US20160312099A1 - Method of Enhancing Hydration of Viscosifiers Using Controlled Mechanically Induced Cavitation - Google Patents
Method of Enhancing Hydration of Viscosifiers Using Controlled Mechanically Induced Cavitation Download PDFInfo
- Publication number
- US20160312099A1 US20160312099A1 US15/135,745 US201615135745A US2016312099A1 US 20160312099 A1 US20160312099 A1 US 20160312099A1 US 201615135745 A US201615135745 A US 201615135745A US 2016312099 A1 US2016312099 A1 US 2016312099A1
- Authority
- US
- United States
- Prior art keywords
- viscosifier
- mixture
- solvent
- cavitation
- powdered
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/02—Well-drilling compositions
- C09K8/03—Specific additives for general use in well-drilling compositions
- C09K8/035—Organic additives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
- B01J8/08—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with moving particles
- B01J8/10—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with moving particles moved by stirrers or by rotary drums or rotary receptacles or endless belts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
- B01F23/50—Mixing liquids with solids
- B01F23/53—Mixing liquids with solids using driven stirrers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
- B01F27/27—Mixers with stator-rotor systems, e.g. with intermeshing teeth or cylinders or having orifices
- B01F27/272—Mixers with stator-rotor systems, e.g. with intermeshing teeth or cylinders or having orifices with means for moving the materials to be mixed axially between the surfaces of the rotor and the stator, e.g. the stator rotor system formed by conical or cylindrical surfaces
- B01F27/2722—Mixers with stator-rotor systems, e.g. with intermeshing teeth or cylinders or having orifices with means for moving the materials to be mixed axially between the surfaces of the rotor and the stator, e.g. the stator rotor system formed by conical or cylindrical surfaces provided with ribs, ridges or grooves on one surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J13/00—Colloid chemistry, e.g. the production of colloidal materials or their solutions, not otherwise provided for; Making microcapsules or microballoons
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J19/008—Processes for carrying out reactions under cavitation conditions
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
- B01J8/0015—Feeding of the particles in the reactor; Evacuation of the particles out of the reactor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
- B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
- B01J8/20—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles with liquid as a fluidising medium
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
- B01J2208/00008—Controlling the process
- B01J2208/00575—Controlling the viscosity
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
- B01J2208/00008—Controlling the process
- B01J2208/00654—Controlling the process by measures relating to the particulate material
- B01J2208/00681—Agglomeration
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
- B01J2208/00796—Details of the reactor or of the particulate material
- B01J2208/00805—Details of the particulate material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
- B01J2208/00796—Details of the reactor or of the particulate material
- B01J2208/00823—Mixing elements
- B01J2208/00858—Moving elements
- B01J2208/00867—Moving elements inside the bed, e.g. rotary mixer
Definitions
- This disclosure relates generally to hydration of natural and synthetic polymers, gums, and other viscosifiers and more specifically to enhancing or increasing the efficiency and effectiveness of such hydration using controlled mechanically induced cavitation.
- Viscosity increasing agents are used in many industries from personal care products, to food, to waste treatment, to fossil fuel (oil) drilling muds. Such agents when mixed with a working fluid function to increase or otherwise affect the viscosity or flow characteristics of the fluid so that the fluid is better suited for an intended use. For example, when preparing drilling mud for use in oil drilling operations, a specific viscosity of the mud is desired to maximize the ability of the mud to, for instance, provide a desired hydrostatic pressure; cool and lubricate the drill head assembly; suspend, carry away, and release cuttings; and other functions.
- Dry or powdered viscosifiers which may be natural or synthetic, commonly are used in many industries to prepare viscosity increasing agents.
- a dried polymer powder is used.
- a small amount of polymeric powder such as guar, starch, cellulose, carageenan, xanthan, or acrylic is first hydrated before being used to thicken a fluid.
- Polymer powder consists of small powder particles wherein the individual polymer molecule chains are often tangled, folded, and compacted together. Hydration of the powdered polymer is nothing more than mixing the powdered polymer thoroughly with water to expand, separate, untangle, and solubilize the polymer chains. As the polymer hydrates, its molecules unfold into long chains, which increase fluid viscosity. It is important to hydrate the polymer completely without breaking or damaging the polymer chains with excess shear forces in the mixing process in order to achieve maximum viscosity improvement and product quality at minimum cost.
- Conventional technologies for hydrating polymers to produce viscosifiers generally include mixing powdered polymer with water in a bulk mixer and then allowing the mixture to age in an ager before being added to a fluid to be viscosified.
- Traditional mixers used for this process often expose the polymer molecules to high shear stresses, which can damage and break apart a significant portion of the polymer molecule chains.
- traditional polymer hydrators often attempt reduce polymer chain damage using additional process steps such as, for instance, conducting hydration at elevated temperatures, mixing more slowly for long periods of time, adding secondary solvents to the mixture, or simply adding excess polymer to make up for damage and consequent incomplete hydration.
- Conventional hydration processes also can result in inferior end product quality in the form of a liquid having lumps of un-hydrated powder surrounded by hydrated powder referred to as “fish eyes” in the industry.
- fish eyes are detrimental in many ways, including waste of polymer not contributing to viscosity, cleaning issues, and lack of homogeneity in the final product.
- an improved method for hydrating or activating a viscosity enhancing substance such as a powdered polymer to produce a more effective viscosifier.
- the method includes subjecting a mixture of polymer powder and water or other solvent to intense cavitation-induced pressure fluctuations in a very low shear controlled cavitation environment. This greatly improves the completeness of hydration and results in minimum damage to the resulting hydrated polymer chains.
- the cavitation induced pressure fluctuations serve to straighten, untangle, and stretch the polymer chains more fully, resulting in more complete hydration and viscosity development when compared to conventional shear mixing.
- the very low shear forces results in far less polymer chain breakage and damage than conventional hydration techniques thereby increasing the viscosity enhancing efficiency of the finished viscosifier.
- the method is carried out without heating or adding secondary solvents and can be carried out at commercial flow rates in a continuous process. The result is a very high quality homogeneous viscosifier produced for low cost in commercially usable volumes.
- An apparatus for carrying out the method also is disclosed.
- FIG. 1 is a schematic illustration showing one embodiment of an apparatus that can be used for carrying out improved hydration according to the method of the present invention.
- FIG. 2 is a schematic illustration of how polymer chains of a polymer powder are detangled, separated, and relaxed during the hydration methodology of the present invention.
- FIG. 3 is a photomicrograph comparing the homogeneity or quality of a hydrated polymer resulting from a traditional hydration method with the homogeneity of the same hydrated polymer using the improved method of the present invention.
- FIG. 1 illustrates one embodiment of a controlled cavitation reactor suitable for carrying out the method of the present invention.
- the structure of the reactor is described in detail in U.S. Pat. No. 7,360,755; and that detailed description as well as the entire contents of the '755 patent is hereby incorporated by reference.
- the reference numerals in FIG. 1 are referred to in the incorporated '755 patent and need not be referred to again here.
- FIG. 1 illustrates that water is fed to the controlled cavitation reactor through a port that, in this case, is shown at the bottom of the drawing.
- a powdered viscosifier is fed to the water flow through another port, which in FIG. 1 is shown at the bottom right of the figure.
- the powdered viscosifier commonly a powdered or dehydrated polymer, mixes with and becomes entrained in the flow of water and the mixture enters the controlled cavitation reactor.
- the mixture flows from the sides of the spinning rotor in the reactor shown in FIG. 1 and through the space between the peripheral surface of the rotor and the cylindrical outer wall of the housing. This space is referred to the cavitation zone or the reaction zone.
- shock waves propagate from the bores through the mixture as the mixture flows through the cavitation zone of the controlled cavitation reactor. This in turn sets up high energy microscopic and macroscopic pressure fluctuations within the mixture.
- the shockwaves and pressure fluctuations first separate and disperse individual particles of powder within the mixture allowing solvent (H 2 O molecules) to contact the powder particles on all sides. This maximizes the surface area contact between solvent molecules and polymer chains. As the polymer chains in the particles begin to hydrate with solvent, the pressure fluctuations drive the water molecules into and out of the particles. This, in turn, detangles, releases, separates, and straightens the individual polymer molecule chains found in each particle of the powder.
- Cavitation pressure fluctuations are controlled by controlling the rotation rate of the rotor and other variables so that maximum straightening, separation, and untangling of polymer chains occurs without covalent bond breakage and polymer chain cision. Virtually complete separation and straightening of the polymer chains is achieved with minimum damage to the chains, resulting in maximum viscosity development.
- the low shear environment within the cavitation zone compared to conventional hydration mixers greatly reduces polymer chain breakage. This results in a maximum number of longer polymer chains within the resulting viscosifier, which in turn improves the viscosity enhancing properties of the viscosifier with a minimum use of powder.
- FIG. 2 illustrates the hydration process schematically.
- H 2 O molecules are seen surrounding a particle of polymer powder.
- the particle has been separated and segregated from other powder particles by high energy pressure variations in the cavitation zone so that the H 2 O molecules can surround the particle completely.
- the polymer chains within the particle are bunched together, folded and convoluted, and entangled with each other.
- the H 2 O molecules are forced by the fluctuations and shock waves into and out of the bunched up polymer chains within the powder particle. This very efficiently untangles and separates the polymer chains, straightens them, and disburses them through the mixture. This result is illustrated on the right in FIG. 2 .
- the untangling, separation, and straightening resulting from the method of the present invention is substantially more effective than prior art hydration techniques.
- the inherently low shear environment within the cavitation zone minimizes polymer chain breakage.
- FIG. 3 shows two photomicrographs of a hydrated polymer.
- the image on the left in FIG. 3 shows a hydrated polymer resulting from a traditional mixing and aging technique commonly used for achieving hydration. It is clear in this image that the resulting viscosifier product lacks homogeneity and contains un-hydrated fish eyes that detract from the effectiveness of the product. Not visible in the left image are the broken and damaged polymer chains that have resulted from the relatively high shear forces to which the mixture is subjected in a traditional hydration mixing process.
- the image on the right in FIG. 3 is a photomicrograph of the end product hydrated in a controlled cavitation reactor according to the method of the present invention.
- the product is seen to be far more homogeneous than the product in the left image with very few if any clumps and fish eyes to detract from the effectiveness of the product. Also not visible in the right image are the straight, separated, and uniformly disbursed polymer chains that exhibit very little damage and breakage due to shear forces.
- the controlled cavitation reactor of this invention can be attached as a side stream of an already existing batch hydration process. Alternatively, it can be part of a continuous hydration process acting upon dry powders mixed with water or another solvent or slurries of polymers and other viscosity inducing agents.
- One advantage of the present invention is that the requirement of aging after mixing that is an integral part of many traditional hydration techniques is eliminated. With the present invention, the end product emerges directly from the controlled cavitation reactor fully hydrated and ready to use.
- temperature may be varied as well as rotor speed and concentration of powder within the mixture.
- gum powder particulate grind size also can be varied and that such variations affect the rate at which viscosifiers are hydrated.
Abstract
A method of hydrating a dry powdered viscosifier such as a powdered polymer is disclosed. The method includes mixing the powdered viscosifier with a solvent such as water to form a mixture; moving the mixture through a cavitation zone; inducing energetic shock waves and pressure fluctuations in the mixture by mechanically inducing cavitation events within the mixture, the shock waves and pressure fluctuations untangling, separating, and straightening polymer molecule chains and distributing the chains throughout the mixture, and extracting the resulting hydrated viscosifier from the cavitation zone.
Description
- Priority is hereby claimed to the filing date of U.S. provisional patent application 62/152,604 entitled Method of Enhancing Hydration of Viscosifiers Using Controlled Mechanically Induced Cavitation and filed on Apr. 24, 2015, the content of which is incorporated by reference.
- This disclosure relates generally to hydration of natural and synthetic polymers, gums, and other viscosifiers and more specifically to enhancing or increasing the efficiency and effectiveness of such hydration using controlled mechanically induced cavitation.
- Viscosity increasing agents are used in many industries from personal care products, to food, to waste treatment, to fossil fuel (oil) drilling muds. Such agents when mixed with a working fluid function to increase or otherwise affect the viscosity or flow characteristics of the fluid so that the fluid is better suited for an intended use. For example, when preparing drilling mud for use in oil drilling operations, a specific viscosity of the mud is desired to maximize the ability of the mud to, for instance, provide a desired hydrostatic pressure; cool and lubricate the drill head assembly; suspend, carry away, and release cuttings; and other functions.
- Dry or powdered viscosifiers, which may be natural or synthetic, commonly are used in many industries to prepare viscosity increasing agents. In most cases, a dried polymer powder is used. A small amount of polymeric powder such as guar, starch, cellulose, carageenan, xanthan, or acrylic is first hydrated before being used to thicken a fluid. Polymer powder consists of small powder particles wherein the individual polymer molecule chains are often tangled, folded, and compacted together. Hydration of the powdered polymer is nothing more than mixing the powdered polymer thoroughly with water to expand, separate, untangle, and solubilize the polymer chains. As the polymer hydrates, its molecules unfold into long chains, which increase fluid viscosity. It is important to hydrate the polymer completely without breaking or damaging the polymer chains with excess shear forces in the mixing process in order to achieve maximum viscosity improvement and product quality at minimum cost.
- Conventional technologies for hydrating polymers to produce viscosifiers generally include mixing powdered polymer with water in a bulk mixer and then allowing the mixture to age in an ager before being added to a fluid to be viscosified. Traditional mixers used for this process often expose the polymer molecules to high shear stresses, which can damage and break apart a significant portion of the polymer molecule chains. To address this problem, traditional polymer hydrators often attempt reduce polymer chain damage using additional process steps such as, for instance, conducting hydration at elevated temperatures, mixing more slowly for long periods of time, adding secondary solvents to the mixture, or simply adding excess polymer to make up for damage and consequent incomplete hydration. Conventional hydration processes also can result in inferior end product quality in the form of a liquid having lumps of un-hydrated powder surrounded by hydrated powder referred to as “fish eyes” in the industry. Such fish eyes are detrimental in many ways, including waste of polymer not contributing to viscosity, cleaning issues, and lack of homogeneity in the final product.
- A need exists for an improved method and apparatus for hydrating or activating powdered polymers in the production of viscosifiers that produce an extraordinarily homogeneous and high quality end product with minimum clumping and minimum polymer chain damage, and all without adding cost or process steps to the method. It is to the provision of such a method and an apparatus for carrying out the method that the present invention is primarily directed.
- Briefly described, an improved method is disclosed for hydrating or activating a viscosity enhancing substance such as a powdered polymer to produce a more effective viscosifier. The method includes subjecting a mixture of polymer powder and water or other solvent to intense cavitation-induced pressure fluctuations in a very low shear controlled cavitation environment. This greatly improves the completeness of hydration and results in minimum damage to the resulting hydrated polymer chains. The cavitation induced pressure fluctuations serve to straighten, untangle, and stretch the polymer chains more fully, resulting in more complete hydration and viscosity development when compared to conventional shear mixing. The very low shear forces results in far less polymer chain breakage and damage than conventional hydration techniques thereby increasing the viscosity enhancing efficiency of the finished viscosifier. Also, the method is carried out without heating or adding secondary solvents and can be carried out at commercial flow rates in a continuous process. The result is a very high quality homogeneous viscosifier produced for low cost in commercially usable volumes. An apparatus for carrying out the method also is disclosed.
- These and other aspects, features, and advantages of the invention disclosed herein will become more apparent upon review of the detailed description set forth below taken in conjunction with the accompanying drawing figures, which are briefly described as follows.
-
FIG. 1 is a schematic illustration showing one embodiment of an apparatus that can be used for carrying out improved hydration according to the method of the present invention. -
FIG. 2 is a schematic illustration of how polymer chains of a polymer powder are detangled, separated, and relaxed during the hydration methodology of the present invention. -
FIG. 3 is a photomicrograph comparing the homogeneity or quality of a hydrated polymer resulting from a traditional hydration method with the homogeneity of the same hydrated polymer using the improved method of the present invention. -
FIG. 1 illustrates one embodiment of a controlled cavitation reactor suitable for carrying out the method of the present invention. The structure of the reactor is described in detail in U.S. Pat. No. 7,360,755; and that detailed description as well as the entire contents of the '755 patent is hereby incorporated by reference. The reference numerals inFIG. 1 are referred to in the incorporated '755 patent and need not be referred to again here. With the description of the apparatus ofFIG. 1 from the '755 patent in mind,FIG. 1 illustrates that water is fed to the controlled cavitation reactor through a port that, in this case, is shown at the bottom of the drawing. While water is the most common substance used in hydration, it will be understood that the present invention is not limited to water but is intended to encompass other hydrating fluids, solvents, and mixtures thereof according to the demands of a particular application. With continued reference toFIG. 1 , a powdered viscosifier is fed to the water flow through another port, which inFIG. 1 is shown at the bottom right of the figure. The powdered viscosifier, commonly a powdered or dehydrated polymer, mixes with and becomes entrained in the flow of water and the mixture enters the controlled cavitation reactor. The mixture flows from the sides of the spinning rotor in the reactor shown inFIG. 1 and through the space between the peripheral surface of the rotor and the cylindrical outer wall of the housing. This space is referred to the cavitation zone or the reaction zone. - As the rotor spins, highly energetic cavitation events are created in the mixture within the bores of the rotor and are continuously replenished within the bores. In a cavitation event, a low pressure zone forms a cavitation bubble in the mixture within a bore, and the bubble then collapses and releases a highly energetic shockwave. These shock waves propagate from the bores through the mixture as the mixture flows through the cavitation zone of the controlled cavitation reactor. This in turn sets up high energy microscopic and macroscopic pressure fluctuations within the mixture. The shockwaves and pressure fluctuations first separate and disperse individual particles of powder within the mixture allowing solvent (H2O molecules) to contact the powder particles on all sides. This maximizes the surface area contact between solvent molecules and polymer chains. As the polymer chains in the particles begin to hydrate with solvent, the pressure fluctuations drive the water molecules into and out of the particles. This, in turn, detangles, releases, separates, and straightens the individual polymer molecule chains found in each particle of the powder.
- Cavitation pressure fluctuations are controlled by controlling the rotation rate of the rotor and other variables so that maximum straightening, separation, and untangling of polymer chains occurs without covalent bond breakage and polymer chain cision. Virtually complete separation and straightening of the polymer chains is achieved with minimum damage to the chains, resulting in maximum viscosity development. In addition, the low shear environment within the cavitation zone compared to conventional hydration mixers greatly reduces polymer chain breakage. This results in a maximum number of longer polymer chains within the resulting viscosifier, which in turn improves the viscosity enhancing properties of the viscosifier with a minimum use of powder.
FIG. 2 illustrates the hydration process schematically. On the left, H2O molecules are seen surrounding a particle of polymer powder. As mentioned above, the particle has been separated and segregated from other powder particles by high energy pressure variations in the cavitation zone so that the H2O molecules can surround the particle completely. The polymer chains within the particle are bunched together, folded and convoluted, and entangled with each other. As the mixture is exposed to cavitation induced pressure fluctuations, the H2O molecules are forced by the fluctuations and shock waves into and out of the bunched up polymer chains within the powder particle. This very efficiently untangles and separates the polymer chains, straightens them, and disburses them through the mixture. This result is illustrated on the right inFIG. 2 . As mentioned, the untangling, separation, and straightening resulting from the method of the present invention is substantially more effective than prior art hydration techniques. The inherently low shear environment within the cavitation zone minimizes polymer chain breakage. - Conventional hydration can also result in inferior product quality with lumps of un-hydrated powder surrounded by hydrated powder referred to as “fish eyes” in the industry. These are detrimental in many ways including waste of polymer powder not contributing to viscosity, cleaning issues, and lack of homogeneity in the final product. With the method of the present invention “fish eyes” are obliterated by the highly energetic shock waves and pressure fluctuations within the cavitation zone, allowing for separation, disbursement, and hydration of the powder and chains within the fish eyes. Thus, lost viscosity due to fish eye formation and the general lack of homogeneity resulting from traditional hydration techniques is eliminated.
-
FIG. 3 shows two photomicrographs of a hydrated polymer. The image on the left inFIG. 3 shows a hydrated polymer resulting from a traditional mixing and aging technique commonly used for achieving hydration. It is clear in this image that the resulting viscosifier product lacks homogeneity and contains un-hydrated fish eyes that detract from the effectiveness of the product. Not visible in the left image are the broken and damaged polymer chains that have resulted from the relatively high shear forces to which the mixture is subjected in a traditional hydration mixing process. The image on the right inFIG. 3 is a photomicrograph of the end product hydrated in a controlled cavitation reactor according to the method of the present invention. The product is seen to be far more homogeneous than the product in the left image with very few if any clumps and fish eyes to detract from the effectiveness of the product. Also not visible in the right image are the straight, separated, and uniformly disbursed polymer chains that exhibit very little damage and breakage due to shear forces. - In commercial use, the controlled cavitation reactor of this invention can be attached as a side stream of an already existing batch hydration process. Alternatively, it can be part of a continuous hydration process acting upon dry powders mixed with water or another solvent or slurries of polymers and other viscosity inducing agents. One advantage of the present invention is that the requirement of aging after mixing that is an integral part of many traditional hydration techniques is eliminated. With the present invention, the end product emerges directly from the controlled cavitation reactor fully hydrated and ready to use.
- Lab results have shown an increase in hydration yield of 20-30% with the method of the present invention over traditional hydration techniques. Contact time between particles of powder and the energy applied (which is directly proportional to the rotation rate of the rotor) have proven to be critical factors. Fortunately, the cavitation reactor of the present invention can be controlled precisely and easily to establish and maintain virtually any dwell time and energy input for maximizing the hydration process.
- Using the microscopic and macroscopic pressure fluctuations of cavitation according to the method of this invention allows for many benefits in hydration. Some of these benefits include:
-
- Cost reduction and/or increased viscosity due to higher hydration yield
- Elimination or reduction of the need for costly secondary solvents
- Reduced temperatures required for complete hydration
- Less shear damage due to the low shear environment of the cavitation zone
- Improved homogeneity and thus quality of the final product
- Many parameters may be varied during the process described above to control the rate of hydration. For example, temperature may be varied as well as rotor speed and concentration of powder within the mixture. It has also been found that gum powder particulate grind size also can be varied and that such variations affect the rate at which viscosifiers are hydrated.
- The invention has been described herein in terms and within the context of preferred embodiments and methodologies considered by the inventor to represent the best modes of carrying out the invention. It will be clear to the skilled artisan, however, that a wide gamut of additions, deletions, and modifications both subtle and gross might be made to the illustrative embodiments presented herein without departing from the spirit and scope of the invention.
Claims (18)
1. A method of enhancing hydration of a powdered viscosifier comprising the steps of:
(a) obtaining a powdered viscosifier to be dehydrated;
(b) obtaining a solvent to be used to dehydrate the viscosifier;
(c) combining the viscosifier and the solvent to produce a mixture;
(d) generating cavitation events within the mixture resulting in shock waves and pressure variations that propagate through the mixture;
(e) as a result of step (d), separating the powder particles in the powdered viscosifier allowing the solvent to surround the powder particles;
(f) as a result of step (d) forcing solvent molecules into and out of powder particles to untangle, hydrate, and straighten viscosifier molecule chains contained within the powder particles;
(g) distributing hydrated molecule chains substantially evenly throughout the mixture; and
(h) collecting the resulting mixture.
2. The method of claim 1 where in step (a) the viscosifier comprises a polymer.
3. The method of claim 2 wherein the polymer comprises dehydrated polymer chains.
4. The method of claim 1 where in step (b) the solvent comprises water containing H2O molecules.
5. The method of claim 1 wherein step (c) comprises establishing a flow of the solvent and introducing the powdered viscosifier into the flow of solvent.
6. The method of claim 1 wherein step (d) comprises moving the mixture through the cavitation zone of a controlled cavitation reactor.
7. The method of claim 6 wherein the controlled cavitation reactor comprises a cylindrical housing having an interior wall and a cylindrical rotor having a peripheral surface rotatably mounted in the housing, the cavitation zone being formed between the peripheral surface of the rotor and the interior wall of the housing.
8. The method of claim 7 further comprising bores formed in the peripheral surface of the rotor, and wherein step (d) comprises rotating the rotor within the housing with mixture within the cavitation zone.
9. The method of claim 1 further comprising the step as a result of step (d) of breaking up lumps of powdered viscosifier powder to minimize fish eyes in the mixture.
10. The method of claim 1 further comprising the step of subjecting the mixture to a batch mixing process before step (a).
11. The method of claim 1 further comprising the step of subjecting the mixture to a batch mixing process following step (h).
12. A method of hydrating a viscosifier powder using a solvent, the method comprising the steps of:
(a) establishing a flow of the solvent through an inlet conduit of a controlled cavitation reactor;
(b) introducing the viscosifier powder into the flow of the solvent to produce a mixture of viscosifier powder and solvent flowing through the inlet conduit;
(c) urging the mixture from the conduit into a controlled cavitation reactor having a generally cylindrical housing containing a cylindrical rotating rotor, the housing having an internal cylindrical wall and the rotor having a peripheral surface with radial bores spaced from the internal cylindrical wall to define a cavitation zone therebetween;
(d) moving the mixture through the cavitation zone of the controlled cavitation reactor;
(e) rotating the rotor to induce cavitation events in the mixture within the bores of the rotor, the cavitation events resulting in shock waves and pressure variations within the mixture in the cavitation zone;
(f) as a result of step (e), separating particles of the viscosifier powder and distributing the separated particles substantially uniformly throughout the mixture;
(g) as a result of step (e), forcing molecules of the solvent into and out of the particles of the viscosifier powder to liberate and hydrate viscosifier molecules of the viscosifier; and
(h) directing the hydrated viscosifier out of the controlled cavitation reactor.
13. The method of claim 12 further comprising subjecting the hydrated viscosifier to a batch mixing process following step (h).
14. The method of claim 12 wherein the powdered viscosifier comprises dehydrated polymer chains.
15. The method of claim 14 wherein the solvent comprises water.
16. A method comprising the steps of mixing a powdered viscosifier with a solvent to form a mixture, mechanically inducing cavitation events within the mixture to cause shock waves and pressure variations to propagate through the mixture; separating particles of the powdered viscosifier from each other and distributing the particles throughout the mixture as a result of the shock waves and pressure variations, forcing molecules of the solvent into and out of the separated particles of powdered viscosifier as a result of the pressure variations to liberate viscosifier molecules from the particles, and allowing the viscosifier molecules to interact with the solvent molecules to hydrate the viscosifier.
17. The method of claim 16 wherein the powdered viscosifier comprises dehydrated polymer chains.
18. The method of claim 17 wherein the solvent comprises H2O molecules.
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/135,745 US20160312099A1 (en) | 2015-04-24 | 2016-04-22 | Method of Enhancing Hydration of Viscosifiers Using Controlled Mechanically Induced Cavitation |
US16/148,833 US11155741B2 (en) | 2015-04-24 | 2018-10-01 | Method of enhancing hydration of viscosifiers using controlled mechanically induced cavitation |
US17/507,856 US20220041914A1 (en) | 2015-04-24 | 2021-10-22 | Method of enhancing hydration of viscosifiers using controlled mechanically induced cavitation |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201562152604P | 2015-04-24 | 2015-04-24 | |
US15/135,745 US20160312099A1 (en) | 2015-04-24 | 2016-04-22 | Method of Enhancing Hydration of Viscosifiers Using Controlled Mechanically Induced Cavitation |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/148,833 Continuation US11155741B2 (en) | 2015-04-24 | 2018-10-01 | Method of enhancing hydration of viscosifiers using controlled mechanically induced cavitation |
Publications (1)
Publication Number | Publication Date |
---|---|
US20160312099A1 true US20160312099A1 (en) | 2016-10-27 |
Family
ID=55913718
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/135,745 Abandoned US20160312099A1 (en) | 2015-04-24 | 2016-04-22 | Method of Enhancing Hydration of Viscosifiers Using Controlled Mechanically Induced Cavitation |
US16/148,833 Active 2036-07-10 US11155741B2 (en) | 2015-04-24 | 2018-10-01 | Method of enhancing hydration of viscosifiers using controlled mechanically induced cavitation |
US17/507,856 Pending US20220041914A1 (en) | 2015-04-24 | 2021-10-22 | Method of enhancing hydration of viscosifiers using controlled mechanically induced cavitation |
Family Applications After (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/148,833 Active 2036-07-10 US11155741B2 (en) | 2015-04-24 | 2018-10-01 | Method of enhancing hydration of viscosifiers using controlled mechanically induced cavitation |
US17/507,856 Pending US20220041914A1 (en) | 2015-04-24 | 2021-10-22 | Method of enhancing hydration of viscosifiers using controlled mechanically induced cavitation |
Country Status (2)
Country | Link |
---|---|
US (3) | US20160312099A1 (en) |
WO (1) | WO2016172504A1 (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10065167B2 (en) * | 2015-07-08 | 2018-09-04 | Arisdyne Systems, Inc. | Rotor and channel element apparatus with local constrictions for conducting sonochemical reactions with cavitation and methods for using the same |
US10315172B2 (en) * | 2014-12-22 | 2019-06-11 | Arisdyne Systems, Inc. | Rotor and stator device having bore holes for cavitational mixing |
US10711180B2 (en) | 2018-06-05 | 2020-07-14 | Economy Mud Products Company | Process for making and using a composition of matter |
US11155741B2 (en) * | 2015-04-24 | 2021-10-26 | Hydro Dynamics, Inc. | Method of enhancing hydration of viscosifiers using controlled mechanically induced cavitation |
CN115414870A (en) * | 2022-08-25 | 2022-12-02 | 江苏博颂能源科技有限公司 | ADHO device is anti for unit again catalyst flourishing device |
US11660581B2 (en) | 2020-04-30 | 2023-05-30 | Hydro Dynamics, Inc. | System and method for treatment of plants for synthesis of compounds therefrom |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11370676B2 (en) | 2019-12-04 | 2022-06-28 | Halliburton Energy Services, Inc. | Methods of removing polymers from treatment fluids for use in subterranean formations |
CN111495286B (en) * | 2020-06-15 | 2021-06-01 | 肇庆市高能达化工有限公司 | Oxygen preparation equipment with raw material recovery function |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5380411A (en) * | 1987-12-02 | 1995-01-10 | Schering Aktiengesellschaft | Ultrasound or shock wave work process and preparation for carrying out same |
US6627784B2 (en) * | 2000-05-17 | 2003-09-30 | Hydro Dynamics, Inc. | Highly efficient method of mixing dissimilar fluids using mechanically induced cavitation |
US20070215346A1 (en) * | 2004-03-15 | 2007-09-20 | Sloan Robert L | Viscosity control and filtration of well fluids |
US20080167204A1 (en) * | 2007-01-09 | 2008-07-10 | Billy Ray Slabaugh | Process for Enhancing Fluid Hydration |
US8430968B2 (en) * | 2008-01-22 | 2013-04-30 | Hydro Dynamics, Inc. | Method of extracting starches and sugar from biological material using controlled cavitation |
US20160059194A1 (en) * | 2014-08-27 | 2016-03-03 | Highland Fluid Technology, Ltd. | Hydrating and Dissolving Polymers in Salt Solutions |
Family Cites Families (26)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1758207A (en) | 1927-06-23 | 1930-05-13 | Heenan & Froude Ltd | Hydraulic heat-generating system |
US2283244A (en) | 1939-08-18 | 1942-05-19 | Heenan & Froude Ltd | Means for the extraction of air from the circulating water of hydraulic brakes or dynamometers |
US4213332A (en) | 1979-01-15 | 1980-07-22 | M & W Gear Company | Rotor-stator configuration for water brake dynamometer |
JPS55102491A (en) | 1979-01-29 | 1980-08-05 | Mitsutoshi Matsuoka | Continuous clarification of waste water |
US4529794A (en) | 1984-03-29 | 1985-07-16 | Diatec Polymers | Method of rapidly dissolving polymers in water |
JPS60226594A (en) | 1984-04-24 | 1985-11-11 | Mitsuhisa Matsuoka | Modification of fuel oil and unit therefore |
JPS62213895A (en) | 1986-03-14 | 1987-09-19 | Mitsutoshi Matsuoka | Apparatus for purifying and heating waste water |
US4864872A (en) | 1988-06-13 | 1989-09-12 | Stahl Jere F | Hydraulic dynamometer |
US5385298A (en) | 1991-04-08 | 1995-01-31 | Hydro Dynamics, Inc. | Apparatus for heating fluids |
US5188090A (en) | 1991-04-08 | 1993-02-23 | Hydro Dynamics, Inc. | Apparatus for heating fluids |
US5184576A (en) | 1991-05-10 | 1993-02-09 | Applied Hydro Dynamics, Inc. | Heat exchange system utilizing cavitating fluid |
US5265629A (en) | 1991-05-10 | 1993-11-30 | Applied Hydro Dynamics, Inc. | Universal cleaning system utilizing cavitating fluid |
US5183513A (en) | 1991-05-10 | 1993-02-02 | Applied Hydro Dynamics, Inc. | Method of cleaning internal surfaces utilizing cavitating fluid |
US5239948A (en) | 1991-05-10 | 1993-08-31 | Applied Hydro Dynamics, Inc. | Heat exchange system utilizing cavitating fluid |
US5571975A (en) | 1995-04-28 | 1996-11-05 | Massachusetts Institute Of Technology | Power absorbing dynamometer |
US5957122A (en) | 1998-08-31 | 1999-09-28 | Hydro Dynamics, Inc. | C-faced heating pump |
US6365555B1 (en) * | 1999-10-25 | 2002-04-02 | Worcester Polytechnic Institute | Method of preparing metal containing compounds using hydrodynamic cavitation |
US7380755B2 (en) | 2005-05-26 | 2008-06-03 | Goodrich Corporation | Frangible pneumatic latch |
US7507014B1 (en) | 2005-08-05 | 2009-03-24 | Hydro Dynamics, Inc. | Controlled cavitation device with easy disassembly and cleaning |
US8465642B2 (en) | 2007-05-04 | 2013-06-18 | Hydro Dynamics, Inc. | Method and apparatus for separating impurities from a liquid stream by electrically generated gas bubbles |
US8518186B2 (en) * | 2007-06-27 | 2013-08-27 | H R D Corporation | System and process for starch production |
WO2013112777A1 (en) * | 2012-01-25 | 2013-08-01 | Kemet Electronics Corporation | Polymerization method for preparing conductive polymer |
US20160129406A1 (en) * | 2014-11-12 | 2016-05-12 | Schlumberger Technology Corporation | Apparatus and methods for enhancing hydration |
US9469548B2 (en) * | 2015-02-20 | 2016-10-18 | Hydro Dynamics, Inc. | Continuous hydrodynamic cavitation crystallization |
WO2016172504A1 (en) * | 2015-04-24 | 2016-10-27 | Hydro Dynamics, Inc. | Method of enhancing hydration of viscosifiers using controlled mechanically induced cavitation |
US11236756B2 (en) * | 2015-05-18 | 2022-02-01 | Highland Fluid Technology, Inc. | Cavitation device |
-
2016
- 2016-04-22 WO PCT/US2016/028873 patent/WO2016172504A1/en active Application Filing
- 2016-04-22 US US15/135,745 patent/US20160312099A1/en not_active Abandoned
-
2018
- 2018-10-01 US US16/148,833 patent/US11155741B2/en active Active
-
2021
- 2021-10-22 US US17/507,856 patent/US20220041914A1/en active Pending
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5380411A (en) * | 1987-12-02 | 1995-01-10 | Schering Aktiengesellschaft | Ultrasound or shock wave work process and preparation for carrying out same |
US6627784B2 (en) * | 2000-05-17 | 2003-09-30 | Hydro Dynamics, Inc. | Highly efficient method of mixing dissimilar fluids using mechanically induced cavitation |
US7360755B2 (en) * | 2000-05-17 | 2008-04-22 | Hydro Dynamics, Inc. | Cavitation device with balanced hydrostatic pressure |
US20070215346A1 (en) * | 2004-03-15 | 2007-09-20 | Sloan Robert L | Viscosity control and filtration of well fluids |
US20080167204A1 (en) * | 2007-01-09 | 2008-07-10 | Billy Ray Slabaugh | Process for Enhancing Fluid Hydration |
US8430968B2 (en) * | 2008-01-22 | 2013-04-30 | Hydro Dynamics, Inc. | Method of extracting starches and sugar from biological material using controlled cavitation |
US20160059194A1 (en) * | 2014-08-27 | 2016-03-03 | Highland Fluid Technology, Ltd. | Hydrating and Dissolving Polymers in Salt Solutions |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10315172B2 (en) * | 2014-12-22 | 2019-06-11 | Arisdyne Systems, Inc. | Rotor and stator device having bore holes for cavitational mixing |
US11155741B2 (en) * | 2015-04-24 | 2021-10-26 | Hydro Dynamics, Inc. | Method of enhancing hydration of viscosifiers using controlled mechanically induced cavitation |
US10065167B2 (en) * | 2015-07-08 | 2018-09-04 | Arisdyne Systems, Inc. | Rotor and channel element apparatus with local constrictions for conducting sonochemical reactions with cavitation and methods for using the same |
US10711180B2 (en) | 2018-06-05 | 2020-07-14 | Economy Mud Products Company | Process for making and using a composition of matter |
US11660581B2 (en) | 2020-04-30 | 2023-05-30 | Hydro Dynamics, Inc. | System and method for treatment of plants for synthesis of compounds therefrom |
CN115414870A (en) * | 2022-08-25 | 2022-12-02 | 江苏博颂能源科技有限公司 | ADHO device is anti for unit again catalyst flourishing device |
Also Published As
Publication number | Publication date |
---|---|
US11155741B2 (en) | 2021-10-26 |
US20190169479A1 (en) | 2019-06-06 |
US20220041914A1 (en) | 2022-02-10 |
WO2016172504A1 (en) | 2016-10-27 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US11155741B2 (en) | Method of enhancing hydration of viscosifiers using controlled mechanically induced cavitation | |
JP7302712B2 (en) | Composition containing fine cellulose fibers | |
Agi et al. | Application of polymeric nanofluid in enhancing oil recovery at reservoir condition | |
US5052486A (en) | Method and apparatus for rapid and continuous hydration of polymer-based fracturing fluids | |
US5558161A (en) | Method for controlling fluid-loss and fracturing high permeability subterranean formations | |
Agi et al. | Synergy of the flow behaviour and disperse phase of cellulose nanoparticles in enhancing oil recovery at reservoir condition | |
US11149519B2 (en) | Smart filtrate for strengthening formations | |
US20150060072A1 (en) | Methods of treatment of a subterranean formation with composite polymeric structures formed in situ | |
CN109097010A (en) | Water-In-Oil/oil-in-water drilling fluid and preparation method thereof can be reversed in high temperature high density | |
CA2693246A1 (en) | Preparing a hydratable polymer concentrate for well treatment applications | |
US10717088B2 (en) | Multifunctional hydrodynamic vortex reactor | |
US20170136427A1 (en) | Rapid High Solids Separation | |
CN105175557A (en) | Preparation method of nano cellulose | |
CN106433603B (en) | A kind of carbon nano tube-doped fracturing fluid system | |
WO2004071614A3 (en) | Method and apparatus for producing particles via supercritical fluid processing | |
Hanafy et al. | Effect of nanoparticle shape on viscoelastic surfactant performance at high temperatures | |
US20200190398A1 (en) | Method of making rod-shaped particles for use as proppant and anti-flowback additive | |
US20110092696A1 (en) | High performance low residue guar for hydraulic fracturing and other applications | |
CN1816586A (en) | Designed particle agglomeration | |
WO2014111854A1 (en) | Method for the production of microfibrillated cellulose from a precursor material | |
CN104209040A (en) | Slurrying device and nano metal oxide powder production equipment comprising slurrying device | |
CN207562813U (en) | A kind of nano material ultrasonic resonance emulsifies blending device | |
CN104119454B (en) | The preparation method of polyanion cellulose | |
JPH0516893B2 (en) | ||
KR20050044367A (en) | Method for the production of particles |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: HYDRO DYNAMICS, INC., GEORGIA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:ARMSTEAD, DANIEL A.;MANCOSKY, DOUGLAS G.;REEL/FRAME:038766/0351 Effective date: 20160516 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |