U.S. patent application number 14/536437 was filed with the patent office on 2016-05-12 for hydration apparatus and method.
The applicant listed for this patent is SCHLUMBERGER TECHNOLOGY CORPORATION. Invention is credited to Rajesh Luharuka, Hau Pham.
Application Number | 20160130924 14/536437 |
Document ID | / |
Family ID | 55909789 |
Filed Date | 2016-05-12 |
United States Patent
Application |
20160130924 |
Kind Code |
A1 |
Pham; Hau ; et al. |
May 12, 2016 |
HYDRATION APPARATUS AND METHOD
Abstract
Vessels including an enclosure having an outer perimeter and an
interior space, a channel disposed in the interior space, a first
port disposed on a surface of the first enclosure at or proximate
to a first end of the channel, and a second port disposed on a
surface of the first enclosure at or proximate to a second end of
the channel, where the channel has a length greater than the
shortest distance between the first port and the second port, and
where the first port and the second port are in fluid communication
with one another. In some cases, the length of the channel is
greater than a length of the outer perimeter. Optionally, the
vessel may have a second enclosure having an outer perimeter and an
interior space with a second channel disposed in the interior
space, a third port disposed on a surface of the second enclosure
at or proximate to a first end of the second channel, and a fourth
port disposed on a surface of the second enclosure at or proximate
to a second end of the second channel, where the second port, the
third port and fourth port are in fluid communication. In yet some
other optional variations, the vessel further includes a plurality
of enclosures each having an outer perimeter and an interior space,
a channel disposed in the interior space, a port disposed on a
surface of the enclosure at or proximate to a first end of the
channel, and a port disposed on a surface of the enclosure at or
proximate to a second end of the channel, where the channel has a
length greater than a shortest distance between the ports, and the
second port and the ports disposed on the surface of the plurality
of enclosures are in fluid communication. The perimeter shape of
the enclosure(s) may be any suitable shape, including, but not
limited to, substantially circular, ovate or rectangular.
Inventors: |
Pham; Hau; (Houston, TX)
; Luharuka; Rajesh; (Katy, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SCHLUMBERGER TECHNOLOGY CORPORATION |
Sugar Land |
TX |
US |
|
|
Family ID: |
55909789 |
Appl. No.: |
14/536437 |
Filed: |
November 7, 2014 |
Current U.S.
Class: |
166/305.1 ;
166/244.1 |
Current CPC
Class: |
E21B 41/00 20130101 |
International
Class: |
E21B 43/16 20060101
E21B043/16; E21B 41/00 20060101 E21B041/00 |
Claims
1. A method for treating at least a portion of a subterranean
formation penetrated by a wellbore, the method comprising: a)
introducing into at least one reaction vessel a mixture comprising:
i) a liquid component comprising a first chemical reactant; ii) a
second chemical reactant; b) passing the mixture through the at
least one reaction vessel; c) preparing a treatment fluid which
comprises the mixture and an optional insoluble particle; and d)
introducing the treatment fluid into the wellbore; wherein the
reaction vessel comprises: a) a first enclosure having an outer
perimeter and an interior space defined therein; b) a channel
disposed in the interior space; c) a first port disposed on a
surface of the first enclosure at or proximate to a first end of
the channel; and, d) a second port disposed on a surface of the
first enclosure at or proximate to a second end of the channel;
wherein the channel has a length greater than a shortest distance
between the first port and the second port, and wherein the first
port and the second port are in fluid communication.
2. The method of claim 1 wherein the first chemical reactant is
water and the second chemical reactant is a water reactable
material.
3. The method of claim 1 wherein the channel has a length greater
than a length of the outer perimeter.
4. The method of claim 1 further comprising a second enclosure
having an outer perimeter and an interior space defined therein,
the second enclosure comprising a second channel disposed in the
interior space, a third port disposed on a surface of the second
enclosure at or proximate to a first end of the second channel, and
a fourth port disposed on a surface of the second enclosure at or
proximate to a second end of the second channel, wherein the second
port, the third port and fourth port are in fluid
communication.
5. The method of claim 1 further comprising a plurality of
enclosures, wherein each of the plurality of enclosures comprise an
outer perimeter and an interior space defined therein, a channel
disposed in the interior space, a port disposed on a surface of the
enclosure at or proximate to a first end of the channel, and a port
disposed on a surface of the enclosure at or proximate to a second
end of the channel, and wherein the channel has a length greater
than a shortest distance between the ports, and wherein the second
port and the ports disposed on the surface of the plurality of
enclosures are in fluid communication.
6. The method of claim 1 wherein the mixture undergoes a rate
limited chemical reaction requiring residence time, while flowing
the mixture through the reaction vessel under the influence
gravity, pressure or combination thereof.
7. The method of claim 2 wherein the concentration of water
reactable material is greater than or equal to about 40 pounds per
1000 gallons of liquid component.
8. The method of claim 1 wherein the mixture is passed through a
plurality of reaction vessels.
9. The method of claim 8 wherein one or more additional chemical
components are injected into the plurality of reaction vessels at
one or more points downstream from the first port.
10. The method of claim 1 wherein the reaction vessel further
comprises at least one static mixing element, an axial mixer, or
combination thereof.
11. The method of claim 1 further comprising measuring pressure
change of the mixture across the at least one reaction vessel to
monitor a reaction of the first chemical reactant with the second
chemical reactant.
12. The method of claim 1 decreasing the concentration of the first
chemical reactant, the second chemical reactant, or both, during
the treating.
13. The method of claim 1 wherein the channel has an archimedian
spiral pattern.
14. The method of claim 13 wherein the mixture is injected into a
high pressure fluid stream.
15. The method of claim 14 wherein the mixture injected into a high
pressure fluid stream is a pill comprising a high concentration of
the second chemical reactant.
16. The method of claim 4 wherein the channel and the second
channel have an archimedian spiral pattern, and wherein a first
fluid flowpath is in a progressively inward direction through the
channel of the first enclosure, and wherein a second fluid flowpath
is in a progressively outward direction through the second
channel.
17. The method of claim 4 wherein the channel and the second
channel have an archimedian spiral pattern, and wherein a first
fluid flowpath is in a progressively outward direction through the
channel of the first enclosure, and wherein a second fluid flowpath
is in a progressively inward direction through the second
channel.
18. A method for treating at least a portion of a subterranean
formation penetrated by a wellbore, the method comprising: a)
introducing into at least one hydration vessel a mixture
comprising: i) a liquid component comprising water; ii) a second
component comprising a hydratable material; b) passing the mixture
through the at least one hydration vessel in a continuous manner to
form a slurry; c) preparing a treatment fluid which comprises the
slurry and an optional insoluble particle; and d) introducing the
treatment fluid into the wellbore; wherein the hydration vessel
comprises: a) an inlet chamber comprising a spiraling first fluid
passageway; and, b) a discharge chamber comprising a spiraling
second fluid passageway; wherein the first fluid passageway and the
second fluid passageway are in fluid communication.
19. The method of claim 18 further comprising at least one
intermediate chamber disposed between the inlet chamber and the
discharge chamber, wherein the at least one intermediate chamber
comprises a spiraling first intermediate fluid passageway, wherein
the first fluid passageway, the second fluid passageway, and the
first intermediate fluid passageway are in fluid communication.
20. The method of claim 19 wherein the at least one intermediate
chamber is at least one pair of intermediate chambers disposed
between the inlet chamber and the discharge chamber, the pair of
intermediate chambers comprising: i) a first intermediate chamber
comprising a spiraling first intermediate fluid passageway; and,
ii) a second intermediate chamber comprising a spiraling second
intermediate fluid passageway; wherein the first fluid passageway,
the second fluid passageway, the first intermediate fluid
passageway and the second intermediate fluid passageway are in
fluid communication.
21. The method of claim 19 wherein the at least one intermediate
chamber comprises a first and a second fluid passageway, wherein
the fluid passageways are partitioned by a plate having a hole
therein, and wherein the first and the second fluid passageways are
in fluid communication.
22. The method of claim 19 wherein the first outer chamber and the
second outer chamber each comprise a first and a second fluid
passageway, wherein the fluid passageways are partitioned by a
plate having a hole therein, and wherein the first and the second
fluid passageway are in fluid communication.
23. The method of claim 22 wherein a first fluid flowpath is in a
progressively inward direction through the first fluid passageway,
and wherein a second fluid flowpath is in a progressively outward
direction through the second fluid passageway.
24. The method of claim 19 wherein a first fluid flowpath is in a
progressively inward direction through the first fluid passageway,
and wherein a second fluid flowpath is in a progressively inward
direction through the second fluid passageway.
25. The method of claim 18 wherein the hydration vessel further
comprises an inlet port disposed on a perimeter of the inlet
chamber, and a discharge port disposed on a perimeter of the
discharge chamber.
26. The method of claim 19 wherein the hydration vessel further
comprises a second pair of intermediate chambers disposed between
the at least one pair of intermediate chambers and the discharge
chamber.
27. The method of claim 26 wherein the hydration vessel further
comprises a third pair of intermediate chambers disposed between
the second pair of intermediate chambers and the discharge
chamber.
28. The method of claim 27 wherein the hydration vessel further
comprises a fourth pair of intermediate chambers disposed between
the third pair of intermediate chambers and the discharge
chamber.
29. The method of claim 20 wherein the inlet chamber, the at least
one intermediate chamber, and the discharge chamber are
substantially circular or ovate in outer perimeter shape.
30. The method of claim 20 wherein the inlet chamber, the at least
one intermediate chamber, and the discharge chamber are
substantially rectangular in outer perimeter shape.
31. The method of claim 19 wherein the hydration vessel further
comprises at least one pair of intermediate chambers disposed
between the first intermediate chamber and the discharge chamber,
the pair of intermediate chambers comprising: i) a second
intermediate chamber comprising a spiraling second intermediate
fluid passageway; and, ii) a third intermediate chamber comprising
a spiraling third intermediate fluid passageway; wherein the first
fluid passageway, the second fluid passageway, the first
intermediate fluid passageway, the second intermediate fluid
passageway and the third intermediate passageway are in fluid
communication.
32. The method of claim 31 wherein the hydration vessel further
comprises a second pair of intermediate chambers disposed between
the at least one pair of intermediate chambers and the discharge
chamber.
33. The method of claim 32 wherein the hydration vessel further
comprises a third pair of intermediate chambers disposed between
the second pair of intermediate chambers and the discharge
chamber.
34. The method of claim 33 wherein the hydration vessel further
comprises a fourth pair of intermediate chambers disposed between
the third pair of intermediate chambers and the discharge
chamber.
35. The method of claim 18 wherein the at least one hydration
vessel is a plurality of hydration vessels connected in a series
configuration.
36. The method of claim 18 wherein the at least one hydration
vessel is a plurality of hydration vessels connected in a parallel
configuration.
37. A method comprising: a) providing an apparatus, the apparatus
comprising: i. an inlet chamber having an outer perimeter and a
first fluid passageway formed therein, wherein the first fluid
passageway has a length greater than a shortest distance between
the outer perimeter and center of the inlet chamber; and, ii. a
discharge chamber having an outer perimeter and a second fluid
passageway formed therein, wherein the second fluid passageway has
a length greater than a shortest distance between the outer
perimeter and center of the discharge chamber; wherein the first
fluid passageway and the second fluid passageway are in fluid
communication; b) introducing into the apparatus, an admixture
comprising: i) a liquid component comprising a first chemical; and,
ii) a second component; c) flowing the admixture through the
apparatus; and, d) discharging from the apparatus a product formed
from the first chemical and the second component.
Description
FIELD
[0001] The disclosure generally relates to the preparation of
subterranean formation treatment fluids, and more particularly, but
not by way of limitation, apparatus and methods for preparing
treatment fluids from a mixture including, in some cases, a
hydratable material and water.
BACKGROUND
[0002] The statements in this section merely provide background
information related to the disclosure and may not constitute prior
art.
[0003] In the oil and gas drilling and production industry, viscous
aqueous fluids are commonly used in treating subterranean wells, as
well as carrier fluids. Such fluids may be used as fracturing
fluids, acidizing fluids, and high-density completion fluids. In an
operation known as well fracturing, such fluids are used to
initiate and propagate underground fractures for increasing
petroleum productivity.
[0004] Viscous fluids, such as gels, are typically an aqueous
solution of a polymer material. A common continuous method used to
prepare viscous fluids at a wellbore site, involves the use of
initial slurry of the polymer material in a hydrocarbon carrier
fluid (i.e. diesel fluid) which facilitates the polymer dispersion
and slurry mixing. Although this process achieves the required gel
quality, the presence of hydrocarbon fluids is often objected to in
particular fields, even though the hydrocarbon represents a
relatively small amount of the total fracturing gel once mixed with
water. Also, there are environmental problems associated with the
clean-up and disposal of both hydrocarbon-based concentrates and
well treatment gels containing hydrocarbons; as well as with the
clean-up of the tanks, piping, and other handling equipment which
have been contaminated by the hydrocarbon-based gel.
[0005] Other applications used for the continuous mixing of viscous
treatment gels include gelling the polymer in a hydrocarbon carrier
that is mixed with water to produce the fracturing gel which is
then flowed through baffled tanks providing first-in/first-out
(FIFO) flow pattern, and allowing for the hydration time of the
gel. Yet another technique for mixing of dry polymer directly to
produce viscous treatment gels is described in Allen, U.S. Pat. No.
5,426,137, Allen, U.S. Pat. No. 5,382,411, and Harms et al., U.S.
Pat. No. 5,190,374. These techniques, while potentially effective,
require several complicated steps to prepare the gel, which
presents drawbacks in an oilwell setting. Further, U.S. Patent
Application 2004/0256106 A1 discloses an apparatus without an
eductor, for substantially hydrating a gel particulate using a
mixer in conjunction with an impeller located within the mixer
housing, which prevents formation of gel balls.
[0006] Other techniques and equipment useful for the continuous
mixing of viscous treatment gels without utilizing a hydratable
polymer in a hydrocarbon are described in Pessin et al., U.S. Pat.
No. 7,866,881, which discloses preparation of a viscous treatment
gel from dry polymer utilizing a constant volume educator and
mixing chimney, where the eductor operates at a constant water rate
and pressure thus producing a concentrated polymer slurry. While
effective in preparing an aqueous slurry from dry hydratable
polymer and water, there still exists need to further minimize
equipment size, space requirements, and efficiency.
[0007] Some hydration tanks configured in a first-in/first-out
configuration are vented tanks which operate by use of gravity to
flow a hydrating gel, formed of a polymeric viscosifier in aqueous
solution, through the tank. As the polymer concentration in the gel
increases, viscosity increases, and gravity flow of the gel is only
possible up to a practical polymer concentration. As a result such
systems are not useful to handle hydration of gels having a high
concentration of viscosifier.
[0008] Therefore, there is a need for apparatus and methods useful
for hydrating constituents at high concentrations to prepare
viscous treatment gels in a continuous mode, without the use of
hydrocarbon carriers, and with decreased equipment size and space
requirements, such need met, at least in part, by the following
disclosure.
SUMMARY
[0009] In a first aspect, an apparatus is disclosed which includes
a first enclosure having an outer perimeter and an interior space
defined therein, the first enclosure having a first continuous
channel in the interior space, the first continuous channel having
a channel-length greater than a length of the outer perimeter of
the first enclosure, a first port disposed on the perimeter of the
first enclosure in communication with a first end of the first
continuous channel, and a second port disposed on a surface of the
first enclosure in communication with a second end of the first
continuous channel. The apparatus also includes a second enclosure
having an outer perimeter and an interior space defined therein,
the second enclosure having a second continuous channel in the
interior space where the channel-length is greater than a length of
the outer perimeter of the second enclosure, a third port disposed
on a surface of the second enclosure in communication with a first
end of the second continuous channel, and a fourth port disposed on
the perimeter of the second enclosure in communication with a
second end of the second continuous channel. The second port and
the third port are in fluid communication.
[0010] The apparatus may further include a pair of intermediate
enclosures disposed between the first enclosure and the second
enclosure, the pair of intermediate enclosures having a first
intermediate enclosure having an outer perimeter and an interior
space defined therein, the first intermediate enclosure including a
continuous channel in the interior space having a channel-length
greater than a length of the outer perimeter of the first
intermediate enclosure, a port disposed on a surface of the first
intermediate enclosure in communication with a first end of the
continuous channel, and a port disposed on a surface of the first
intermediate enclosure and located proximate the outer perimeter,
the port in communication with a second end of the continuous
channel. The apparatus may further include a second intermediate
enclosure having an outer perimeter and an interior space defined
therein, where the second intermediate enclosure has a continuous
channel in the interior space having a channel-length greater than
a length of the outer perimeter of the second intermediate
enclosure, a port disposed on a surface of the second intermediate
enclosure and located proximate the outer perimeter, the port in
communication with a first end of the continuous channel and
connected to the port disposed on the first intermediate enclosure
in communication with the second end of the continuous channel of
the first intermediate enclosure, and a port disposed on a surface
of the second intermediate enclosure and located proximate the
outer perimeter, the port in communication with a second end of the
continuous channel. The first enclosure, the second enclosure, the
first intermediate enclosure and the second intermediate enclosure
may be substantially circular, rectangular, oval, triangular, or
any suitable outer perimeter shape, and the continuous channels of
the first enclosure, the second enclosure, the first intermediate
enclosure and the second intermediate enclosure may be orientated
in a spiral configuration. In some instances, a first fluid
flowpath is in a progressively inward direction through the
continuous channels of the first enclosure and the second
intermediate enclosure, and a second fluid flowpath is in a
progressively outward direction through the continuous channels of
the second enclosure and the first intermediate enclosure.
[0011] Alternatively, the apparatus may include a third continuous
channel in the interior space having a channel-length greater than
the length of the outer perimeter of the first enclosure, with a
first end of the third continuous channel disposed at or proximate
to a port, and a fifth port disposed at or proximate to a second
end of the third continuous channel. The second port, the third
port, and the fifth port are in fluid communication. The first
enclosure may further have at least one pair of continuous channels
in the interior space, the pair of continuous channels including a
fourth continuous channel having a channel-length greater than a
length of the outer perimeter of the first enclosure, a first end
at or proximate to a port, and a sixth port disposed at or
proximate to a second end. In addition, the apparatus may include a
fifth continuous channel having a channel-length greater than a
length of the outer perimeter of the first enclosure, a first end
at or proximate to the sixth port, and a seventh port disposed at
or proximate to a second end. The second port, the third port, the
fifth port, the sixth port and the seventh port are in fluid
communication. In some cases, the first enclosure further includes
two pair of continuous channels in the interior space.
[0012] In another aspect of the disclosure, hydration vessels are
disclosed, which include an inlet chamber having an outer perimeter
and a first fluid passageway formed therein, where the length of
the first fluid passageway is greater than a length of the outer
perimeter and wherein the first fluid passageway is inwardly or
outwardly spiraling, a discharge chamber having an outer perimeter
and a second fluid passageway formed therein, wherein the length of
the second fluid passageway is greater than a length of the outer
perimeter and wherein the second fluid passageway is inwardly or
outwardly spiraling. In some aspects, at least one intermediate
chamber may be disposed between the inlet chamber and the discharge
chamber. The first fluid passageway and the second fluid passageway
are in fluid communication. The outer perimeter shape of the
chambers may be substantially circular, rectangular, ovate,
triangular, or any other suitable shape.
[0013] In some cases the at least one intermediate chamber of the
hydration vessel is a pair of intermediate chambers, where the
first intermediate chamber includes an outer perimeter and a first
intermediate fluid passageway therein, and where the length of the
first intermediate fluid passageway is greater than a length of the
outer perimeter and is outwardly spiraling. The second intermediate
chamber has an outer perimeter and a second intermediate fluid
passageway therein, the length of the second intermediate fluid
passageway greater than a length of the outer perimeter, and the
second fluid passageway is inwardly spiraling.
[0014] In some other cases, the inlet chamber, the discharge
chamber, and at least one intermediate chamber of the hydration
vessel each include a first and a second continuous channel, where
the continuous channels are partitioned by a plate having a hole
therein, and where the first and the second continuous channel are
in fluid communication. A first fluid flowpath within each chamber
is in a progressively inward direction through the first continuous
channel, and a second fluid flowpath is in a progressively outward
direction through the second continuous channel. The first and
second continuous channels may be orientated in a substantially
spiral configuration.
[0015] Alternatively, the inlet chamber of the apparatus may
include a third fluid passageway formed therein, where the length
of the third fluid passageway is outwardly spiraling and greater
than the length of the outer perimeter, and the first fluid
passageway, the second fluid passageway and the third fluid
passageway are in fluid communication. In some aspects, the inlet
chamber may further have at least one pair of fluid passageways in
the interior space, where the pair fluid passageways have a fourth
fluid passageway, inwardly spiraling, having a channel-length
greater than a length of the outer perimeter, and a fifth outwardly
spiraling fluid passageway having a channel-length greater than a
length of the outer perimeter, where the first fluid passageway,
the second fluid passageway, the third fluid passageway, the fourth
fluid passageway and the fifth fluid passageway are in fluid
communication. In some cases, the inlet chamber includes two such
pair of fluid passageways in the interior space.
[0016] In yet another aspect of the disclosure, a hydration vessel
includes a first outer chamber including an inlet port, a second
outer chamber including a discharge port, and at least one
intermediate chamber including a first port and a second port,
where the at least one intermediate chamber is disposed between the
first outer chamber and the second outer chamber. The first outer
chamber, the second outer chamber, and at least one intermediate
chamber each have a perimeter and contain at least one continuous
channel therein, and each continuous channel has a length greater
than the length of the respective chamber perimeter, and each
continuous channel is disposed substantially parallel with each of
the perimeters. The inlet port, the discharge port, and the
continuous channels are in fluid communication. The chambers may be
substantially circular, rectangular, ovate or triangular in outer
perimeter shape.
[0017] In some embodiments, the first outer chamber, the second
outer chamber, and the at least one intermediate chamber of the
hydration vessel each have a first and a second continuous channel
disposed therein, where the continuous channels are portioned by a
plate having a hole therein, and the first and the second
continuous channel are in fluid communication. A first fluid
flowpath is in a progressively inward direction through the first
continuous channel, and a second fluid flowpath is in a
progressively outward direction through the second continuous
channel. The first and second continuous channels may be orientated
in a substantially spiral configuration in some cases.
[0018] In some other embodiments, the at least one intermediate
chamber of the hydration vessel is a pair of intermediate chambers.
Each intermediate chamber contains one continuous channel therein.
Fluid flowpaths within the continuous channels of the intermediate
chambers may alternate in an outwardly spiraling/inwardly spiraling
fashion as mixtures travel through the sequence of pair(s) of
intermediate chambers.
[0019] Alternatively, the hydration vessel further includes a pair
of intermediate chambers disposed between the first outer chamber
and the at least one intermediate chamber, where each intermediate
chamber of the pair of intermediate chambers has a perimeter and
contain at least one continuous channel therein. Each continuous
channel has a length greater than a length of the perimeter, each
continuous channel is disposed substantially parallel with each of
the perimeters, and the inlet port, the discharge port, and the
continuous channels are in fluid communication. In some aspects,
the hydration vessel also has a second pair of intermediate
chambers disposed between the pair of intermediate chambers and the
second outer chamber, where each intermediate chamber of the second
pair of intermediate chambers has a perimeter and contains at least
one continuous channel therein; each continuous channel has a
length greater than a length of the perimeter, and each continuous
channel is disposed substantially parallel with each of the
perimeters; and the inlet port, the discharge port, and the
continuous channels are in fluid communication. In yet another
aspect, a third pair of intermediate chambers is disposed between
the second pair of intermediate chambers and the second outer
chamber, each intermediate chamber of the third pair of
intermediate chambers has a perimeter and contains at least one
continuous channel, each continuous channel has a length greater
than a length of the perimeter, each continuous channel is disposed
substantially parallel with each of the perimeters, and the inlet
port, the discharge port, and the continuous channels are in fluid
communication.
[0020] Another aspect of the disclosure is a method for treating at
least a portion of a subterranean formation penetrated by a
wellbore, the method including introducing into at least one
hydration vessel a mixture of a liquid component containing water,
a solid component containing a hydratable material, then passing
the mixture through the at least one hydration vessel in a
continuous manner to form a slurry. A treatment fluid is then
prepared which includes the slurry and an optional insoluble
particle, and the fluid introduced into the wellbore to treat the
subterranean formation. The hydration vessel includes an inlet
chamber an inwardly spiraling first fluid passageway, and a
discharge chamber having an outwardly spiraling second fluid
passageway. In some embodiments, at least one intermediate chamber
may be disposed between the inlet chamber and the discharge
chamber.
[0021] In some embodiments where there is at least one intermediate
chamber, the at least one intermediate chamber is a pair of
intermediate chambers, where a first intermediate chamber of the
pair has an outwardly spiraling first intermediate fluid
passageway, the second intermediate chamber of the pair has an
inwardly spiraling second intermediate fluid passageway formed
therein, and the first fluid passageway, the second fluid
passageway, the first intermediate fluid passageway and the second
intermediate fluid passageway are in fluid communication. In some
other embodiments, the at least one intermediate chamber includes a
first and a second continuous channel, where the continuous
channels are partitioned by a plate having a hole therein, and the
first and the second continuous channel are in fluid communication.
Further, the first outer chamber and the second outer chamber may
each have a first and a second continuous channel, the continuous
channels are partitioned by a plate having a hole therein, and the
first and the second continuous channels are in fluid
communication. A first fluid flowpath may be in a progressively
inward direction through the first continuous channels, and a
second fluid flowpath may be in a progressively outward direction
through the second continuous channels.
[0022] In some aspects, the disclosure also relates to a vessel(s)
including an enclosure having an outer perimeter and an interior
space, a channel disposed in the interior space, a first port
disposed on a surface of the first enclosure at or proximate to a
first end of the channel, and a second port disposed on a surface
of the first enclosure at or proximate to a second end of the
channel, where the channel has a length greater than the shortest
distance between the first port and the second port, and where the
first port and the second port are in fluid communication with one
another. In some cases, the length of the channel is greater than a
length of the outer perimeter. Optionally, the vessel may have a
second enclosure having an outer perimeter and an interior space
with a second channel disposed in the interior space, a third port
disposed on a surface of the second enclosure at or proximate to a
first end of the second channel, and a fourth port disposed on a
surface of the second enclosure at or proximate to a second end of
the second channel, where the second port, the third port and
fourth port are in fluid communication. In yet some other optional
variations, the vessel further includes a plurality of enclosures
each having an outer perimeter and an interior space, a channel
disposed in the interior space, a port disposed on a surface of the
enclosure at or proximate to a first end of the channel, and a port
disposed on a surface of the enclosure at or proximate to a second
end of the channel, where the channel has a length greater than a
shortest distance between the ports, and the second port and the
ports disposed on the surface of the plurality of enclosures are in
fluid communication. The perimeter shape of the enclosure(s) may be
any suitable shape, including, but not limited to, substantially
circular, ovate or rectangular. Additionally, the vessels may
further include one or more static mixing elements disposed within
the channel to introduce mixing at specific intervals or stages of
chemical reaction.
[0023] Methods for treating at least a portion of a subterranean
formation penetrated by a wellbore are also provided, which include
introducing into one or more reaction vessels a mixture of a liquid
component containing a first chemical reactant, and a second
chemical reactant, and the mixture is passed through the at least
one reaction vessel. A treatment fluid is then prepared and
contains the mixture and an optional insoluble particle, and is
subsequently introduced into a wellbore. The reaction vessel has a
first enclosure having an outer perimeter and an interior space
defined therein, a channel disposed in the interior space, a first
port disposed on a surface of the first enclosure at or proximate
to a first end of the channel, and a second port disposed on a
surface of the first enclosure at or proximate to a second end of
the channel. The channel may have a length greater than a shortest
distance between the first port and the second port, and the first
port and the second port are in fluid communication. In some cases,
the channel has a length greater than a length of the outer
perimeter.
[0024] Some other method embodiments according to the disclosure
include methods for treating at least a portion of a subterranean
formation penetrated by a wellbore where a liquid component
comprising water and a second component comprising a hydratable
polymer are introduced into at least one hydration vessel, the
mixture passed through the at least one hydration vessel in a
continuous manner to form a slurry, a treatment fluid then prepared
which contains the slurry and an optional insoluble particle, and
the treatment fluid introduced into the wellbore. The at least one
hydration vessel includes an inlet chamber having a spiraling first
fluid passageway, a discharge chamber having a spiraling second
fluid passageway, where the first fluid passageway and the second
fluid passageway are in fluid communication. In some cases, at
least one intermediate chamber is disposed between the inlet
chamber and the discharge chamber, where the intermediate chamber
comprises a spiraling first intermediate fluid passageway, and the
first fluid passageway, the second fluid passageway, and the first
intermediate fluid passageway are in fluid communication.
[0025] Other method aspects of the disclosure relate to providing
an apparatus including an inlet chamber having an outer perimeter
and a first fluid passageway formed therein, where the first fluid
passageway has a length greater than a shortest distance between
the outer perimeter and center of the inlet chamber, and the
apparatus further includes a discharge chamber having an outer
perimeter and a second fluid passageway formed therein, where the
second fluid passageway has a length greater than a shortest
distance between the outer perimeter and center of the discharge
chamber. The first fluid passageway and the second fluid passageway
are in fluid communication. An admixture of a liquid component
containing a first chemical and a second component is introduced
into the apparatus, and flowed through the apparatus. A product
formed from the first chemical and the second component is then
discharged from the apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Certain embodiments of the disclosure will hereafter be
described with reference to the accompanying drawings, wherein like
reference numerals denote like elements. It should be understood,
however, that the accompanying figures illustrate the various
implementations described herein and are not meant to limit the
scope of various technologies described herein, and:
[0027] FIG. 1 illustrates some apparatus embodiments in accordance
with the disclosure.
[0028] FIG. 2 depicts an exploded plan view of a hydration vessel
in accordance with the disclosure.
[0029] FIG. 3 shows a top plan view of an inlet chamber or
enclosure in accordance with the disclosure.
[0030] FIG. 4 depicts a bottom plan view of an inlet chamber or
enclosure in accordance with the disclosure.
[0031] FIG. 5 illustrates a top plan view of an intermediate
chamber or enclosure in accordance with the disclosure.
[0032] FIG. 6 shows a bottom plan view of an intermediate chamber
or enclosure in accordance with the disclosure.
[0033] FIG. 7 illustrates a top plan view of another intermediate
chamber or enclosure in accordance with the disclosure.
[0034] FIG. 8 depicts a bottom plan view of another intermediate
chamber or enclosure in accordance with the disclosure.
[0035] FIG. 9 illustrates a top plan view of a discharge chamber or
enclosure in accordance with the disclosure.
[0036] FIG. 10 shows a bottom plan view of a discharge chamber or
enclosure in accordance with the disclosure.
[0037] FIG. 11 illustrates a system of enclosures, or chambers,
which are configured and constructed as depicted in FIGS. 1 through
10, in accordance with the disclosure.
[0038] FIGS. 12 and 13 depict an alternating inward/outward
substantially spiral mixture flow pattern through an apparatus,
without showing the apparatus in FIG. 12, and showing the apparatus
in a transparent shadowed form in FIG. 13, in accordance with the
disclosure.
[0039] FIGS. 14 and 15 show a top and bottom view of a rectangular
chamber or enclosure, in accordance with the disclosure.
[0040] FIG. 16 depicts some embodiments of the disclosure where two
hydration vessel apparatus are fluidly connected in series, in
accordance with the disclosure.
[0041] FIG. 17 illustrates some further apparatus embodiments, in
accordance with the disclosure.
[0042] FIG. 18 depicts some further apparatus embodiments, in
accordance with the disclosure.
[0043] FIG. 19 illustrates a plate useful for affixing to outer
ends of chambers or enclosures, in accordance with the
disclosure.
[0044] FIG. 20 shows a partition plate useful for affixing to
chambers or enclosures, in accordance with the disclosure.
[0045] FIGS. 21 and 22 depict an outer chamber or enclosure in a
top plan view and an opposing bottom plan view, in accordance with
the disclosure.
[0046] FIGS. 23 and 24 illustrate an intermediate chamber or
enclosure in a top plan view and an opposing bottom plan view, in
accordance with the disclosure.
[0047] FIGS. 25 and 26 show another outer chamber or enclosure in a
top plan view and an opposing bottom plan view, in accordance with
the disclosure.
[0048] FIG. 27 illustrates, in an exploded view, a system of
chambers or enclosures configured and constructed as depicted in
FIGS. 18 through 26, in accordance with the disclosure.
[0049] FIGS. 28 and 29 illustrate alternating inward/outward
substantially spiral mixture flow pattern through a hydration
vessel, without showing the vessel in FIG. 28, and showing vessel
in a transparent shadowed form in FIG. 29, in accordance with the
disclosure.
[0050] FIG. 30 depicts some embodiments of the disclosure where two
hydration vessel apparatus are fluidly connected in series, in
accordance with the disclosure.
[0051] FIG. 31 illustrates another hydration vessel, or apparatus,
in accordance with the disclosure.
[0052] FIG. 32 shows the hydration vessel depicted in FIG. 31, in a
cross-section format, in accordance with the disclosure.
[0053] FIG. 33 illustrates, in an interior view, the series of
continuous channels, or first fluid passageways, within the
interior of hydration vessel, in accordance with the
disclosure.
[0054] FIG. 34 depicts an apparatus with enclosures shown in
shadowed form, according to some aspects of the disclosure, to
further illustrate how the hydration concept of this disclosure
would function in the embodiment described.
[0055] FIG. 35 illustrates, in cross-section view, a hydration
vessel with nonparallel partitions, or plates, between channels or
fluid passageways in nonparallel orientations, in accordance with
the disclosure.
DETAILED DESCRIPTION
[0056] In the following description, numerous details are set forth
to provide an understanding of some embodiments of the present
disclosure. However, it will be understood by those of ordinary
skill in the art that the system and/or methodology may be
practiced without these details and that numerous variations or
modifications from the described embodiments may be possible.
[0057] Unless expressly stated to the contrary, "or" refers to an
inclusive or and not to an exclusive or. For example, a condition A
or B is satisfied by anyone of the following: A is true (or
present) and B is false (or not present), A is false (or not
present) and B is true (or present), and both A and B are true (or
present).
[0058] In addition, use of the "a" or "an" are employed to describe
elements and components of the embodiments herein. This is done
merely for convenience and to give a general sense of the inventive
concept. This description should be read to include one or at least
one and the singular also includes the plural unless otherwise
stated.
[0059] The terminology and phraseology used herein is for
descriptive purposes and should not be construed as limiting in
scope. Language such as "including," "comprising," "having,"
"containing," or "involving," and variations thereof, is intended
to be broad and encompass the subject matter listed thereafter,
equivalents, and additional subject matter not recited.
[0060] Finally, as used herein any references to "one embodiment"
or "an embodiment" means that a particular element, feature,
structure, or characteristic described in connection with the
embodiment is included in at least one embodiment. The appearances
of the phrase "in one embodiment" in various places in the
specification are not necessarily referring to the same
embodiment.
[0061] As used herein the term "enclosure" means a volume of space
surrounded by outer surfaces of an apparatus, and is inclusive of
such outer surfaces. The term "chamber" herein means a volume of
space defined within outer surfaces of an apparatus. The term
"channel" means a substantially enclosed elongated opening within a
chamber or enclosure. The term "passageway" means a continuing
volume of space which connects a first point to a second point
within a chamber or enclosure. The phrase "outer perimeter" means
the distance around a two-dimensional cross-sectional shape of a
chamber or enclosure, and is not necessarily limited to such a
dimension measured on the exterior or the interior of the
apparatus.
[0062] Some aspects of the disclosure relate to apparatus for, and
methods of, forming a solvated mixture, or suspension, of a solids
portion and a liquid medium by increasing residence time of the
mixture within the apparatus. Some other aspects relate to
apparatus for, and methods of, forming a product of a chemical
contained in a liquid component and a second component through
increasing residence time of the admixture within the apparatus.
Some other aspects relate to hydration of hydratable material by
increasing residence time of a mixture of water and hydratable
material within a hydration apparatus. The hydratable material may
be a solid material, or other chemical, which is hydratable in an
aqueous liquid, or even slurry of a hydratable material, which is
mixed with the aqueous liquid portion. Some non-limiting examples
of hydratable material include viscosifying polymers, friction
reducers, viscoelastic surfactants, cement components, drilling
fluid constituents, and the like. Some other aspects of the
disclosure relate to apparatus and methods involving a flow of
mixture of chemicals undergoing a rate limited chemical process, or
reaction, requiring residence time with the help of a motive force
such as gravity, pressure or a combination of both. The apparatus
of the disclosure, as well as use thereof, are useful in preparing
a fluid from a mixture containing one or more materials which may
react in any way, including association, such as surfactant,
polymer or solids separation and association with water in
hydration, or even chemical reaction to form another material
through ionic or covalent bonding. As such, apparatus of the
disclosure may be referred to as hydration or reaction vessels. The
apparatus and methods may also be applied where a
first-in/first-out (FIFO) process is used where different chemicals
are introduced in sequence, and where time for a chemical reaction
to complete, or substantially complete, is allowed before a second
chemical is added to the flow.
[0063] Residence time within the apparatus may be improved, or
extended, by directing the fluid mixtures through the apparatus via
one or a plurality of chambers, or otherwise interior spaces,
formed within an enclosure, or enclosures. In some aspects, the
directing of the mixture may be accomplished by passing the mixture
through a continuous channel or passageway which has a length
greater than a distance between the perimeter and center of a
chamber, or even a length greater than the outer perimeter of the
chamber, or interior space of the enclosure. In some embodiments,
the mixture is passed through a plurality of successive fluidly
connected channels or passageways. The channel or passageway, or
plurality of channels or passageways, are fluidly connected with an
inlet and outlet of the apparatus. A mixture may be introduced into
the apparatus, flow in a nonlinear pattern through the apparatus,
and subsequently discharge in a greater hydrated, solvated or
suspended state. In some embodiments, channels or passageways are
disposed on opposing sides of a structure within the apparatus,
where each side of the structure imparts turbulent flow
characteristics into the mixture as it passes through the channels
or passageways, which may in turn provide a reduction in requisite
equipment volume to achieve suitable mixing or hydration. The
figures and description only depict how some embodiments may be
enabled and function in a practical sense within the spirit of the
concept of disclosure, and the concept is not solely limited to the
embodiments described.
[0064] In some embodiments of the disclosure, preparation of
subterranean formation treatment fluids, and more particularly, but
not by way of limitation, apparatus and methods for preparing a
viscous gel from essentially dry hydratable polymer constituents
and water in a continuous mode are described. In some cases, the
apparatus and methods are useful for preparing a viscous hydrated
gel from dry polymer at a wellbore site for fracturing a
subterranean formation. Some embodiments of the disclosure relate
to first-in/first-out gel hydration vessels which provide effective
polymer hydration by forcing a hydratable polymer and fluid mixture
to sweep a significant volume of a hydration vessel. The volumetric
capacity may be determined by the desired polymer concentration,
the required hydration time for the polymer concentration, and the
desired rate of hydrated polymer slurry production. In some
aspects, the vessel design may be a pressure vessel design
comprised of a series of flanged spiral-partitioned modular
components that are affixed with one another to form a staged
assembly. In some embodiments, a pressurized polymer/fluid mixture
may be introduced into the vessel by a tangentially located inlet
port on the vessel, and may flow in a spiral direction toward the
center of the vessel within that stage, move to the next stage
level and flow in spiral direction outwardly from the center, move
to the next stage level and flow in a spiral direction inward
toward the center, and so on, until an at least partially, if not
fully hydrated polymer slurry, emerges from an outlet. By enabling
the mixture to flow in a substantially spiral direction from stage
to stage, pressure drops within the staged assembly due to flow
direction reversal are minimized, thus allowing for more efficient
power requirements to sustain the mixture flow through the vessel.
Additionally, in some embodiments, more than one of these staged
vessel assemblies may be connected to each other in series to
effectively increase the volume through which the polymer/fluid
mixture sweep through the vessels, in first-in/first-out fashion,
to achieve the desired hydration for a given polymer concentration,
flow rate, and required hydration time.
[0065] As used herein: the term "gel" means any liquid material in
a viscous state suitable for any number of applications known in
the art, including, but not limited to, treating a wellbore; "dry
polymer", "hydratable polymer", "hydratable material" may mean, in
some cases, any form of polymer material which is commercially
available, transferred, or supplied, in a solid, slurried and/or
coated form (crystalline, amorphous, or otherwise), and not
necessarily in an aqueous or non-aqueous solution or slurry, and
may be any polymer type useful for well treatments, including, but
not limited to, guar gums, which are high-molecular weight
polysaccharides composed of mannose and galactose sugars, or guar
derivatives such as hydroxypropyl guar (HPG), carboxymethyl guar
(CMG), and carboxymethylhydroxypropyl guar (CMHPG). Cellulose
derivatives such as hydroxyethylcellulose (HEC) or
hydroxypropylcellulose (HPC) and carboxymethylhydroxyethylcellulose
(CMHEC) may also be used. Any useful polymer may be used in either
crosslinked form, or without crosslinker in linear form. Xanthan,
diutan, and scleroglucan, three biopolymers, may also be useful as
polymers in accordance with the disclosure. Synthetic polymers such
as, but not limited to, polyacrylamide and polyacrylate polymers
and copolymers, used typically for high-temperature and/or friction
reduction applications, may also be used. Also, associative
polymers for which viscosity properties are enhanced by suitable
surfactants and hydrophobically modified polymers can be used, such
as cases where a charged polymer in the presence of a surfactant
having a charge that is opposite to that of the charged polymer,
the surfactant being capable of forming an ion-pair association
with the polymer resulting in a hydrophobically modified polymer
having a plurality of hydrophobic groups, as described in published
application U.S. 20040209780A1, Harris et. al. Any dry polymer may
contain commercially acceptable moisture levels, or have a coating
or pre-treatment. The term "gel" may also mean a slurry of partial
or fully hydrated polymer in water. Hydratable material may also
include other types of viscosifying agents, such as viscoelastic
surfactants, or silicates, for example.
[0066] In some aspects of the disclosure, the liquid portion of a
mixture may be an aqueous medium which can include, for example,
produced water, fresh water, seawater, brine or a combination
thereof. In embodiments in which the aqueous medium includes brine,
the brine can be, for example, water including an inorganic salt,
organic salt or a combination thereof. Suitable inorganic salts can
include alkali metal halides such as potassium chloride. The brine
phase can include an organic salt such as sodium or potassium
formate, or sodium or potassium salicylate. Suitable inorganic
divalent salts can include calcium halides such as calcium
chloride, calcium bromide or a combination thereof. Sodium bromide,
potassium bromide, or cesium bromide can be used, either alone or
in combination. The salt can be chosen for compatibility
reasons.
[0067] Further, as used herein, the term "slurry" or "slurries"
means any fluid mixture of the respective hydratable material with
a liquid, which may flow under low shear condition and is also
capable of being pumped under pressure. Generally, to form the
slurry, a mixture of the hydratable material and liquid are
introduced into apparatus according to the disclosure, subject to a
suitable hydration residence time with the apparatus, and
discharged from the apparatus where the hydratable material is at
least partially hydrated. The unique interior design features of
the apparatus enable significantly improved hydration effectiveness
compared to traditional hydration tanks with like volumetric
space.
[0068] Now referring generally to FIG. 1, which illustrates some
apparatus embodiments according to the disclosure. FIG. 1 shows an
apparatus useful for hydrating a mixture of water and a hydratable
material, such as hydratable polymers used to viscosify and/or
reduce the turbulent flow properties of a subterranean formation
treatment fluid. Apparatus 100, which may be a vessel for at least
partially hydrating, includes a first enclosure 110 and may further
include a second enclosure 120. In some aspects of the disclosure,
apparatus 100 may further include one or more intermediate
enclosures 130, 140 (eight shown). Apparatus 100 may further
include a port 112 disposed on the perimeter 114 of the first
enclosure 110. Port 112 may receive the mixture of water and a
hydratable polymer, or any suitable mixture liquid and solid, for
blending, or otherwise further mixing, to form a slurry. Port 122
may also be disposed on the perimeter 124 of the second enclosure
120 of apparatus 100, and may produce, or otherwise discharge a
slurry of liquid and polymer, such as water and hydratable
material, or any desired mixture of materials in a liquid medium.
Ports 112 and 122 may be flush or extend outward from perimeters
114 and 124, and in some instances, may extend outward in
tangential direction relative perimeters 114 and 124. In some
aspects, the enclosures 110, 120, 130, and 140 are separate
chambers, through which the mixture travels a distance over a time
period for hydration. The enclosures, or chambers, are in fluid
communication which allows the mixture to pass from port 112,
through first enclosure 110, then into any intermediate
enclosure(s), then into second enclosure 120, and finally out of
port 122.
[0069] Apparatus 100 may further include first plate 150 (as shown
in FIG. 2) which is affixed to first enclosure 110, which may serve
to help confine the mixture within the enclosure while passing
through first enclosure 110. First plate 150 may be affixed to
enclosure 110 by any suitable technique, including removable
fasteners attaching with a flange of the enclosure, welding, formed
as an integrated portion of enclosure 110, and the like. Likewise,
enclosures 110, 130 and 120 may affixed with one another by same or
similar techniques. In FIG. 1, the enclosures shown each include a
flange extending from the top and bottom perimeters (116 and 118
for example), for receiving fasteners, such as nuts and bolts, and
securing the enclosures (as well as plates where used) with one
another.
[0070] Now referring to FIG. 2, which is an exploded plan view of
vessel 200, according to some aspects of the disclosure. Enclosures
110, 120, 130 and 140 include interior spaces 160, 170, 180 and 190
defined within each enclosure. Within each interior space, at least
one continuous channel, or fluid passageway, may be disposed, or
otherwise formed, therein. The continuous channel, or fluid
passageway may be of length greater than the length of the
perimeter of the enclosure. For example, continuous channel 162
formed within the interior space 160 of enclosure 110, has a length
greater than perimeter 114. Referencing FIG. 3, in those cases
where the perimeter 114 is circular in shape, the length of
perimeter 114 is the circumference of enclosure 110, where the
circumference lies on a plane perpendicular to axial centerline
102. Similarly, in those instances where the shape of the perimeter
is other than circular (i.e. rectangular, triangular, ovate,
square, etc.), the perimeter length is the distance around the
two-dimensional shape formed in a plane perpendicular to axial
centerline.
[0071] As shown in FIG. 2, interior spaces 160, 170, 180 and 190
include continuous channels or passageways 162, 172, 182 and 192,
respectively. The continuous channels are orientated and connected
in such way to enable ports 112 and 122 to be in fluid
communication. To illustrate, referring to FIGS. 3 and 4, in some
embodiments, first port 112 disposed on perimeter 114 is in fluid
communication with the first end 164 of continuous channel 162, and
another port 166 (shown in FIG. 4) is disposed on a surface of
enclosure 110 is in communication with a second end 168 of
continuous channel 162. FIG. 3 shows a top plan view, while FIG. 4
shows an opposing bottom plan view. A fluid mixture may be
introduced into port 112, travel through continuous channel, or
fluid passageway, 162, and exit, or otherwise discharge, enclosure
110 at port 166 positioned upon, or proximate, axial centerline
102. The mixture may then flow into a next enclosure, such as
enclosure 120 or enclosure 180, for example. In some embodiments,
the mixture flows from port 166 into enclosure 180, shown in FIG.
2.
[0072] Now referring to FIGS. 5 and 6, which show an intermediate
enclosure, or chamber, in accordance with some aspects of the
disclosure. FIGS. 5 shows a top plan view, while FIG. 6 shows an
opposing bottom plan view. Intermediate enclosure 130 includes
continuous channel or passageway 182 within interior space 180. The
center of enclosure 130 is positioned on axial centerline 102. A
mixture may enter continuous channel 182 at or near axial
centerline 102, at end 188. The mixture may be supplied from port
166 of enclosure 110, shown in FIG. 4, for example. Disposed on the
opposing end 184 of channel 182 is port 186, which is positioned
proximate perimeter 134. A mixture may exit enclosure 130 through
port 186, and flow into a next enclosure, such as enclosure 140
shown in FIGS. 1 and 2. Referencing FIGS. 7 and 8, which illustrate
another intermediate enclosure, or chamber, in accordance with some
aspects of the disclosure, in top plan view (FIG. 7) and opposing
bottom plan view (FIG. 8). Intermediate enclosure 140 includes
channel 192 within interior spaces 190, and the center of enclosure
140 positioned on axial centerline 102. The mixture may be
introduced into channel 192 at or near at end 194 proximate
perimeter 144. The mixture may be supplied from port 186 of
enclosure 130, shown in FIG. 6. The mixture travels through
continuous channel 192, exits enclosure 140 through port 196, and
flows into a next enclosure, such as enclosure 120 shown in FIGS. 1
and 2. Alternatively, one or more pair of like enclosures 130 and
140 could be disposed in similar fashion between enclosure 140 and
enclosure 120, such as the three additional pair shown in FIG. 1.
While some illustrations show one pair of intermediate enclosures,
or intermediate chambers, while others show four pair intermediate
enclosures/chambers, it is within the spirit and scope of the
disclosure to include any suitable number of pairs of intermediate
enclosures, or even no pair of enclosures, between enclosures 110
and 120. Further, enclosures 110 and 120 may also be considered
inlet chambers and discharge chambers, respectively.
[0073] Referencing FIGS. 9 and 10, which illustrate second
enclosure 120 in top and bottom plan views. Second enclosure 120
includes continuous channel or passageway 172 within interior space
170. The center of enclosure 120 is positioned on axial centerline
102. A mixture may enter continuous channel 172 at or near axial
centerline 102, at end 178, and the mixture may be supplied from
port 196 of enclosure 140, shown in FIG. 8. Port 122 is disposed on
the opposing end 174 of channel 172 which is positioned proximate
perimeter 124. The mixture exits, or is otherwise discharged, from
the second enclosure 120 through port 122, in a fully or partially
slurried mixture of liquid and hydratable polymer, or even a
product of an admixture in a liquid medium.
[0074] FIG. 11 illustrates a system of enclosures, or chambers,
which are configured and constructed as depicted in FIGS. 1 through
10, and described herein above. Apparatus, such as a hydration
vessel, 300 includes enclosures 110, 120, 130 and 140, as well as
pairs of intermediate enclosures 132, 134 and 136. Pairs of
intermediate enclosures 132, 134 and 136, may be the same design as
intermediate enclosures 130 and 140, in some aspects. Apparatus 300
further includes first plate 150 as part of enclosure 110, and
ports 112 and 122. A fluid mixture may be introduced into the
apparatus 112, travel through the system of continuous channels, or
fluid passageways, of vessel 300, and discharge through port 122.
The mixture introduced into port 112 may travel in a progressively
inward direction toward the center of enclosure 110, while moving
substantially parallel with the perimeter of enclosure 110. The
mixture then transfers from enclosure 110 to intermediate enclosure
130, travels in a progressively outward direction toward the
perimeter of enclosure 130, while moving substantially parallel
with the perimeter, until transferring to enclosure 140. In vessel
140, the mixture travels in a progressively inward direction toward
the center of enclosure 140, while moving substantially parallel
with the perimeter of enclosure 140. The mixture then transfers to,
and travels through each of the enclosures included in the pairs of
enclosures 132, 134 and 136, in successive order, moving through
the enclosures in the same fashion as described for enclosures 130
and 140. The mixture then transfers from the last pair of
enclosures 136, into enclosure 120, travels in a progressively
outward direction toward the perimeter of enclosure 120, while
moving substantially parallel with the perimeter, until discharged
through port 120. To summarize the order of travel through the
channels or passageways, the mixture travels first through channel
162 in a progressively inward direction, then through 182 in a
progressively outward direction, channel 192 in a progressively
inward direction, channel 183 in a progressively outward direction,
then channel 193 in a progressively inward direction, channel 185
in a progressively outward direction, then channel 195 in a
progressively inward direction, then channel 187 in a progressively
outward direction, channel 197 in a progressively inward direction,
and then channel 172 in a progressively outward direction. The flow
path of the mixture throughout apparatus 300 is in alternating
inward/outward substantially spiral patterns which is illustrated
in FIG. 11. While spiral or substantially spiral flow patterns are
illustrated in some embodiments of the disclosure, any pattern of
mixture flow which is movement substantially parallel with an
enclosure perimeter while moving progressively inward or
progressively outward, is within the scope of the disclosure. Also,
the terms `spiral` and `substantially spiral`, as used in the
disclosure are not solely limited to patterns within a circle, but
may also mean patterns within ovate, square, rectangular,
triangular, and the like, perimeter enclosures where directional
movement is progressively inward or progressively outward, and the
length of the pattern, or otherwise pathway of movement, is at
least greater than the distance formed between the center of the
enclosure and greatest distance from the center on the perimeter of
the enclosure. Some spiral patterns useful in some enclosure
embodiments, or over a combination of multiple enclosures, may be
variable pitch and multiple pitch. Also, the spiral pattern may be
single pitched, such as an archimedean spiral, which is a plane
curve generated by a point moving away from or toward a fixed point
at a constant rate while the radius vector from the fixed point
rotates at a constant rate.
[0075] In another aspect of the disclosure, vessels may have a
single enclosure, such as 110 depicted in FIGS. 3 and 4, with a
port 112 in fluid communication with the first end 164 of channel
162, and another port 166 disposed on a surface of enclosure 110 in
fluid communication with a second end 168 of continuous channel
162. A fluid mixture may be introduced into port 112, travel
through the channel, or fluid passageway, 162, and exit 110 at port
166. While enclosure 110 is shown in FIG. 3 as open, a cover, such
as 150 in FIG. 2, may be disposed over the opening to seal the
enclosure. The mixture may exit through port 166, or even a pipe or
conduit disposed upon the port.
[0076] Now referencing FIGS. 12 and 13, which together, illustrate
an alternating inward/outward substantially spiral mixture flow
pattern 400 through apparatus 300, without showing apparatus 300 in
FIG. 12, and showing apparatus 300 in a transparent shadowed form
in FIG. 13. In accordance with the disclosure, the term
`substantially spiral`, also referred to as `spiral` herein, means
the pattern of flow is spiral in nature, but may not be perfectly
spiral due to enclosure design features and requirements, which
would be readily apparent to those of skill in the art, given the
benefit of this disclosure. The mixture is introduced into the
inlet port 112 of chamber (or enclosure) 110 at point 402, then
travels in an inwardly spiral direction 406 before transferring to
the next chamber 130 at point 414. The mixture then moves outwardly
spiraling 416 before transferring to the next chamber 140 at point
424, then inwardly spiraling 426, transferring into chamber 132A at
point 434, outwardly spiraling 436, transferring to chamber 132B at
444, then inwardly spiraling 446, transferring into chamber 134A at
point 454, then outwardly spiraling 456, transferring to chamber
134B at 464, inwardly spiraling 466, transferring into chamber 136A
at point 474, outwardly spiraling 476, transferring to chamber 136B
at 484, then inwardly spiraling 486, transferring to discharge
chamber 120 at point 494, outwardly spiraling 496, and then
discharging from the chamber 120 through discharge port 122 at
point 404. As shown in FIG. 12, inner transfer points 414, 434,
454, 474 and 494 lie upon or proximate axial centerline 102 of the
apparatus. However, it will be appreciated that the inner transfer
points may lie at any suitable position within a chamber with the
understanding that the inner transfer points are nearer the axial
centerline of the apparatus than the transfer points positioned
nearer the perimeter, such as outer transfer points 424, 444, 464
and 484. While it is shown in FIG. 12 example that first flowpath
406 may spiral in a counterclockwise direction relative axial
centerline 102, and the next flowpath 416 may spiral in a
counterclockwise direction, and so on, the flowpaths may also be in
a clockwise direction. Also, it is within the scope of the
disclosure that a first flowpath is in a clockwise direction, the
second in a counterclockwise direction, and as applicable,
subsequent directions alternating in the same way. The inverse is
also applicable, such as counterclockwise first, clockwise second,
etc. Further, the flowpath need not be limited to one direction, or
alternate directions, and successive directions may be
inconsistent, such as, for example, clockwise, clockwise, then
counterclockwise, clockwise, counterclockwise, etc. Any suitable
combination of directions may be used in accordance with the
disclosure, and the disclosure is not limited in any arrangement of
flowpaths.
[0077] Referring now to FIGS. 14 and 15 which show a top and bottom
view of a chamber according to some aspects of the disclosure.
Chamber 500 has a substantially rectangular outer perimeter shape,
in contrast to the circular chambers, or enclosures, shown in FIGS.
1 through 11. Other than the general difference in outer perimeter
shape, the features and function of the components described for
the vessels and enclosures illustrated in FIGS. 1 through 13 could
be applied to a plurality of substantially rectangular chambers
500. To illustrate, chamber 500 may include a perimeter 514, and
continuous channel, or fluid passageway, 562 with a first end 564
and second end 568. Second end 568 may be disposed upon or
proximate axial centerline 102, while the first end 564 disposed
proximate perimeter 514. A port 566 may be disposed on surface 540
of the chamber, and in fluid communication with a second end 568 of
continuous channel 562. In those cases where chamber 500 is located
at the inlet end of a hydration vessel, an inlet port may be
disposed upon perimeter 514, proximate first end 564, at point 590,
for example. Likewise, in instances where chamber 500 is located at
the discharge end of a hydration vessel, a discharge port may be
disposed upon perimeter 514, at point 590, and proximate first end
564. However, when chamber 500 is located at the discharge end,
port 566 would not be disposed upon surface 540, as a fluid mixture
would be received at second end 568 from a similar chamber disposed
above chamber 500. Fluid passageway 562 may be of length greater
than the length of the perimeter 514 of the chamber. The flow
pattern of a mixture through fluid passageway 562 may substantially
spiral in shape, or otherwise parallel with perimeter 514, in a
plane perpendicular to centerline 102. While chamber 500 depicts a
substantially rectangular shape, chamber perimeter shapes which are
triangular, ovate, square, and the like, are within the scope of
the disclosure.
[0078] FIG. 16 depicts some embodiments of the disclosure where two
hydration vessel apparatus are fluidly connected in series. A
plurality of hydration vessels may be used to further increase
swept volume capacity of a hydration vessel system. Hydration
vessel system 600 includes hydration vessels 602 and 604 shown in
transparent shadowed form, and fluid flowpaths 606 and 608 are
shown therein. Vessels 602 and 604 may include any of the features
and function of the components described for the vessels and
enclosures illustrated in FIGS. 1 through 15. For example,
hydration vessels 602 and 604 may be similar or like vessel 300,
with vessel 604 orientated in an inverted vertical orientation, or
in other instances, orientated in the same manner with a suitable
conduit connecting the vessels. A fluid mixture of water and
hydratable polymer may be introduced into system 600 at inlet port
610, and move through vessel 602 by flowpath 606. The mixture,
which may be at least partially hydrated, exits vessel 602 at
discharge port 612, then enters vessel 604 at inlet 614. The
mixture moves through vessel 604 by flowpath 608, and exits vessel
604 at discharge port 616, produced as a substantially hydrated
slurry of hydratable material and water.
[0079] Now referencing FIG. 17, which illustrates some further
apparatus embodiments according to the disclosure, such as a
hydration vessel useful for hydrating a mixture of water and a
hydratable material, or even forming a product from an admixture of
components and chemicals. Apparatus 700 includes a first chamber
710 and a second chamber 720. In some aspects of the disclosure,
apparatus 700 may further include one or more intermediate chambers
as shown in FIG. 18. Apparatus 700 may further include an inlet
port 712 disposed on the perimeter 714 of first chamber 710. Port
712 may receive the mixture of water and a hydratable material, or
any suitable mixture liquid and solid, for blending, or otherwise
further mixing, to form a slurry. Port 722 is disposed on the
perimeter 724 of the second chamber 720 of apparatus 700, and may
produce, or otherwise discharge a slurry of liquid and polymer,
such as water and hydratable material. Ports 712 and 722 may be
flush or extend outward from perimeters 714 and 724, and in some
instances, may extend outward in tangential direction relative
perimeters 714 and 724. In some aspects, the chambers 710 and 720
are separate chambers, through which the mixture travels a distance
over a time period for hydration. The chambers, or enclosures, are
in fluid communication which allows the mixture to pass from port
712, through first chamber 710, then into any intermediate
chamber(s), then into second chamber 720, and finally out of port
722.
[0080] Apparatus 700 may further include a first plate 760 disposed
on an outer end of first chamber 710, a second plate 762 (not
shown) disposed on an outer end of second chamber 720, and a
partition plate 770 (not shown) disposed between first chamber 710
and second chamber 720, which may serve to help confine the mixture
within the chambers 710 and 720. Plates 760, 762 and 770 may be
affixed to the chambers by any suitable technique, including, but
not limited to, removable fasteners attaching with a flange of the
enclosure, welding, formed as an integrated portion of the chamber,
and the like. Similarly, chambers 710, 720, as well as any
intermediate chambers, may be affixed with one another by same or
similar techniques. In FIG. 17, the chambers shown each include a
flange extending from the top and bottom perimeters, for receiving
fasteners, such as nuts and bolts, and securing the chambers (as
well as plates where used) with one another.
[0081] Partition plate 770 further includes a port to establish
fluid communication between inlet port 712 and discharge port 722.
Within each of first chamber 710 and second chamber 720 are
disposed a first and second continuous channels (or fluid
passageways), with an intermediate partition plate separating the
first and second continuous channels. The intermediate partition
plate includes a port to maintain fluid communication between the
first and second continuous channels, as well as fluid
communication between inlet port 712 and discharge port 722.
[0082] Referring to FIG. 18, which depicts some further hydration
vessel embodiments according to the disclosure. Similar to
apparatus 700, hydration vessel 800 includes a first chamber 710
and a second chamber 720. Hydration vessel 800 further includes at
least one intermediate chamber, and in the illustration three are
shown, 730, 740 and 750. Hydration vessel may further include an
inlet port 712 disposed on the perimeter 714 of first chamber 710,
for receiving a mixture of water and a hydratable material. Port
722 is disposed on the perimeter 724 of the second chamber 720, and
may produce, or otherwise discharge a slurry. As described above,
ports 712 and 722 may be flush with or extend outward from
perimeters 714 and 724, and in some instances, may extend outward
in tangential direction relative perimeters 714 and 724. Chambers
710, 720, 730, 740 and 750 are in fluid communication which allows
the mixture to pass from inlet port 712 and out of discharge port
722. Partition plates 770, 772, 774 and 776 are disposed between
respective chambers 710 and 730, 730 and 740, 740 and 750, as well
as 750 and 720. Partition plates 770, 772, 774 and 776 include a
port to maintain fluid communication between inlet port 712 and
discharge port 722. Similar with chamber 710 and second chamber
720, chambers 730, 740 and 750 each include first and second
continuous channels, with an intermediate partition plate
separating the first and second continuous channels. Each
intermediate partition plate includes a port to maintain fluid
communication between the first and second continuous channels, as
well as fluid communication between inlet port 712 and discharge
port 722. Hydration vessel also includes first plate 760 disposed
upon an outer end of first chamber 710, and second plate 762 (not
shown) disposed on an outer end of second chamber 720.
[0083] FIG. 19 illustrates a plate, which may be 760 or 762, useful
for affixing to outer ends of chambers 710 and 720. Plate 760 and
762 may include holes 763 (twenty shown) disposed about the
perimeter, in a flange bolt-hole pattern. FIG. 20 depicts a
partition plate, which may be 770, 772, 774 or 776, useful for
helping maintain fluid communication within hydration vessels 700
and 800, and affixed between chambers. The partition plate shown
also includes holes 765 (twenty shown) disposed about the
perimeter, in a flange bolt-hole pattern. Partition plates 770,
772, 774 and 776 further include port 767 proximate the outer
perimeter of each plate.
[0084] Now turning to FIGS. 21 and 22, which illustrate first outer
chamber 710 depicted in FIGS. 17 and 18. FIG. 21 shows a top plan
view, while FIG. 22 shows an opposing bottom plan view. First port
712, which may be an inlet port, disposed on perimeter 714 is in
fluid communication with the first end 764 of a continuous channel,
or fluid passageway, 792. Continuous channel 792 is disposed within
first chamber 710 in a substantially spiral pattern, and includes
second end 768 positioned at or near axial centerline 702.
Continuous channel 792 is positioned upon intermediate partition
plate 704. Intermediate partition plate 704 is disposed within
chamber 710, in a plane substantially perpendicular to axial
centerline 702, and further includes a port 766 (not shown)
positioned at or near second end 768. As illustrated in FIG. 22, a
continuous channel 794 is disposed on an opposed surface of
intermediate partition plate 704. Continuous channel 794 includes
first end 796 disposed at or near axial centerline 702, and second
end 798 positioned proximate perimeter 714. Continuous channel 794
has a substantially spiral pattern as well. Continuous channel 792
and continuous channel 794 are in fluid communication by port 766.
A mixture water and hydratable material may enter chamber 710
through port 712, pass through continuous channel 792 in an
inwardly spiraling manner, transfer to continuous channel 794
through port 766, travel through continuous channel 794 in an
outwardly spiraling pattern, and exit chamber 710 at end 798. In
those cases where a partition plate with a port is disposed over
continuous channel 794, such as partition plate 770 with a port 767
(as shown in FIGS. 17, 18 and 20), the mixture may exit chamber 710
through port 767 positioned at end 798, and then enter another
chamber.
[0085] FIGS. 23 and 24 depict an intermediate chamber useful in
some embodiments of the disclosure, and which describes
intermediate chambers 730, 740 and 750 shown in FIG. 18. FIG. 23
shows a top plan view, while FIG. 24 shows an opposing bottom plan
view. The intermediate chamber includes a continuous channel, or
fluid passageway, 802 disposed upon an intermediate partition plate
804. Continuous channel 802 includes a first end 806 positioned
proximate perimeter 814 of the intermediate chamber. Continuous
channel 802 further includes a second end 808 positioned at or near
axial centerline 702, and intermediate partition plate 804 includes
a port 816 (not shown) positioned at or near second end 808.
Continuous channel 802 is disposed within the intermediate chamber
in a substantially spiral pattern. As illustrated in FIG. 24, a
continuous channel 822 is disposed on an opposed surface of
intermediate partition plate 804. Continuous channel 822 includes
first end 824 disposed at or near axial centerline 702, and second
end 826 positioned proximate perimeter 814. Continuous channel 822
has a substantially spiral pattern as well. Continuous channel 802
and continuous channel 822 are in fluid communication by port 816.
A mixture, such as water and hydratable material, may enter chamber
730, 740 or 750 at end 806 from a port, such as port 767 of
partition plate 770, pass through continuous channel 802 in an
inwardly spiraling manner, transfer to continuous channel 822
through port 816, travel through continuous channel 822 in an
outwardly spiraling pattern, and exit chamber 730, 740 or 750 at
end 826. In instances where another partition plate with a port is
disposed over continuous channel 822, such as partition plate 770
with a port 767 (as shown in FIGS. 17, 18 and 20), the mixture may
exit chamber 730, 740 or 750 through port 767 positioned at end
826, and then enter another chamber. While FIG. 18 shows a
hydration vessel including three intermediate chambers 730, 740 and
750, and FIG. 17 depicts a vessel with no intermediate chamber,
these example are not limiting, and it is within the spirit and
scope of the disclosure to include any suitable number of
intermediate chambers.
[0086] Referencing FIGS. 25 and 26, which show second outer chamber
720 depicted in FIGS. 17 and 18. FIG. 25 depicts a top plan view,
while FIG. 26 shows an opposing bottom plan view. Continuous
channel, or fluid passageway, 852 is disposed within second chamber
720 in a substantially spiral pattern, and positioned upon an
intermediate partition plate 854. Continuous channel 852 includes a
first end 856 positioned proximate perimeter 724 of chamber 720,
and a second end 858 positioned at or near axial centerline 702.
Intermediate partition plate 854 includes a port 866 (not shown)
positioned at or near second end 858. Now turning to FIG. 26, a
continuous channel 874 is disposed on an opposed surface of
intermediate partition plate 854. Continuous channel 874 includes a
first end 876 disposed at or near axial centerline 702, and second
end 878 positioned proximate perimeter 714. Disposed on the
perimeter of chamber 720 and at the second end 878 is discharge
port 722. Continuous channel 874 has a substantially spiral pattern
as well. Continuous channel 852 and continuous channel 874 are in
fluid communication through port 866. A mixture of water and
hydratable material may enter chamber 720 at first end 856 from a
port disposed above, pass through continuous channel 852 in an
inwardly spiraling flowpath, transfer to continuous channel 874
through port 866, travel through continuous channel 874 in an
outwardly spiraling manner to second end 878, and exit chamber 720
at discharge port 722.
[0087] FIG. 27 illustrates, in an exploded view, the system of
enclosures, or chambers, which are configured and constructed as
depicted in FIGS. 18 through 26, and described herein above.
Hydration vessel, 800 includes chambers 710, 720, 730, 740 and 750,
each with a pair of alternating spiraling continuous channels
disposed therein. The center of chambers 710, 720, 730, 740 and 750
are positioned upon axial centerline 702. Each chamber includes
intermediate partition plates within as well, the intermediate
partition plates each including a port disposed at or near axial
centerline 702. Partition plates 770, 772, 774 and 776 are
positioned between the respective chambers, and further include
ports 767 proximate the outer perimeter of each plate. Plate 760 is
disposed upon an outer end of first chamber 710, and plate 762
disposed on an outer end of second chamber 720. A liquid/polymer
mixture may be introduced into inlet port 712, passing through the
plurality of chambers through the series of substantially spiraling
continuous channels and ports, then exit at discharge port 722 in
the form of an at least partially hydrated slurry.
[0088] While chambers 710, 720, 730, 740 and 750 are depicted
circular perimeter shapes, other perimeter shapes such as
rectangular, triangular, ovate, square, and the like, are within
the scope of the disclosure. Further, while the flow pattern of the
continuous channels are described as substantially spiral in FIGS.
17 through 26, the continuous channels, or fluid passageways, are
essentially of length greater than the length of the perimeter of
its respective chamber. The number of rotations of a spiral pattern
is not necessarily limiting for embodiments of the disclosure, as
long as the continuous channels, are essentially of length greater
than perimeter length.
[0089] In yet another aspect of the disclosure, vessels may have a
single enclosure, such as 710 depicted in FIGS. 21 and 22, with
port 712 in fluid communication with the first end 764 of channel
792. Channel 792 is disposed within first chamber 710 and includes
second end 768, and partition plate 704 disposed within chamber
710, and further includes a port 766 positioned at or near second
end 768. FIG. 22 shows channel 794 disposed on an opposed surface
of intermediate partition plate 704, and channel 794 includes first
end 796 disposed at or near axial centerline 702, and second end
798 positioned proximate perimeter 714. Disposed on the perimeter
of chamber 710 and at the second end 798 may be a discharge port,
such as 722 shown in FIGS. 25 and 26. While enclosure 710 is shown
in FIGS. 21 and 22 as open, covers such as 760 shown in FIG. 19,
may be disposed over the openings to seal the enclosure.
[0090] FIGS. 28 and 29 illustrate alternating inward/outward
substantially spiral mixture flow pattern 1000 through hydration
vessel 800, without showing vessel 800 in FIG. 28, and showing
vessel 800 in a transparent shadowed form in FIG. 29. Flow pattern
1000 is illustrated to provide a general depiction of material flow
through hydration vessel like or similar to the vessel 800, and may
be applicable to any variations in vessel design utilizing chambers
with intermediate partition plates and partition plates, such as
those described above. The mixture is introduced into the inlet
port 712 of outer chamber (or enclosure) 710 at point 1002, then
travels through a first continuous channel in an inwardly spiral
direction 1006 before transferring, at or near axial centerline
702, to a second continuous channel of chamber 710 at point 1014.
The mixture then moves outwardly spiraling 1016 before transferring
to the next chamber 730 at point 1024. The mixture then travels
through a first continuous channel of chamber 730 in an inwardly
spiral direction 1026 before transferring to a second continuous
channel of chamber 730 at point 1034, and then moves through the
second continuous channel of chamber 730 in an outwardly spiraling
pattern 1036 to then transfer to the next chamber 740 at point
1044. The mixture then enters a first continuous channel of chamber
740 and travels in an inwardly spiraling fashion 1046 to point
1054, and transfers to a second continuous channel of chamber 740.
In the second continuous channel of chamber 740, the mixture moves
in an outwardly spiraling pattern 1056 to point 1064, and moves to
chamber 750. Upon entering chamber 750, the mixture moves in an
inwardly spiral direction 1066 through a first continuous channel,
then transfers at point 1074 into a second continuous channel and
travels in an outwardly spiral direction 1076 to point 1084. The
mixture then transfers to a first continuous channel in outer
chamber 720 and moves in an inwardly spiraling direction 1086
through a first continuous channel, to point 1094. At point 1094,
the mixture transfers to a second continuous channel in outer
chamber 720, travels in an outwardly spiraling pattern 1096, and
then discharges from outer chamber 720 at point 1004.
[0091] FIG. 30 depicts some embodiments of the disclosure where two
hydration vessel apparatus, such as vessels 800, are fluidly
connected in series. The plurality of hydration vessels may be used
to further increase swept volume capacity of a hydration vessel
system. Hydration vessel system 900 includes hydration vessels 902
and 904 shown in transparent shadowed form, and fluid flowpaths 906
and 908 are shown therein. Vessels 902 and 904 may include any of
the features and function of the components described for the
vessels and enclosures illustrated in FIGS. 17 through 29. For
example, hydration vessels 902 and 904 may be similar or like
vessel 800, with vessel 904 orientated in a like vertical
orientation as vessel 902 with a suitable conduit connecting the
vessels, or in other instances, orientated in an inverted manner. A
fluid mixture of water and hydratable material may be introduced
into system 900 at inlet port 910, and move through vessel 902 by
flowpath 906. The mixture, which may be at least partially hydrated
in some cases, exits vessel 902 at discharge port 912, then enters
vessel 904 at inlet 914. The mixture moves through vessel 904 by
flowpath 908, and exits vessel 904 at discharge port 916, produced
as a substantially hydrated slurry of hydratable material and
water.
[0092] Referring now to FIG. 31, which illustrates another
hydration vessel, or apparatus, according to the disclosure. The
hydration vessel 1200 includes first enclosure 1204 having an
interior space defined therein, and second enclosure 1206 having an
interior space defined therein, where enclosures 1204 and 1206 may
be affixed with one another at flanges 1208 and 1210. In some
aspects of the disclosure, the interior space defined within an
outer portion 1216 of first enclosure 1204 may be considered an
inlet chamber, while the interior space defined within an outer
portion 1218 of second enclosure 1206 may be considered a discharge
chamber. First enclosure 1204 further includes an inlet port 1212
disposed on the surface, which may be useful for receiving a
mixture of hydratable material and water. A discharge port 1214
(shown in FIG. 32) is disposed on a surface of the second enclosure
1206, and may be utilized to produce a slurry of water and at least
partially hydrated material.
[0093] FIG. 32 shows the hydration vessel 1200 in a cross-section
format, where the cross-section is made at plane 1-1 parallel to
and lying upon axial centerline 1202 of vessel 1200 depicted in
FIG. 31. The interior space defined within outer portion 1216 of
first enclosure 1204 includes a first continuous channel, or first
fluid passageway, 1218 having a channel-length greater than a
length of the outer perimeter of the first enclosure 1204. In the
embodiment illustrated, a mixture may be introduced through inlet
port 1212 (shown in FIG. 31) and travel in a progressively inward
pattern through first continuous channel 1218 to port 1222 disposed
at, or proximate axial centerline 1202. In some alternative
embodiments, the mixture may be introduced through an inlet port
disposed in other suitable locations on the surface of first
enclosure 1204 and travel through first continuous channel, or
first fluid passageway, 1218 in a progressively outward pattern.
Referring again to the embodiment depicted in FIG. 32, the mixture
may pass through a series of additional continuous channels, or
fluid passageways, within the hydration vessel 1200, as described
in further detail below, and then enter into second continuous
channel, or second fluid passageway, 1220, through port 1224 (shown
in FIG. 33). Port 1224 may be disposed at, or proximate, the
perimeter of outer portion 1218 of second enclosure 1206. The
mixture may then travel in a progressively inward pattern through
second continuous channel 1220 and discharge as a partially or
substantially fully hydrated slurry of water and hydratable
material through discharge port 1214. While discharge port 1214 is
depicted as disposed at, or proximate to, the axial centerline 1202
of outer portion 1218 of second enclosure 1206, in some alternative
embodiments, the mixture may travel through second continuous
channel 1218 in a progressively outward pattern, and discharge
through a port disposed at any suitable location on second
enclosure 1206. Inlet port 1212 and discharge port 1214 of
hydration vessel 1200 are in fluid communication.
[0094] Now referencing FIG. 33 which illustrates in an interior
view, the series of continuous channels, or first fluid
passageways, within the interior of hydration vessel 1200, as well
as referencing FIG. 32. The series of continuous channels, or first
fluid passageways, are in fluid communication with one another, as
well as inlet port 1212 and discharge port 1214, of hydration
vessel 1200. The mixture described above, is introduced into first
continuous channel 1218 at point 1226, and travels in a
progressively inward pattern, substantially parallel to the
perimeter of enclosure, or chamber, 1204, to point 1228. At point
1228, the mixture exits continuous channel 1218 at port 1222 (shown
in FIG. 32), and enters third continuous channel, or fluid
passageway 1230. The mixture may then travel in a progressively
outward pattern, and substantially parallel to the above described
perimeter, to point 1232. At point 1232, a fourth port is disposed
at or proximate an end of third continuous channel, or fluid
passageway, 1230 where the mixture then enters fourth continuous
channel, or fluid passageway 1234. The mixture travels in a
progressively inward pattern to port 1236, and enters fifth
continuous channel, or fluid passageway 1238. Travelling in a
progressively outward pattern, the mixture reaches point 1240, and
transfers to a sixth continuous channel, or fluid passageway, 1242,
through a port. The mixture then travels in a progressively inward
pattern, and exits channel 1242 at port 1244. After entering
seventh continuous channel, or fluid passageway, 1246, the mixture
continues in a progressively outward pattern through channel 1246
to point 1248. At point 1248, the mixture transfers to second
continuous channel, or fluid passageway, 1220, through port 1224,
then travels in a progressively inward pattern, substantially
parallel with the perimeter, and is discharged through port
1214.
[0095] FIG. 34 depicts apparatus 1200, with enclosures shown in
shadowed form, according to some aspects of the disclosure, to
further illustrate how the hydration concept of this disclosure
would function in the embodiment described. Mixtures described
above would enter hydration vessel 1200 though inlet port 1212,
spiral through first channel 1218, transfer to and spiral through
third channel 1230, transfer to and spiral through fourth channel
1234, transfer to and spiral through fifth channel 1238, transfer
to and spiral through sixth channel 1242, transfer to and spiral
through sixth channel 1246, transfer to and spiral through second
channel 1220, and discharge from port 1214 (shown in FIG. 32).
While FIGS. 31 through 34 illustrate one apparatus, or hydration
vessel, 1200, a plurality of such apparatus be may connected in
series, parallel, or combination of series and parallel, is within
the scope and spirit of the disclosure.
[0096] FIG. 35 illustrates another aspect of the disclosure, in
cross-section view, which is a hydration vessel with nonparallel
partitions, or plates, between continuous channels or fluid
passageways, in nonparallel orientations. The cross-section is made
on plane parallel to and lying upon axial centerline 1252,
otherwise the vessel is substantially cylindrical in an overall
three dimensional shape. Hydration vessel 1250 includes a first
enclosure 1254 and second enclosure 1256. A mixture may be
introduced into hydration vessel 1250 at point 1258 and move in an
inwardly spirally pattern through fluid passageway 1260, which is
disposed upon partition plate 1262. As shown, partition plate 1262
lies in a plane substantially perpendicular to axial centerline
1252. The vertical dashed lines shown in the illustration represent
the wall structures which form the vertical limits of the fluid
passageways, the passageways are fluidly continuous from the inner
perimeter to the center of the hydration vessel, and the
passageways are substantially spiral in shape. Hence, the fluid
passageways have a length greater than the perimeter of the
hydration vessel.
[0097] At point 1264, the mixture transfers through a port to fluid
passageway 1266, which is disposed between partition plates 1262
and 1268. As shown, partition plate 1268 is not orientated parallel
with plate 1262. The mixture passes in an outwardly spiral pattern
through fluid passageway 1266 to point 1270, and transfers through
a port to fluid passageway 1272. Fluid passageway 1272 is disposed
between partition plates 1268 and 1274, and the plates are not
orientated in parallel planes. The mixture then moves in an
inwardly spiral through fluid passageway 1272 to point 1276, and
passes through a port, near or at axial centerline 1252, to fluid
passageway 1278. Fluid passageway 1278 is disposed between
partition plates 1274 and 1280, the plates not orientated in
parallel planes. The mixture then passes in an outwardly spiral
pattern through fluid passageway 1278 to point 1282, and transfers
through a port to fluid passageway 1284. Fluid passageway 1284 is
disposed between partition plates 1280 and 1286, the plates not
orientated in parallel planes. The mixture then moves in an
inwardly spiral pattern through fluid passageway 1284 to point
1288, and passes through a port to fluid passageway 1290. Fluid
passageway 1290 is disposed between partition plates 1286 and 1292,
and planes 1286 and 1292 are not orientated in planes perpendicular
with axial centerline 1252. The mixture then passes in an outwardly
spiral pattern through fluid passageway 1290 to point 1294, and
moves through a port into fluid passageway 1296. The mixture then
travels in an inwardly spiral pattern through fluid passageway 1296
to point 1298, enters a discharge outlet 1300, and exits hydration
vessel 1250 at point 1302, produced as slurry of partially or
substantially hydrated material and water. While the embodiment
illustrated in FIG. 35 shows an arrangement of a plurality of
partition plates orientated in different planes, and other figures
illustrate partition plates orientated in similar planes, the
illustrations are merely examples, and the disclosure is not
limited to those plate orientations described and shown. It will be
appreciated that any suitable orientation is within the scope of
the disclosure.
[0098] Some embodiments shown in the illustrations and described
above depict partition plates, or surfaces, which substantially
separate a continuous channel, or fluid passageway, from another
continuous channel, or fluid passageway, while allowing the
channels or passageways to be in fluid communication with each
other, as well as an inlet and outlet of the apparatus. While
plates are shown, other structures which would enable the same
balance of separation and adequate fluid communication may be
utilized, such as baffles, or any other structure which serves as a
flow-directing vane or panel. Further, while continuous channels or
passageways are depicted as connected by ports, continuous channels
could also be in the form of augers, a series of augers, or any
other suitable structure which enable the mixture to be hydrated,
suspended, or dissolved by traveling through the apparatus in a
distance greater than the length of the perimeter of the
apparatus.
[0099] Further, while the foregoing examples and figures describe
continuous channels or fluid passageways which are formed within
the chambers or interior of the enclosures with a continuous wall
or partition configuration, embodiments of the disclosure are not
limited to only such designs, and it is well within the scope of
the disclosure to have such channels or passageways constructed by
any suitable design, such as pipe, conduit, square tubular, and the
like. Additionally, components of the apparatus described may be
constructed of any suitable material or combinations thereof,
including, but not limited to metal, plastic, composites, etc.
Further, while it is general shown that apparatus of the disclosure
include a port for receiving a mixture, and a port for discharging
a slurry, mixture or product, some alternative embodiments may
include ports on the periphery of the apparatus for various
purposes, including, sampling, monitoring, controlling, injecting
other materials into the mixture during movement through the
apparatus, and the like.
[0100] Also within the scope of the disclosure are methods for
treating at least a portion of a subterranean formation penetrated
by a wellbore, which include introducing into one or more reaction
vessels (such as those vessels and apparatus described herein) a
mixture of a liquid component containing a first chemical reactant,
and a second chemical reactant, and the mixture is passed through
the at least one reaction vessel. A treatment fluid is then
prepared and contains the mixture and an optional insoluble
particle, and subsequently introduced into a wellbore. The reaction
vessel has a first enclosure having an outer perimeter and an
interior space defined therein, a channel disposed in the interior
space, a first port disposed on a surface of the first enclosure at
or proximate to a first end of the channel, and a second port
disposed on a surface of the first enclosure at or proximate to a
second end of the channel. The channel may have a length greater
than a shortest distance between the first port and the second
port, and the first port and the second port are in fluid
communication. In some cases, the channel has a length greater than
a length of the outer perimeter, and the channel has an archimedian
spiral pattern. The reaction vessel, as well as any vessels and
apparatus according to the disclosure, may further include at least
one static mixing element within the channel, an axial mixer within
the vessel, or combination of both. The mixture produced in the
vessel may be injected into a high pressure fluid stream, and in
some instances, the mixture injected is a pill comprising a high
concentration of the second chemical reactant.
[0101] The second chemical reactant may be a water hydratable
material, or otherwise water reactable material, and the liquid
component may be aqueous based including water as a first chemical
reactant. The mixture may undergo a rate limited chemical reaction
requiring residence time, while flowing the mixture through the
reaction vessel under the influence of gravity, pressure or
combination thereof. The concentration of water reactable material
may be any suitable concentration, including, but not limited to
about 25 pounds per 1000 gallons of liquid component or greater,
about 30 pounds per 1000 gallons of liquid component or great,
about 40 pounds per 1000 gallons of liquid component or greater, or
even about 50 pounds per 1000 gallons of liquid component or
greater.
[0102] The method may further include decreasing the concentration
of the first chemical reactant, the second chemical reactant, or
both, during the course of the treatment. Such a decrease in
concentration may enable improved flushing and cleaning of the
vessel and overall system. In some aspects, pressure change of the
mixture is measured across the at least one reaction vessel to
monitor a reaction of the first chemical reactant with the second
chemical reactant. Also, the mixture may be passed through a
plurality of such reaction vessels.
[0103] Some methods may further include use of a second enclosure
having an outer perimeter and an interior space defined therein,
where the second enclosure has a second channel disposed in the
interior space, a third port disposed on a surface of the second
enclosure at or proximate to a first end of the second channel, and
a fourth port disposed on a surface of the second enclosure at or
proximate to a second end of the second channel. The second port,
the third port and fourth port are in fluid communication. The
channel of the first enclosure and the second channel may have an
archimedian spiral pattern, where a first fluid flowpath is in a
progressively inward direction through the channel of the first
enclosure, and a second fluid flowpath is in a progressively
outward direction through the second channel, or alternatively, a
first fluid flowpath is in a progressively outward direction
through the channel of the first enclosure, and a second fluid
flowpath is in a progressively inward direction through the second
channel. Such a change in direction of fluid flowpaths may impart
energy into the mixture to further optimize the reaction of the two
materials.
[0104] In yet other methods, a plurality of enclosures is used, or
any suitable number thereof, where each of the enclosures has an
outer perimeter and an interior space defined therein, a channel
disposed in the interior space, a port disposed on a surface of the
enclosure at or proximate to a first end of the channel, and a port
disposed on a surface of the enclosure at or proximate to a second
end of the channel, and wherein the channel has a length greater
than a shortest distance between the ports, and wherein the second
port and the ports disposed on the surface of the plurality of
enclosures are in fluid communication. One or more additional
chemical components are injected into the plurality of reaction
vessels at one or more points downstream from the first port.
[0105] Some other method embodiments according to the disclosure
include methods for treating at least a portion of a subterranean
formation penetrated by a wellbore where a liquid component
including water and a second component having a hydratable polymer
are introduced into at least one hydration vessel, the mixture
passed through the at least one hydration vessel in a continuous
manner to form a slurry, a treatment fluid then prepared which
contains the slurry and an optional insoluble particle, and the
treatment fluid introduced into the wellbore. The hydration vessel
includes an inlet chamber having a spiraling first fluid
passageway, and a discharge chamber having a spiraling second fluid
passageway, where the first fluid passageway and the second fluid
passageway are in fluid communication. A first fluid flowpath may
be orientated in a progressively inward direction through the first
fluid passageway, and a second fluid flowpath in a progressively
inward direction through the second fluid passageway. The
alternative may be the case as well, where the first fluid flowpath
may be orientated in a progressively outward direction, and the
second fluid flowpath in a progressively outward direction. The
hydration vessel may further include an inlet port disposed on a
perimeter of the inlet chamber, and a discharge port disposed on a
perimeter of the discharge chamber. Some method embodiments also
involve utilizing a plurality of hydration vessels connected in a
series configuration, a parallel configuration, or combination
thereof.
[0106] In some of the methods, the hydration vessel may further
include at least one intermediate chamber disposed between the
inlet chamber and the discharge chamber, where the at least one
intermediate chamber comprises a spiraling first intermediate fluid
passageway, and the first fluid passageway, the second fluid
passageway, and the first intermediate fluid passageway are in
fluid communication. In some cases, the at least one intermediate
chamber is at least one pair of intermediate chambers disposed
between the inlet chamber and the discharge chamber, the pair of
intermediate chambers including a first intermediate chamber having
a spiraling first intermediate fluid passageway, and a second
intermediate chamber having a spiraling second intermediate fluid
passageway, where the first fluid passageway, the second fluid
passageway, the first intermediate fluid passageway and the second
intermediate fluid passageway are in fluid communication. A second
pair of intermediate chambers may further be disposed between the
at least one pair of intermediate chambers and the discharge
chamber, a third pair of intermediate chambers disposed between the
second pair of intermediate chambers and the discharge chamber, a
fourth pair of intermediate chambers disposed between the third
pair of intermediate chambers and the discharge chamber, and so on.
Any practical number of intermediate chambers, or pairs thereof,
are within the scope and spirit of the disclosure.
[0107] In some aspects, at least one intermediate chamber is
disposed between the inlet chamber and the discharge chamber, where
the intermediate chamber comprises a spiraling first intermediate
fluid passageway, and the first fluid passageway, the second fluid
passageway, and the first intermediate fluid passageway are in
fluid communication. Optionally, the at least one intermediate
chamber is at least one pair of intermediate chambers disposed
between the inlet chamber and the discharge chamber, and have a
first intermediate chamber comprising a spiraling first
intermediate fluid passageway, and a second intermediate chamber
comprising a spiraling second intermediate fluid passageway, where
the first fluid passageway, the second fluid passageway, the first
intermediate fluid passageway and the second intermediate fluid
passageway are in fluid communication. The at least one
intermediate chamber may include a first and a second fluid
passageway, where the fluid passageways are partitioned by a plate
having a hole therein, and where the first and the second fluid
passageways are in fluid communication. Also, the first outer
chamber and the second outer chamber may each have a first and a
second fluid passageway, where the fluid passageways are
partitioned by a plate having a hole therein, and where the first
and the second fluid passageway are in fluid communication.
[0108] Yet other method aspects of the disclosure relate to
preparing a product from an admixture of a first chemical contained
in a liquid component, and a second component. The first chemical
may be the same as the liquid component in some cases, while in
other cases, a chemical suspended or dissolved in the liquid
component. The admixture mixture includes one or more materials
that may react in any way, such as polymer, surfactant or solids
separation and association with water in hydration, or even
chemical reaction to form another material through ionic or
covalent bonding. The admixture is introduced into an apparatus
including an inlet chamber (such as 110 of FIG. 1, referenced as
one example) having an outer perimeter 114 and a first fluid
passageway 162 formed therein, where the first fluid passageway has
a length greater than a shortest distance between the outer
perimeter and center of the inlet chamber. The admixture may be
introduced into the first fluid passageway through a port, such as
112 or 162, flowed through the first fluid passageway, to then exit
and then enter a discharge, or otherwise second chamber of the
apparatus, through another port. The discharge chamber includes an
outer perimeter and a second fluid passageway formed therein, and
the second fluid passageway has a length greater than a shortest
distance between the outer perimeter and center of the discharge
chamber. The first fluid passageway and the second fluid passageway
are in fluid communication. The admixture is flowed through the
apparatus and discharged from the apparatus as a product formed
from the first chemical and the second component. The direction of
admixture flow through the first fluid passageway and the second
fluid passageway may be in opposite directions in some aspects,
different directions in other aspects, or even in like directions.
Ports may be disposed at any practical position upon and/or within
the combination of chambers. The chambers may be formed within
separate enclosures, or formed within a single enclosure. The
apparatus may also include additional chambers as well.
[0109] Apparatus and methods of the disclosure may be useful in
subterranean formation treatments where continuous mixing and
hydration of well viscous treatment gels from dry polymer are
required at a wellbore site, whether land based or offshore.
However, the processes and apparatus may however be used for mixing
other types of powder material with liquids as well. At a wellbore
site once the well has been drilled and constructed and the drill
rig removed, the site may be prepared for subterranean formation
treatment or stimulation. The surface, or rig facilities and layout
typically involve a number of pieces of mobile equipment including
fracture fluid storage tanks, sand storage units, chemical trucks,
blending equipment and pumping equipment. All facets of the
hydraulic fracturing job from the blending and pumping of the
fracture fluids and proppants--solid material, usually sand or
other solid material, that is pumped into fractures to hold them
open--to the way the rock formation responds to the fracturing, are
often managed from a single control location. Apparatus of the
disclosure may be a component of the blending equipment, and in
fluid communication with pumping equipment. Integration of the
apparatus and methods into the formation treatment equipment set up
will be readily apparent to those of skill in the art having the
benefit of this disclosure.
[0110] Lastly, in accordance with the disclosure, the hydratable
polymer may be present at any suitable concentration in the mixture
or produced slurry. In various embodiments hereof, the hydratable
polymer can be present in an amount of from about 0.1 wt. % to
about 10 wt. % of total weight of the mixture, from about 0.1 wt. %
to about 7 wt. % of total weight of the mixture, from about 0.1 wt.
% to about 5 wt. % of total weight of the mixture, from about 0.1
wt. % to about 4 wt. % of total weight of the mixture, from about
0.1 wt. % to about 3 wt. % total weight of the mixture, from about
0.1 wt. % to about 2 wt. % of total weight of the mixture, or even
from about 0.1 wt. % to about 1 wt. % of total weight of the
mixture. Slurries incorporating the hydratable polymer may have any
suitable viscosity, and in some instances a viscosity value of
about 50 mPa-s or greater at a shear rate of about 100 s.sup.-1 at
treatment temperature, or about 75 mPa-s or greater at a shear rate
of about 100.sup.s-1, or even about 100 mPa-s or greater at a shear
rate of about 100.sup.s-1.
[0111] The foregoing description of the embodiments has been
provided for purposes of illustration and description. Example
embodiments are provided so that this disclosure will be thorough,
and will fully convey the scope to those who are skilled in the
art. Numerous specific details are set forth such as examples of
specific components, devices, and methods, to provide a thorough
understanding of embodiments of the disclosure, but are not
intended to be exhaustive or to limit the disclosure. Individual
elements or features of a particular embodiment are generally not
limited to that particular embodiment, but, where applicable, are
interchangeable and can be used in a selected embodiment, even if
not specifically shown or described. The same may also be varied in
many ways. Such variations are not to be regarded as a departure
from the disclosure, and all such modifications are intended to be
included within the scope of the disclosure.
[0112] It will be apparent to those skilled in the art that
specific details need not be employed, that example embodiments may
be embodied in many different forms and that neither should be
construed to limit the scope of the disclosure. In some example
embodiments, well-known processes, well-known device structures,
and well-known technologies are not described in detail. Further,
it will be readily apparent to those of skill in the art that in
the design, manufacture, and operation of apparatus to achieve that
described in the disclosure, variations in apparatus design,
construction, condition, erosion of components, gaps between
components may present, for example.
[0113] Although the terms first, second, third, etc. may be used
herein to describe various elements, components, regions, layers
and/or sections, these elements, components, regions, layers and/or
sections should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer or
section from another region, layer or section. Terms such as
"first," "second," and other numerical terms when used herein do
not imply a sequence or order unless clearly indicated by the
context. Thus, a first element, component, region, layer or section
discussed below could be termed a second element, component,
region, layer or section without departing from the teachings of
the example embodiments.
[0114] Spatially relative terms, such as "inner," "outer,"
"beneath," "below," "lower," "above," "upper," and the like, may be
used herein for ease of description to describe one element or
feature's relationship to another element(s) or feature(s) as
illustrated in the figures. Spatially relative terms may be
intended to encompass different orientations of the device in use
or operation in addition to the orientation depicted in the
figures. For example, if the device in the figures is turned over,
elements described as "below" or "beneath" other elements or
features would then be oriented "above" the other elements or
features. Thus, the example term "below" can encompass both an
orientation of above and below. The device may be otherwise
oriented (rotated 90 degrees or at other orientations) and the
spatially relative descriptors used herein interpreted
accordingly.
[0115] Although various embodiments have been described with
respect to enabling disclosures, it is to be understood the
invention is not limited to the disclosed embodiments. Variations
and modifications that would occur to one of skill in the art upon
reading the specification are also within the scope of the
invention, which is defined in the appended claims.
* * * * *