivered to one or more
downstream components 146, at a step 512, and ultimately may
include delivery to a well head.
[0042] Additional commercial advantages of the disclosed apparatus
are related to the current problem faced in unconventional gas
development and the requirement to mix/blend chemicals and a
proppant, namely sand with fracturing fluids (e.g., liquid
CO.sub.2, liquid propane gas) that require they always be contained
at a suitable fracture fluid blending pressure to avoid
vaporization of these fracturing fluids. Accordingly, disclosed is
apparatus and method of delivering a fluid mixture using a solid
feed pump assembly and direct proppant injection into a pressurized
mixing apparatus in such a way that a continuous flow of proppant
can be provided without being constrained by the total volume
limits of the known lock hopper based approaches.
[0043] The foregoing has described an apparatus and method of
delivering a fluid mixture using direct injection of a proppant
into a pressurized mixing apparatus. While the present disclosure
has been described with respect to a limited number of embodiments,
those skilled in the art, having benefit of this disclosure, will
appreciate that other embodiments may be devised which do not
depart from the scope of the disclosure as described herein. While
the present disclosure has been described with reference to
exemplary embodiments, it will be understood by those skilled in
the art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the disclosure. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
present disclosure without departing from the essential scope
thereof. Therefore, it is intended that the present disclosure not
be limited to the particular embodiment disclosed as the best mode
contemplated for carrying out the disclosure. It is, therefore, to
be understood that the appended claims are intended to cover all
such modifications and changes as fall within the true spirit of
the disclosure.
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