U.S. patent application number 16/911526 was filed with the patent office on 2020-10-15 for process for using a composition of matter.
The applicant listed for this patent is ECONOMY MUD PRODUCTS COMPANY. Invention is credited to Samuel Stratton, Matthew White, Walter White.
Application Number | 20200325386 16/911526 |
Document ID | / |
Family ID | 1000004916923 |
Filed Date | 2020-10-15 |
United States Patent
Application |
20200325386 |
Kind Code |
A1 |
Stratton; Samuel ; et
al. |
October 15, 2020 |
Process for Using a Composition of Matter
Abstract
A process for making and using a ground product that includes
the step of: forming a guar-based derivative. The process includes
treating the derivative to form a ground product, and mixing the
ground product into a water or slickwater stream to form a frac
fluid. The process includes injecting the frac fluid into a
subterranean formation.
Inventors: |
Stratton; Samuel; (Houston,
TX) ; White; Walter; (Houston, TX) ; White;
Matthew; (Houston, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ECONOMY MUD PRODUCTS COMPANY |
Houston |
TX |
US |
|
|
Family ID: |
1000004916923 |
Appl. No.: |
16/911526 |
Filed: |
June 25, 2020 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
16230704 |
Dec 21, 2018 |
10711180 |
|
|
16911526 |
|
|
|
|
PCT/US18/36127 |
Jun 5, 2018 |
|
|
|
16230704 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C08B 37/0096 20130101;
C09K 8/68 20130101 |
International
Class: |
C09K 8/68 20060101
C09K008/68; C08B 37/00 20060101 C08B037/00 |
Claims
1. A process for using a ground hydroxypropyl guar-based product
composition of matter, the process comprising: providing a water
stream; mixing the ground hydroxypropyl guar-based product into the
water stream to form a frac fluid blend; and injecting the frac
fluid blend into a subterranean formation.
2. The process of claim 1, wherein the water stream is
characterized as having a salinity value in the range of about
100,000 ppm to about 300,000 ppm total dissolved solids (TDS).
3. The process of claim 1, wherein the water stream is a slickwater
blend.
4. The process of claim 1, wherein the ground hydroxypropyl
guar-based product is formed from a reaction that comprises use of
sodium hydroxide, a reagent comprising propylene oxide, and a
powdered acid comprising a carboxylic acid.
5. The process of claim 4, wherein prior to the mixing step the
ground hydroxypropyl guar-based product is in powdered form.
6. The process of claim 1, wherein the ground hydroxypropyl
guar-based product is characterized by at least 90% by weight of a
given quantity thereof having an average particle bulk diameter
less than or equal to 74 microns.
7. The process of claim 1, wherein during the mixing step the
ground hydroxypropyl guar-based product is hydrated at least about
80% in about one minute or less, characterized by the water stream
having a higher viscosity than the resultant frac fluid blend.
8. A process for using a ground hydroxypropyl guar-based product
composition of matter, the process comprising: providing a water
stream; mixing the ground hydroxypropyl guar-based product into the
water stream to form a frac fluid blend; and injecting the frac
fluid blend into a subterranean formation, wherein during the
mixing step the ground hydroxypropyl guar-based product is dry at
first but then hydrated at least about 80% in about one minute or
less, characterized by the water stream having a higher viscosity
than the resultant frac fluid blend.
9. The process of claim 8, wherein the water stream is
characterized as having a salinity value in the range of about
100,000 ppm to about 300,000 ppm total dissolved solids (TDS).
10. The process of claim 9, wherein the water stream is a
slickwater blend comprising a polyacrylamide.
11. The process of claim 8, wherein the ground hydroxypropyl
guar-based product is formed from a reaction that comprises use of
sodium hydroxide, a reagent comprising propylene oxide, and a
powdered acid comprising a carboxylic acid.
12. The process of claim 11, wherein prior to the mixing step the
ground hydroxypropyl guar-based product is in powdered form.
13. The process of claim 12, wherein the ground hydroxypropyl
guar-based product is characterized by at least 90% by weight of a
given quantity thereof having an average particle bulk diameter
less than or equal to 74 microns.
14. A process for using a hydroxypropyl guar-based product, the
process comprising: providing a water stream; mixing the
hydroxypropyl guar-based product into the water stream to form a
frac fluid blend; and injecting the frac fluid blend into a
subterranean formation, wherein during the mixing step the
hydroxypropyl guar-based product is dry at first but then hydrated
at least about 80% in about one minute or less, characterized by
the water stream having a higher viscosity than the resultant frac
fluid blend.
15. The process of claim 14, wherein the water stream comprises a
salinity value in the range of about 100,000 ppm to about 300,000
ppm total dissolved solids (TDS).
16. The process of claim 15, wherein the hydroxypropyl guar-based
product is formed from a reaction that comprises use of sodium
hydroxide, propylene oxide, and a powdered acid.
17. The process of claim 16, wherein prior to the mixing step the
hydroxypropyl guar-based product is in powdered form.
18. The process of claim 17, wherein the hydroxypropyl guar-based
product is characterized by at least 90% by weight of a given
quantity thereof having an average particle bulk diameter less than
or equal to 74 microns.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Non-provisional
application Ser. No. 16/230,704, filed on Dec. 21, 2018, which is a
bypass continuation of PCT Application Ser. No. PCT/US18/36127,
filed on Jun. 5, 2018. The disclosure of each application is hereby
incorporated herein by reference in its entirety for all
purposes.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND
Field of the Disclosure
[0003] This disclosure relates to making and/or using a composition
of matter useful to improve performance of hydraulic fracturing.
Particular embodiments pertain to making and/or using a natural
polymer-based additive, which may be useful as a friction reducer
in a high-brine solution used in fracking.
Background of the Disclosure
[0004] In a stimulation process, such as frac operation, a frac
fluid (with varying additives) may be injected into a subterranean
formation. In such an operation a large amount of frac fluid is
pumped down a wellbore under high pressure to a depth of anywhere
from 1000 feet to 20,000 feet or more, which results in fractures
of the surrounding rock formation. The pressure is then relieved
allowing valuable hydrocarbonaceous fluids to permeate out through
the fractures and into the wellbore, where the fluids can be
produced to a surface unit or facility.
[0005] Turbulence produced as the frac fluid is pumped through a
tubular under pressure results in friction, which increases (in
some instances, significantly) the amount of energy required to
pump the injection fluid at sufficient speed and pressure.
[0006] Additives, including those of a polymeric nature, can be
used to alter the rheological properties of the frac fluid so that
friction is reduced, thereby reducing consequent energy loss. This
type of additive (or combination of ingredients) is conventionally
known as a `friction reducer`. Friction reducers have a wide range
of variation in terms of composition, utility, characteristics, and
so forth. But in general a good friction reducer will result in a
decrease in friction at small concentrations, will be inexpensive,
environmentally approved, and will have high-shear, temperature,
and pressure stability.
[0007] Various polymers can be used in friction reducers, some
being better than others, and the selection of which being further
dependent on factors such as formation type and the type of fluid
(usually water) available for injection fluid.
[0008] A friction reducer does not directly make it easier to
produce formation fluids; instead, it typically helps get more frac
fluid (and/or proppant) into the formation fractures, and reduces
the overall energy requirement of the injection process. The
reduction in friction means the same energy output can pump more
frac fluid into the formation, which means more proppant/sand can
be introduced into the fractures (to hold open), and thus more
formation fluid (liquid, gas) can permeate out of the formation and
into the wellbore.
[0009] An additive to frac fluid can also be useful for increasing
the viscosity (or carrying capacity) of the frac fluid. This type
of additive typically results in the frac fluid having a higher gel
strength in order to carry more sand/proppant. Such additives are
used to increase overall operation efficiency, meaning less water,
less energy, less stress on equipment, smaller equipment, and so
forth, to obtain a similar or better result.
[0010] Thus, there are significant technical differences in
function and purpose between a material used to build viscosity,
and that of which reduces friction (or in some instances
accomplishes both).
[0011] The composition of the additive and choice thereof is thus
dependent on what type of function is desired, as well as other
variables such as formation properties and the water source. While
fresh water may be used, the cost may be high such that other
options are considered, including produced water from the formation
or previously used water (flowback, recycle, etc.). Whatever the
case may be, the water and any contaminants therein can have
detrimental effects on additives.
[0012] In some instances, a synthetic polymer-based additive may be
desired. This type of additive tends to be uncrosslinked and may
provide better friction reducing ability, particularly if fresh or
cleaner water is available. A common practice is to use a synthetic
polymer additive mixed with water to make a frac fluid called
"slickwater".
[0013] In some instances, a natural polymer-based additive may be
desired, such as a guar-based additive. These types of additives
tend to be degradable, and better suited for environmental
disposal. They tend to be cross-linked. A cross-linked polymer
tends to be stronger, and better suited to handle harsher water
choices, including salt- or oil-ladened produced water. Natural
polymers tend to be selected for their viscosity building
ability.
[0014] Guar gum has diverse industrial uses including its use as a
thickener and/or stabilizer in the textile, food, cosmetic and
pharmaceutical industries, and has been given consideration for
varied use in the oil and gas industry.
[0015] Guar gum comes from a legume-type plant that produces a pod
with seeds inside. Upon heating, the seeds `split` open and expose
two endosperm sections, and the germ therebetween. The exposed
endosperm sections contain a polymer known as polygalactomannan, or
`gum`. The gum is contained in tiny cells having a water-insoluble
cell wall, which may be disrupted to obtain the material, which is
usually via some kind of processing in the form of dehusking,
milling, screening, roasting, differential attrition, sieving,
polishing and so forth. The remnant material is substantially gum,
possibly with minor amounts of proteinaceous material, inorganic
salts, water-insoluble gum, cell membranes, as well as some
residual seedcoat and embryo, which can be further processed and
separated.
[0016] This resultant gum material develops a high viscosity via
hydration of the fluid to be thickened, similar to the action of
starch; however, the guar endosperm polymer is much more efficient
than starch in developing viscosity.
[0017] Guar derivatives are also useful, such as hydroxyalkyl guar,
carboxyalkyl guar, carboxyalkyl hydroxyalkyl guar, cationic guar,
hydrophobically modified guar, and hydroxypropyl guar (or
"HPG").
[0018] Other guar and guar derivative applications include, among
others, animal litter, explosives, foodstuff, paperstock, synthetic
fuel briquettes, shampoo, personal care lotion, household cleaner,
diapers, sanitary towels, and adsorbent in food packaging. In such
applications, it is known that faster hydration of the guar or guar
derivative for any of these applications would be an advantage.
[0019] Conventionally linear (no cross-linking), hydrated HPG tends
to have characteristics that make it commercially viable in
industry for viscosity building. Whereas for friction reducing,
particularly for fresh(er) water applications, polyacrylamides have
characteristics (e.g., crosslinking) that tend to be viewed as
commercially viable. In such an application, HPG is not viewed as
commercially practicable or viewed as workable.
[0020] However, in certain uses polyacrylamides lose their
effectiveness. For example, when high-brine fluids are used,
polyacrylamides typically fail. An example of a high-brine fluid is
a variant of produced water. The high amount of salt in brine, and
particularly high-brine, results in the salt attacking the
polyacrylamide via ionic attraction, with the polymer collapsing
and becoming ineffective.
[0021] Polyacrylamides also have hydration, storage, and transport
problems. First, polyacrylamides are large molecules, which means
great amounts of energy and equipment are needed in order to
hydrate. Next, while powders tend to be a preferred medium because
of ease of transport and storage, dry polyacrylamide tends to be
prone to clumping and absorbing moisture. This is attributable to
particle size, meaning in order to have desired friction reducing
effects, the polyacrylamide needs to have fast hydration. To
achieve fast hydration, the particle size is smaller; however,
smaller particle size results in undesired hydration in storage.
Thus, polyacrylamide systems have been largely relegated to use
liquid carriers and solvents, which results in higher storage and
transport costs.
[0022] There is a need in the art for a composition of matter that
has fast hydration characteristics that can also be readily
storable and transportable in powder form. There is a need for a
composition of matter for use as an additive into a frac fluid that
can be both friction reducing and viscosity building, or better at
one or the other with slight compositional change. There is a need
in the art for a cost-effective, expedient, and scalable process
that can be used to make a composition of matter for use as an
additive into a frac fluid. What is further needed is a natural
polymer-based material that can be used with high brine
solutions.
SUMMARY
[0023] Embodiments herein may be useful for a process for making
and/or using a ground product composition of matter that may
include a guar-based material.
[0024] The process may include forming the composition via one or
more pre-treatment steps. One or more steps may include: reacting a
guar split with at least one reagent at a reaction temperature in a
range of 120.degree. F. to 180.degree. F. to form a guar
derivative; and treating the guar derivative with at least one of
washing and drying to form a resultant treated derivative.
[0025] The process may include a transfer step, such as
transferring the resultant treated derivative to a co-grinder
operably associated with a heated vacuum system. The process may
include co-grinding the resultant treated derivative with a
powdered acid to form a ground product.
[0026] The reacting step may occur in a substantially oxygen-free
environment. A reaction time of the reacting step may be in a
reaction time range of about 1.5 hours to about 2.5 hours.
[0027] The reacting step may include use of sodium hydroxide. The
reagent may be propylene oxide. The powdered acid may be a
carboxylic acid.
[0028] The process may include mixing the ground product with a
high-brine water stream. The water stream may have a salinity value
in the range of about 100,000 ppm to about 300,000 ppm total
dissolved solids (TDS).
[0029] The mixing step may include the ground product in
substantially powdered form.
[0030] The mixing step comprises the ground product in slurry or
liquidious form.
[0031] The ground product may be characterized by at least 90% by
weight of a given quantity thereof having an average particle bulk
diameter less than or equal to 74 microns.
[0032] In aspects, the heated vacuum system may include one or more
of a combustion burner; a micropulsair dust collector configured
for use as a dryer; and a blower configured for pulling a
vacuum.
[0033] In aspects, the heated vacuum system may include various
operating parameters such as one or more of an average operating
combustion temperature output of about 600.degree. F., a grinder
exhaust temperature in a range of about 175.degree. F. to about
185.degree. F., and a dust collector exhaust temperature range of
about 170.degree. F. to about 175.degree. F.
[0034] The ground product may be (or have a characteristic of
being) hydrated at least about 80% in about one minute or less.
[0035] Other embodiments of the disclosure pertain to a process for
making and/or using a ground product composition that may include
one or more steps of: reacting a guar split with propylene oxide at
a reaction temperature in a range of 120.degree. F. to 180.degree.
F. to form a guar derivative; and treating the guar derivative with
at least one of washing and drying to form a resultant treated
derivative.
[0036] The process may include transferring the resultant treated
derivative to a co-grinder operably associated with a heated vacuum
system. The process may include co-grinding the resultant treated
derivative with a powdered carboxylic acid to form a ground
product.
[0037] The process may include mixing the ground product with a
water stream. The water stream may have a salinity value in the
range of about 100,000 ppm to about 300,000 ppm total dissolved
solids (TDS).
[0038] The reacting step may occur in a substantially oxygen-free
environment.
[0039] The reaction time wherein a reaction time is in the range of
1.5 hours to 2.5 hours.
[0040] The reacting step may include use of a caustic material.
[0041] The mixing step may include the ground product in powdered
form. The powdered form may be substantially dry.
[0042] The mixing step may include the ground product in slurry or
liquidious form. Thus, the ground product may be mixed with one or
more liquidious agents.
[0043] The ground product may be characterized by or have the
physical property of at least 90% by weight of a given quantity
thereof having an average particle bulk diameter less than or equal
to 74 microns.
[0044] In aspects, the heated vacuum system may include one or more
of: a combustion burner; a micropulsair dust collector configured
for use as a dryer; and a blower configured for pulling a
vacuum.
[0045] The heated vacuum system may have various operable
parameters, including one or more of: an average operating
combustion temperature output of about 600.degree. F., a grinder
exhaust temperature in a range of about 175.degree. F. to about
185.degree. F., and a dust collector exhaust temperature range of
about 170.degree. F. to about 175.degree. F.
[0046] The ground product may be (or have the physical property of
being) hydrated at least about 80% in about one minute or less.
[0047] The process may include pumping a resultant mixture of the
water stream and the ground product into a wellbore.
[0048] These and other embodiments, features and advantages will be
apparent in the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] A full understanding of embodiments disclosed herein is
obtained from the detailed description of the disclosure presented
herein below, and the accompanying drawings, which are given by way
of illustration only and are not intended to be limitative of the
present embodiments, and wherein:
[0050] FIG. 1 shows an overview flow diagram of a process for
making and/or using a composition of matter according to
embodiments of the disclosure; and
[0051] FIG. 2 shows a process flow diagram of a system for making
and/.or using a composition of matter according to embodiments of
the disclosure.
DETAILED DESCRIPTION
[0052] Herein disclosed are novel apparatuses, systems, and methods
that pertain to a polymeric-based additive for use in wellbore
fluid, details of which are described herein. It has been
discovered that a natural polymer.
[0053] Embodiments of the present disclosure are described in
detail with reference to the accompanying Figures. In the following
discussion and in the claims, the terms "including" and
"comprising" are used in an open-ended fashion, such as to mean,
for example, "including, but not limited to . . . ". While the
disclosure may be described with reference to relevant apparatuses,
systems, and methods, it should be understood that the disclosure
is not limited to the specific embodiments shown or described.
Rather, one skilled in the art will appreciate that a variety of
configurations may be implemented in accordance with embodiments
herein.
[0054] Although not necessary, like elements in the various figures
may be denoted by like reference numerals for consistency and ease
of understanding. Numerous specific details are set forth in order
to provide a more thorough understanding of the disclosure;
however, it will be apparent to one of ordinary skill in the art
that the embodiments disclosed herein may be practiced without
these specific details. In other instances, well-known features
have not been described in detail to avoid unnecessarily
complicating the description. Directional terms, such as "above,"
"below," "upper," "lower," "front," "back," etc., are used for
convenience and to refer to general direction and/or orientation,
and are only intended for illustrative purposes only, and not to
limit the disclosure.
[0055] Connection(s), couplings, or other forms of contact between
parts, components, and so forth may include conventional items,
such as lubricant, additional sealing materials, such as a gasket
between flanges, PTFE between threads, and the like. The make and
manufacture of any particular component, subcomponent, etc., may be
as would be apparent to one of skill in the art, such as molding,
forming, press extrusion, machining, or additive manufacturing.
Embodiments of the disclosure provide for one or more components to
be new, used, and/or retrofitted to existing machines and
systems.
[0056] Various equipment may be in fluid communication directly or
indirectly with other equipment. Fluid communication may occur via
one or more transfer lines and respective connectors, couplings,
valving, and so forth. One or more valves may need to be opened so
that respective components transfer into the gun assembly. Fluid
movers, such as pumps, may be utilized as would be apparent to one
of skill in the art.
[0057] Numerical ranges in this disclosure may be approximate, and
thus may include values outside of the range unless otherwise
indicated. Numerical ranges include all values from and including
the expressed lower and the upper values, in increments of smaller
units. As an example, if a compositional, physical or other
property, such as, for example, molecular weight, viscosity, melt
index, etc., is from 100 to 1,000. it is intended that all
individual values, such as 100, 101, 102, etc., and sub ranges,
such as 100 to 144, 155 to 170, 197 to 200, etc., are expressly
enumerated. It is intended that decimals or fractions thereof be
included. For ranges containing values which are less than one or
containing fractional numbers greater than one (e.g., 1.1, 1.5,
etc.), smaller units may be considered to be 0.0001, 0.001, 0.01,
0.1, etc. as appropriate. These are only examples of what is
specifically intended, and all possible combinations of numerical
values between the lowest value and the highest value enumerated,
are to be considered to be expressly stated in this disclosure.
Numerical ranges are provided within this disclosure for, among
other things, the relative amount of reactants, surfactants,
catalysts, etc. by itself or in a mixture or mass, and various
temperature and other process parameters.
[0058] The term "frac operation" as used herein can refer to
fractionation of a downhole well that has already been drilled.
`Frac operation` can also be referred to and interchangeable with
the terms fractionation, hydraulic fracturing, hydrofracturing,
hydrofracking, fracking, fraccing, and frac. A frac operation can
be land or water based.
[0059] The term "frac fluid" as used herein can refer to a fluid
injected into a well as part of a frac operation. Frac fluid is
often characterized as being largely water, but with other
constituents such as proppant, friction reducers, and other
additives or compounds. `Frac` can be short for fracking,
fracturing and other related terms. The term `frac fluid` can be
analogous to injection fluid, and other comparable terms of the
art. The composition of the frac fluid often depends on numerous
factors, with the ultimate goal being to improve the results of the
frac operation and the productivity of the well. This typically
occurs from the frac fluid being pumped down a wellbore and out
into a subterranean formation in a suitable amount and pressure to
cause fracturing in the surrounding rock.
[0060] The term "water" as used herein can refer to the main
constituent for a frac fluid, and can include fresh water,
seawater, produced water, treated variations thereof, mixes
thereof, etc., and can further include impurities, dissolved
solids, ions, salts, minerals, and so forth. Water for the frac
fluid can also be referred to as `frac water`.
[0061] The term "produced water" as used herein can refer to water
recovered from a subterranean formation or other area near the
wellbore. Produced water can include `flowback water`, which is
water recovered from the subterranean formation after a frac
operation.
[0062] The term "friction reducer" as used herein can refer to a
chemical additive that alters fluid rheological properties to
reduce friction associated with a fluid as it flows through
tubulars or similar restrictions. The use of a friction reducer is
intended to, among other things, reduce losses attributable to the
effects of the friction. A hypothetical example of `loss` can be
the extra energy needed for a pump to pump a fluid without a
friction reducer into a subterranean formation versus the reduced
energy needed to pump the same amount of the same fluid having the
added friction reducer.
[0063] The term "natural polymer-based friction reducer" as used
herein can refer to a friction reducer characterized as having a
`natural` polymer as a constituent. A guar-based polymer (and/or
copolymer) is an example of a natural polymer known to be useful
for a friction reducer. A natural polymer-based friction reducer
may have a characteristic of being cross-linked.
[0064] The term "synthetic polymer-based friction reducer" as used
herein can refer to a friction reducer characterized as having a
`synthetic` or man-made polymer as a constituent. An
acrylamide-based polymer (and/or copolymer) is an example of a
synthetic polymer known to be useful for a friction reducer.
[0065] The term "crosslinked" as used herein can refer to polymer
chains that have multiple bonds, such as covalent or ionic bonds,
linking them together. Cross-links in chains can be formed by
initiating a chemical reaction, including with various mediums such
as heat, pressure, change in pH, radiation, and so forth. For
example, mixing of an unpolymerized or partially polymerized resin
with specific chemicals (e.g., crosslinking reagents) can result in
a chemical reaction that forms cross-links.
[0066] The term "proppant" as used herein can refer to particulate
material added to a frac fluid that is ultimately intended to
maintain space between in the formed fractures.
[0067] The term "slickwater" (or "slick water") as used herein can
refer to a frac fluid having a synthetic polymer-based friction
reducer. Conventional slickwater frac fluid solutions can be
characterized as having lower viscosity and proppant carrying
capability, including significantly so.
[0068] The term "chemical" as used herein can analogously mean or
be interchangeable to material, chemical material, ingredient,
component, chemical component, element, substance, compound,
chemical compound, molecule(s), constituent, and so forth and vice
versa. Any `chemical` discussed in the present disclosure need not
refer to a 100% pure chemical. For example, although `water` may be
thought of as H2O, one of skill would appreciate various ions,
salts, minerals, impurities, and other substances (including at the
ppb level) may be present in `water`. As used with respect to a
chemical, unless specifically indicated otherwise, the singular
includes all isomeric forms and vice versa (for example, "hexane",
includes all isomers of hexane individually or collectively).
[0069] The term "salt" as used herein can refer to an ionic
compound. A salt can be formed via a neutralization reaction. A
salt can be electrically neutral (i.e., no net charge).
[0070] The term "acrylamide" as used herein can be a material
identified by CAS Number 79-06-01.
[0071] The term "polyacrylamide" (or `PAM`) as used herein can be a
material identified by CAS Number 9003-05-08. PAM can be
synthesized as a linear copolymer, can be crosslinked, and can be
part of a copolymer.
[0072] The term "monomer" as used herein can refer to a chemical
(or material thereof) characterized as having a molecule (or unit)
that can bind to other molecules. Large numbers of monomer units
can bind to form polymers. Small numbers of monomer units can
combine to form oligomers.
[0073] The term "oligomer" as used herein can refer to a molecular
complex having a few monomer units (e.g., dimers--two monomers,
trimers--three monomers, tetramers--four monomers, etc.).
[0074] The term "polymer" as used herein can refer to large
molecule (or material thereof) having linked (bonded) monomer units
linked. A polymer can be considered to be a chain of monomer units.
A polymer can be composed of one or more monomers. Copolymers can
refer to a molecule (or material thereof) having two monomers. The
polymer chain may be linear or branched. A polymer can be anionic,
cationic, non-ionic, and in some instances be a combination. For
example, a copolymer may have anionic and cationic properties.
`Polymer` may refer to copolymer.
[0075] The term "polymeric", "polymer-based", and the like can
refer to a chemical (or material thereof) made of a polymer.
"Polymeric-based" as used herein can refer to a chemical or
chemical blend (or material thereof) that includes or has a
polymeric constituent as part of its compositional makeup. The
chemical or blend may be referred to as a composition of matter.
The polymeric constituent can be, but need not have to be,
copolymeric.
[0076] The term "splits", "dry splits", "Guar Gum Split", "guar
gum", and other comparable known nomenclature, as used herein can
refer to commercially dry guar splits which contain less than 10%
moisture. Splits may contain greater or lesser amounts of hull
material, the better quality having the lesser amount of hull.
Splits can refer to the mucilage found in the seed of the
leguminous plant Cyamopsis Tetragonoloba, essentially being refined
endosperm derived from the guar seed or cluster bean. It is a
non-ionic polysaccharide galacomannan.
[0077] The term "hydroxypropyl guar" or "HPG" as used herein can
refer to a guar derivative, or a material made from guar. HPG can
refer to a propylene glycol ether of guar gum.
[0078] The term "high-brine" as used herein can refer to a brine
solution having between about 100K ppm to about 300K ppm TDS.
[0079] Embodiments herein may pertain to a process for making
and/or using a ground product composition of matter. The process
may include a reactor operated with a reaction temperature range of
120.degree. F. to 180.degree. F. The guar split and an at least one
reagent may be fed to, and reacted within, the reactor to form a
guar derivative.
[0080] The process may include a transfer and treatment section
operably coupled with the reactor. Accordingly, the guar derivative
may be treated and/or transferred.
[0081] There may be a co-grinder operably associated with the
transfer and treatment section. In aspects, the guar derivative
(which may be a treated guar derivative) may be transferred
thereto.
[0082] The co-grinder may be fed an acid. The co-grinder may
operate to grind the guar derivative and the acid together to form
a ground product. The ground product may be characterized by or
have the physical property of at least 90% by weight of a given
quantity thereof having an average particle bulk diameter less than
or equal to 74 microns.
[0083] The process may include a heated vacuum system operably
associated with the co-grinder. The heated vacuum system may
include one or more of: a combustion burner; a dust collector
configured for use as a dryer; and a blower configured for pulling
a vacuum.
[0084] The reactor may be a batch reactor. The reactor may be
operated with a batch reaction time in the range of 1.5 hours to
2.5 hours.
[0085] The process may include a caustic feed source comprising a
caustic material. The caustic feed source may be in communication
with the reactor. Accordingly, the caustic material may be fed to
the reactor. The acid may be powdered carboxylic acid.
[0086] The process may include one or more mixers, which may be
(but need not be) inline or static mixers. The process may thus
include such a first blend mixer. The first blend mixer may be
operated to mix the ground product (optionally treated prior
thereto) with an at least one other constituent to form a blend
product.
[0087] The process may include another mixer, such as a second
blend mixer. The second blend mixer operated to mix each of the
blend product with a water stream fed thereto. The water stream may
have a salinity value in the range of about 100,000 ppm to about
300,000 ppm total dissolved solids (TDS).
[0088] In aspects, the ground product may be in substantially dry
powdered form. In other aspects, the ground product may be in
slurry or liquidious form.
[0089] The process may have a plurality of predetermined operating
parameters. The process may include the combustion burner operated
with a combustion temperature output of about 400.degree. F. to
about 600.degree. F. In aspects, the burner is operated with the
combustion temperature output of about 600.degree. F. The
co-grinder may be operated with an exhaust temperature in a range
of about 175.degree. F. to about 185.degree. F. The dust collector
may be operated with an exhaust temperature range of about
170.degree. F. to about 175.degree. F.
[0090] The process may include a hydration unit. The hydration unit
may be operated to hydrate at least about 80% of the ground product
in one minute or less.
[0091] Yet other embodiments of the disclosure pertain to a process
for making and/or using a ground product composition of matter that
may include a reactor. The reactor may be operated with a reaction
temperature range of 120.degree. F. to 180.degree. F.
[0092] In aspects, each of a guar split and at least one reagent
may be fed to, and reacted within, the reactor to form a guar
derivative.
[0093] The process may include a transfer and treatment section
operably coupled with the reactor. In this respect, the guar
derivative may be optionally treated, and transferred, such as to a
co-grinder.
[0094] The co-grinder may be operably associated with the transfer
and treatment section. The guar derivative (which may be optionally
treated) may be transferred thereto. The co-grinder may also be fed
a powdered acid (such as from an acid source). The co-grinder may
operate to grind the guar derivative and the acid together to form
a ground product.
[0095] In aspects, the ground product may be characterized by (or
have the physical property of) at least 90% by weight of a given
quantity thereof having an average particle bulk diameter less than
or equal to 74 microns.
[0096] The co-grinder may be operated with an exhaust temperature
in a range of about 175.degree. F. to about 185.degree. F.
[0097] The process may include a vacuum system operably associated
with the co-grinder. The vacuum system may include one or more of:
a combustion burner, a dust collector, and a blower. In aspects,
the dust collector may be operated as dryer to dry the ground
product. The blower may be operated to pull a vacuum on at least
one of the reactors and the co-grinder.
[0098] The guar derivative may be formed with the reactor operating
with a reaction time in the range of 1.5 hours to 2.5 hours.
[0099] The process may include a caustic feed source comprising a
caustic material. The caustic feed source may be in communication
with the reactor. The caustic material may be fed to the reactor.
The powdered acid may include carboxylic acid.
[0100] The process may include one or more mixers, any of which may
be inline, static, and so forth. Thus, there may be a first blend
mixer. In aspects, the first blend mixer may be operated to mix the
ground product with an at least one other constituent to form a
blend product.
[0101] The process may include another or a second blend mixer. The
second blend mixer may be operated to mix either or both of the
blend product and the ground product with a water stream. The water
stream may have a range of about 100,000 ppm to about 300,000 ppm
total dissolved solids (TDS).
[0102] In aspects, the ground product may be in substantially dry
powdered form.
[0103] In aspects, the ground product may be in slurry or
liquidious form.
[0104] The combustion burner may be operated with a combustion
temperature output of about 400.degree. F. to about 700.degree. F.
In aspects, the combustion temperature output may be about
600.degree. F.
[0105] The process may include a hydration unit. The hydration unit
may be operated to hydrate at least about 80% of the ground product
in one minute or less.
[0106] Referring now to FIG. 1, an overview flow diagram of a
process for making a composition of matter, in accordance with
embodiments disclosed herein, is shown. FIG. 1 illustrates a
process 100 suitable for making a chemical product 128 a/b
(a-solid, b-liquidious) that may be polymeric-based. The product
128 a/b may equivalently be referred to as `final product`, `blend
product`, `composition of matter`, `additive`, and other comparable
variations. The composition of matter may be a polymeric-based frac
fluid additive.
[0107] In this respect the product 128 a/b may be a composition of
matter that includes a polymer. Although the use of the product 128
a/b is not meant to be limited, the blend product 128 a/b may be
suitable for use as an additive into a water stream (or `frac
water`) 123, subsequently forming a frac fluid 125. One of skill in
the art would appreciate that the term `frac fluid` can have a wide
meaning, but typically entails a liquid stream--largely water--with
various additives added (mixed) therein that is then pumped or
injected into a subterranean formation. In aspects, the product 128
a/b may be added into the water 123. The product 128 a/b added may
be in solid (a) or liquid (b) form.
[0108] The product 128 a/b may be added into the water stream 123
in any manner known in the art, including `onsite` at a surface
facility associated with a frac operation. The product 128 a/b may
be characterized as being a friction-reducer whereby the resultant
frac fluid 125 may have characteristics of or otherwise promote
lower or reduced friction losses as compared to what the fluid 125
would be without the product 128 a/b. The product 128 a/b may be
characterized as being a viscosity builder, whereby the resultant
frac fluid 125 may have greater proppant carrying capability as
compared to what the fluid 125 would be without the product 128
a/b. In aspects, the product 128 a/b may be synergistically
characterized as being both a friction reducer and a viscosity
builder.
[0109] j The process 100 has been successfully utilized to make the
desirous product 128 a/b, which has been unexpectedly found to be a
suitable and desirable alternative to synthetic polymer-based
additives especially in the presence of high brine solutions. Thus,
in embodiments, the stream 123 may be a high brine solution.
Preliminary Reaction
[0110] Preliminary reaction step 104 may include mixing a `Split`
(i.e., guar gum) 102, like that provided by and made commercially
available by the Applicant, with other materials, which may include
materials useful for forming a guar derivative 112. As just one
example, the split 102 may be reacted with a reagent 108, such as
propylene oxide. The reaction step 104 may include an aqueous
reaction, and thus use water 110, and may further use a catalyst
106 suitable for making guar derivatives, such as caustic (sodium
hydroxide). The reaction step 104 may utilize known reactive
methods and conditions for forming the derivative 112. In
embodiments, the derivative 112 may be hydroxypropyl guar or `HPG`,
which may be formed from an aqueous reaction between the split 102
and propylene oxide. The forming of HPG may further include use of
sodium hydroxide.
[0111] The reaction step 104 may occur in a batch or continuous
process, as may be desired. Step 104 may include reagents mixed
together with heat and/or agitation. Heating may be in the range of
about 120.degree. F. to about 180.degree. F. The reaction step 104
may produce at least an 80% yield of guar derivative 112. In
aspects, the yield of resultant derivative may be about 80% to
about 95%. Residence or batch reaction time may be about 2 hours,
although the time of reaction may be varied to promote a desired
yield. In embodiments, the reaction time is about 1.5 hours to
about 2.5 hours. The guar derivative 112 may be of at least 80%
purity.
[0112] Reaction step 104 may occur in an oxygen-free environment.
Thus, reaction step 104 may include a vacuum purge. The reaction
step 104 may occur in a jacketed pressure vessel.
[0113] The guar derivative 112 may be further processed via a
secondary treatment step 114 resulting in treated derivative 118,
which may be (although not required) higher purity then derivative
112. `Treatment` is not meant be limited in the sense that
derivative 112 may be treated, processed, reacted, etc. in whatever
manner may be desired or applicable for process 100. Moreover, the
treatment step 114 may include multiple treatments. In a
non-limiting example, the guar derivative 112 may be HPG, which may
be further washed, and then dried to result in a treated HPG
powder.
[0114] In embodiments, derivative 112 may be conveyed to a washing
section using bean flow control with a weir overflow. After
treatment, the intermediate derivative may be transferred, such as
by pumping, to shaker configured with a mesh screen. The shaker may
be suitable to de-water and classify the derivative.
[0115] The intermediate derivative may be transferred to a second
wash. For example, by using a weir overflow into a Sharples P-2000
decanter centrifuge containing a discharge beech.
[0116] The resultant derivative 118 may be characterized as having
a certain degree of substitution. The amount of reagent 108 may be
adjusted to achieve a desired degree of substitution in the
derivative 118.
Co-Grinding
[0117] The resultant derivative 118 may have a gooey, pasty
appearance. The derivative 118 may be fed (i.e., transferred,
pumped, etc.) to a co-grinding step 122 where it may be mixed with
another material 120, which may be an acid.
[0118] Grinding 122 may occur via a grinder as would be known to
one of skill in the art, such as with a Hammermill. In embodiments,
derivative 118 may be collected and fed via a volumetric feeder
into a Pulva Hammermill using a 0.015 wedgewire screen for a first
pulverizing. Co-grinding step 122 may be occur in a batch or
continuous manner Although co-grinding may occur in substantially
dry conditions, it is within the scope of the disclosure that some
amount of moisture may be present. In embodiments, grinding step
122 may take place in a heated vacuum system. The vacuum system may
include one or more of a combustion burner, a micropulsair dust
collector (suitable for use as a dryer), and a blower (suitable for
pulling a vacuum).
[0119] `Co`-grinding in this sense refers to the grinding together
of at least two constituents, in this case the derivative 118 and
material 120. Although not meant to be limited to any particular
material or acid, suitable acid examples include carboxylic acids
(saturated or unsaturated), such as acrylic acid (or propanoic
acid), and other organic acids, such as citric, fumaric, and so
forth.
[0120] After the grinding step, co-ground product 124 may be
dried.
[0121] It has been unexpectedly discovered that the co-grinding
step 122 may be beneficial to the overall process 100 and product
128 a/b.
[0122] Typically, fast hydration is especially important in
oilfield stimulations, the standard technique being to hydrate a
product to full hydration in a large hydration tank as quickly as
possible so as to waste as little product as possible. Rapid
hydration also enhances fluid pumping performance. Fast hydrating
guars would be advantageous to simplify the hydration process by
eliminating the conventional hydration unit or minimizing it to a
very small volume.
[0123] Also, by eliminating the hydration unit or minimizing the
size of the hydration unit, better real-time control of the
fracturing operation could be achieved. Also, fast hydrating
product 128 a/b could be added directly in water, a brine, etc. as
a powder or dispersed in a solvent and then added to water or other
hydrating fluid such as brine.
[0124] With respect to guar, and particularly HPG, HPG is normally
reacted under caustic conditions; the caustic acts as the catalyst
for the reaction with propylene oxide. The resultant product is
normally washed after that reaction, but ultimately some caustic
remains, which inhibits the hydration of HPG.
[0125] It has been unexpectedly discovered that co-grinding
powdered acid with powdered HPG may result in a co-ground product
124 having a reduced or lower pH, which may be useful for speeding
up hydration rates. Moreover, because acid may be added via step
122, a downstream customer is beneficially alleviated from having
to add acid.
[0126] The co-ground product 124 may be ground until a
predetermined particle size. In embodiments, the co-ground product
124 may have an average particle bulk diameter whereby at least 90%
by weight of a given quantity thereof passes through 200-mesh
screen (comparably .ltoreq.74 microns). Thus, for example, if 10
lbs. of co-ground product 124 was processed through a 200-mesh
screen (which may further be agitated or shaken), at least 9 lbs.
of product 124 would pass therethrough. In embodiments, co-ground
product 124 may gravity fall through a polishing mill for a final
sizing specification.
[0127] Material moisture content of product 124 and general
production speed may be dictated by regulating the combustion
exhaust temperature of the combustion burner. This may occur by
addition or extraction of hydrated bean using volumetric feeder
speed control.
[0128] In a non-limiting example, the vacuum system may have
parameters of an average operating combustion temperature output of
about 600.degree. F., a grinder exhaust temperature in a range of
about 175.degree. F. to about 185.degree. F., and a dust collector
exhaust temperature range of about 170.degree. F. to about
175.degree. F.
Powder/Liquid Processing
[0129] The resultant product 124, or parts thereof, of the
co-grinding step 122 may be fed to a processing step 126.
Optionally, the co-ground product 124 may be further processed or
treated via step 126, which may include settling, washing, drying,
wetting, sifting, separating, heating, mixing and any other
processing desired to achieve either or both of a dry product 128a
or wet/liquidious product 128b.
[0130] The dry product 128a may be that which has less than 5%
moisture. The wet product 128b may be organic-based, such as a
slurrified mixture of resultant product 124 and oil. The wet
product 128b may be a homogeneous mixture of about 40% to about 60%
by weight of product 124.
Hydration and Final Product
[0131] Either of dry product 128a and wet product 128b may be
hydrated.
[0132] The product 128 a/b may be hydrated upon mixing with water
stream 123. The product 128 a/b may have particles of the size
according to embodiments herein. In aspects, the individual polymer
molecule chains may be tangled, folded, and compacted together.
Hydration of the product 128 a/b may include mixing the product 128
a/b with a liquid such as water to expand, separate, untangle, and
solubilize the polymer chains. As the polymer hydrates, its
molecules unfold into long chains. In general, it may be desirous
to hydrate the polymer completely without breaking or damaging the
polymer chains with excess shear forces in the mixing process in
order to achieve the highest degree of desired product
characteristics.
[0133] A particular characteristic of interest is hydration rate.
In aspects, the product 128 a/b may be able to be hydrated at least
about 80% in about one minute or less, or "fast" hydrating. The
characteristic may be tested and evaluated by measuring viscosity.
That is, a fluid may be tested for viscosity. For example, if a
fully hydrated product results in a fluid viscosity of about 100
cp, then a product hydrated to about 80% would have a viscosity of
about 80 cp.
[0134] Fast hydrating means a much smaller footprint is needed for
a hydrating unit.
[0135] As shown the product 128 a/b may be mixed with a water
stream 123. The product 128 a/b may be referred to as a composition
of matter. The water stream 123 may be any type of water (e.g.,
river water, fresh water, sea water, produced water, etc.) suitable
for forming the frac fluid 125. Although not meant to be limited,
typically the water-additive mixing step 132 may occur onsite at a
frac operation. One of skill would appreciate the mixing step 132
may occur via an inline mixer where the resultant frac fluid 125 is
immediately injected (pumped) into the wellbore. Just the same, the
frac fluid 125 may be maintained in a storage tank. It is within
the scope of the disclosure that the composition of matter stream
128 a/b may be further processed, treated, etc. prior to the mixing
step 132.
[0136] The product 128 a/b may have a composition of HPG and acid.
The concentration of the product 128 a/b (which may be in the form
of liquid, liquidous, slurry, or dry solid) in the frac fluid 125
may determine the traits associated with the frac fluid 125. The
product 128 a/b desired may depend on the salinity of the water
stream 123 available for the frac operation. In embodiments, the
blend 128 a/b may be suitable for a salinity value of the water
stream 123 in the range of about 100,000 ppm to about 300,000 ppm
total dissolved solids (TDS).
[0137] Referring now to FIG. 2, a process flow diagram of a system
for making and using a composition of matter, in accordance with
embodiments disclosed herein, is shown. FIG. 2 illustrates an
operative system 200 suitable for the process shown in FIG. 1 (and
as described in the accompanying text). Unless expressed otherwise,
aspects of system 200 may be like that of the process 100, and thus
may only be described in brevity. For example, system 200 may be
operated to provide or otherwise produce a chemical blend product
228 a/b that may be polymeric-based and like that of blend 128 a/b.
The product 228 a/b may equivalently be referred to as `final
product`, `composition of matter`, `additive`, and other comparable
variant nomenclature. However, that is not to say that system 200
may not have differences from that of the process.
[0138] The composition may be a polymeric-based frac fluid
additive. In this respect the product 228 a/b may be a composition
of matter that includes a polymer. Although the use of the product
228 a/b is not meant to be limited, the blend product 228 a/b may
be suitable for use as an additive into a water stream (or `frac
water`) 223, subsequently forming a frac fluid 225. One of skill in
the art would appreciate that the term `frac fluid` can have a wide
meaning, but typically entails a liquid stream--largely water--with
various additives added (mixed) therein that is then pumped or
injected into a subterranean formation. In aspects, the product 228
a/b may be added into the water 223. The product 228 a/b added may
be in solid (a) or liquid (b) form.
[0139] The product 228 a/b may be added into the water stream 223
in any manner known in the art, including `onsite` at a surface
facility associated with a frac operation. The product 228 a/b may
be characterized as being a friction-reducer whereby the resultant
frac fluid 225 may have characteristics of or otherwise promote
lower or reduced friction losses as compared to what the fluid 225
would be without the product 228 a/b. The product 228 a/b may be
characterized as being a viscosity builder, whereby the resultant
frac fluid 225 may have greater proppant carrying capability as
compared to what the fluid 225 would be without the product 228
a/b. In aspects, the product 228 a/b may be synergistically
characterized as being both a friction reducer and a viscosity
builder.
[0140] The system 200 has been successfully utilized to make the
desirous product 228 a/b, which has been unexpectedly found to be a
suitable and desirable alternative to synthetic polymer-based
additives especially in the presence of high brine solutions. Thus,
in embodiments, the stream 223 may be a high brine solution.
Preliminary Reaction
[0141] The operation of a reactor 204 may include mixing a `Split`
(i.e., guar gum) 202, like that provided by and made commercially
available by the Applicant, with other materials, which may include
materials useful for forming a guar derivative 212 product. As just
one example, the split 202 may be reacted with a reagent 208, such
as propylene oxide. The reactor 204 may include or be used for an
aqueous reaction, and thus use water 210, and may further use a
catalyst 206 suitable for making guar derivatives, such as caustic
(sodium hydroxide). The reactor 204 may utilize known reactive
methods and conditions for forming the derivative 212. In
embodiments, the derivative 212 may be hydroxypropyl guar or `HPG`,
which may be formed from an aqueous reaction between the split 202
and propylene oxide. The forming of HPG may further include use of
sodium hydroxide.
[0142] The reactor 204 may operate in a batch or continuous
process, as may be desired. The reaction within reactor 204 may
include reagents mixed together with heat and/or agitation. Heating
may be in the range of about 120.degree. F. to about 180.degree. F.
The product from the reaction within reactor 204 may produce at
least an 80% yield of a guar derivative 212. In aspects, the yield
of resultant derivative may be about 80% to about 95%. Residence or
batch reaction time may be about 2 hours, although the time of
reaction may be varied to promote a desired yield. The guar
derivative 212 may be of at least 80% purity.
[0143] The reaction within reactor 204 may occur in an oxygen-free
environment. Thus, the reactor may include or be operably
associated with a vacuum purge. The reactor may be a jacketed
pressure vessel.
[0144] The guar derivative 212 may be further processed via a
secondary treatment operation 214 resulting in treated derivative
218, which may be (although not required) higher purity then
derivative 212. `Treatment` is not meant be limited in the sense
that derivative 212 may be treated, processed, reacted, etc. in
whatever manner may be desired or applicable for system 200.
Moreover, the treatment operation 214 may include multiple
treatments. In a non-limiting example, the guar derivative 212 may
be HPG, which may be further washed, and then dried to result in a
treated HPG powder.
[0145] In embodiments, derivative 212 may be conveyed to a washing
section using bean flow control with a weir overflow. After
treatment, the intermediate derivative may be transferred, such as
by pumping, to shaker configured with a mesh screen. The shaker may
be suitable to de-water and classify the derivative.
[0146] The intermediate derivative may be transferred to a second
wash. For example, by using a weir overflow into a Sharples P-2000
decanter centrifuge containing a discharge beech.
[0147] The resultant derivative 218 may be characterized as having
a certain degree of substitution. The amount of reagent 208 may be
adjusted to achieve a desired degree of substitution in the
derivative 218.
Co-Grinding
[0148] The resultant derivative 218 may have a gooey, pasty
appearance. The derivative 218 may be fed (i.e., transferred,
pumped, etc.) to a co-grinder 222 where it may be mixed with
another material 220, which may be an acid.
[0149] Grinder 222 may be a typical grinder as would be known to
one of skill in the art, such as with a Hammermill. In embodiments,
derivative 218 may be collected and fed via a volumetric feeder
into a Pulva Hammermill using a 0.015 wedgewire screen for a first
pulverizing. Co-grinder 222 may be operated in a batch or
continuous manner Although co-grinding may occur in substantially
dry conditions, it is within the scope of the disclosure that some
amount of moisture may be present. In embodiments, grinder 222 may
include or be operably associated with a heated vacuum system. The
vacuum system may include one or more of a combustion burner, a
micropulsair dust collector (suitable for use as a dryer), and a
blower (suitable for pulling a vacuum).
[0150] `Co`-grinding in this sense refers to the grinding together
of at least two constituents, in this case the derivative 218 and
material 220. Although not meant to be limited to any particular
material or acid, suitable acid examples include carboxylic acids
(saturated or unsaturated), such as acrylic acid (or propanoic
acid), and other organic acids, such as citric, fumaric, and so
forth.
[0151] After grinding, co-ground product 224 may be dried.
[0152] It has been unexpectedly discovered that the use of
co-grinder 222 in a particular manner may be beneficial to the
overall process 200 and product 228 a/b.
[0153] Typically, fast hydration is especially important in
oilfield stimulations, the standard technique being to hydrate a
product to full hydration in a large hydration tank as quickly as
possible so as to waste as little product as possible. Rapid
hydration also enhances fluid pumping performance. Fast hydrating
guars would be advantageous to simplify the hydration process by
eliminating the conventional hydration unit or minimizing it to a
very small volume.
[0154] Also, by eliminating the hydration unit or minimizing the
size of the hydration unit, better real-time control of the
fracturing operation could be achieved. Also, fast hydrating
product 228 a/b could be added directly in water, a brine as a
powder or dispersed in a solvent and then added to water or other
hydrating fluid such as brine.
[0155] With respect to guar, and particularly HPG, HPG is normally
reacted under caustic conditions; the caustic acts as the catalyst
for the reaction with propylene oxide. The resultant product is
normally washed after that reaction, but ultimately some caustic
remains, which inhibits the hydration of HPG.
[0156] It has been expectedly discovered that co-grinding powdered
acid with powdered HPG may result in a co-ground product 224 having
a reduced or lower pH, which may be useful for speeding up
hydration rates. Moreover, because acid may be added into the
co-grinder 222, a downstream customer is beneficially alleviated
from having to add acid.
[0157] The co-ground product 224 may be ground until a
predetermined particle size. In embodiments, the co-ground product
224 may have an average particle bulk diameter whereby at least 90%
by weight of a given quantity thereof passes through 200-mesh
screen (comparably .ltoreq.74 microns). Thus, for example, if 10
lbs. of co-ground product 224 was processed through a 200-mesh
screen (which may further be agitated or shaken), at least 9 lbs.
of product 224 would pass therethrough. In embodiments, co-ground
product 224 may gravity fall through a polishing mill for a final
sizing specification.
[0158] Material moisture content of product 224 and general
production speed may be dictated by regulating the combustion
exhaust temperature of the combustion burner. This may occur by
addition or extraction of hydrated bean using volumetric feeder
speed control.
[0159] In a non-limiting example, the vacuum system may have
parameters of an average operating combustion temperature output of
about 600.degree. F., a grinder exhaust temperature in a range of
about 175.degree. F. to about 185.degree. F., and a dust collector
exhaust temperature range of about 170.degree. F. to about
175.degree. F.
Powder/Liquid Processing
[0160] The resultant product 224, or parts thereof, from the
co-grinder 222 may be fed to a subsequent processing operation.
Optionally, the co-ground product 224 may be further processed or
treated via operation 226, which may include one or more of
settling, washing, drying, wetting, sifting, separating, heating,
mixing and any other processing desired to achieve either or both
of a dry product 228a or wet/liquidious product 228b.
[0161] The dry product 228a may be that which has less than 5%
moisture. The wet product 228b may be organic-based, such as a
slurrified mixture of resultant product 224 and oil. The wet
product 228b may be a homogeneous mixture of about 40% to about 60%
by weight of product 224.
Hydration and Final Product
[0162] Either of dry product 228a and wet product 228b may be
hydrated.
[0163] The product 228 a/b may be hydrated upon mixing with a water
stream 223. The product 228 a/b may have particles of the size
according to embodiments herein. In aspects, the individual polymer
molecule chains may be tangled, folded, and compacted together.
Hydration of the product 228 a/b may include mixing the product 228
a/b with a liquid such as water to expand, separate, untangle, and
solubilize the polymer chains. As the polymer hydrates, its
molecules unfold into long chains. In general, it may be desirous
to hydrate the polymer completely without breaking or damaging the
polymer chains with excess shear forces in the mixing process in
order to achieve the highest degree of desired product
characteristics.
[0164] A particular characteristic of interest is hydration rate.
In aspects, the product 228 a/b may be able to be hydrated at least
about 80% in about one minute or less, or "fast" hydrating. The
characteristic may be tested and evaluated by measuring viscosity.
That is, a fluid may be tested for viscosity. For example, if a
fully hydrated product results in a fluid viscosity of about 100
cp, then a product hydrated to about 80% would have a viscosity of
about 80 cp.
[0165] Fast hydrating means a much smaller footprint is needed for
a hydrating unit.
[0166] As shown the product 228 a/b may be mixed with a water
stream 223. The product 228 a/b may be referred to as a composition
of matter. The water stream 123 may be any type of water (e.g.,
river water, fresh water, sea water, produced water, etc.) suitable
for forming the frac fluid 225. Although not meant to be limited,
typically the water-additive mixing may occur in a mixer 232, which
may occur onsite at a frac operation. One of skill would appreciate
the mixer 232 may be an inline mixer where the resultant frac fluid
225 may be immediately injected (pumped) into the wellbore (not
shown here). Just the same, the frac fluid 225 may be maintained in
a storage tank (not shown here). It is within the scope of the
disclosure that the composition of matter stream 228 a/b may be
further processed, treated, etc. prior to being fed to the mixer
232.
[0167] The product 228 a/b may have a composition of HPG and acid.
The concentration of the product 228 a/b (which may be in the form
of liquid, liquidous, slurry, or dry solid) in the frac fluid 225
may determine the traits associated with the frac fluid 225. The
product 228 a/b desired may depend on the salinity of the water
stream 223 available for the frac operation. In embodiments, the
blend 228 a/b may be suitable for a salinity value of the water
stream 223 in the range of about 100,000 ppm to about 300,000 ppm
total dissolved solids (TDS).
Advantages
[0168] Embodiments herein advantageously provide for a composition
of matter that has fast hydration characteristics and can also be
readily storable and transportable in powder form. Dry HPG is
beneficial for friction reducing in rugged conditions, such as
high-brine. Dry HPG as a friction reducer provides benefits over
polyacrylamides, because it can be readily stored, transported,
used, and/or hydrated from its powder form. Hydration need not
require large amounts of time or cost-prohibitive equipment.
[0169] Embodiments herein provide for a cost-effective, expedient,
and scalable process that can be used to make a dry, natural
polymer-based friction-reducer additive for a frac fluid,
particularly for high-brine.
[0170] While embodiments of the disclosure have been shown and
described, modifications thereof can be made by one skilled in the
art without departing from the spirit and teachings of the
disclosure. The embodiments described herein are exemplary only and
are not intended to be limiting. Many variations and modifications
of the disclosure presented herein are possible and are within the
scope of the disclosure. Where numerical ranges or limitations are
expressly stated, such express ranges or limitations should be
understood to include iterative ranges or limitations of like
magnitude falling within the expressly stated ranges or
limitations. The use of the term "optionally" with respect to any
element of a claim is intended to mean that the subject element is
required, or alternatively, is not required. Both alternatives are
intended to be within the scope of any claim. Use of broader terms
such as comprises, includes, having, etc. should be understood to
provide support for narrower terms such as consisting of,
consisting essentially of, comprised substantially of, and the
like.
[0171] Accordingly, the scope of protection is not limited by the
description set out above but is only limited by the claims which
follow, that scope including all equivalents of the subject matter
of the claims. Each and every claim is incorporated into the
specification as an embodiment of the present disclosure. Thus, the
claims are a further description and are an addition to the
preferred embodiments of the disclosure. The inclusion or
discussion of a reference is not an admission that it is prior art
to the present disclosure, especially any reference that may have a
publication date after the priority date of this application. The
disclosures of all patents, patent applications, and publications
cited herein are hereby incorporated by reference, to the extent
they provide background knowledge; or exemplary, procedural or
other details supplementary to those set forth herein.
* * * * *