EP3110539B1 - Appareil de mélange avec stator et procédé de mélange - Google Patents

Appareil de mélange avec stator et procédé de mélange Download PDF

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Publication number
EP3110539B1
EP3110539B1 EP15755550.9A EP15755550A EP3110539B1 EP 3110539 B1 EP3110539 B1 EP 3110539B1 EP 15755550 A EP15755550 A EP 15755550A EP 3110539 B1 EP3110539 B1 EP 3110539B1
Authority
EP
European Patent Office
Prior art keywords
slinger
fluid
impeller
stator
mixer
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.)
Active
Application number
EP15755550.9A
Other languages
German (de)
English (en)
Other versions
EP3110539A4 (fr
EP3110539A1 (fr
Inventor
Rajesh Luharuka
Gocha Chochua
Hau Nguyen-Phuc Pham
Mark AYYAD
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Services Petroliers Schlumberger SA
Schlumberger Technology BV
Original Assignee
Services Petroliers Schlumberger SA
Schlumberger Technology BV
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from US14/192,821 external-priority patent/US10137420B2/en
Priority claimed from US14/192,838 external-priority patent/US11819810B2/en
Application filed by Services Petroliers Schlumberger SA, Schlumberger Technology BV filed Critical Services Petroliers Schlumberger SA
Publication of EP3110539A1 publication Critical patent/EP3110539A1/fr
Publication of EP3110539A4 publication Critical patent/EP3110539A4/fr
Application granted granted Critical
Publication of EP3110539B1 publication Critical patent/EP3110539B1/fr
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Classifications

    • 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
    • B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
    • B01F25/80—Falling particle mixers, e.g. with repeated agitation along a vertical axis
    • B01F25/85—Falling particle mixers, e.g. with repeated agitation along a vertical axis wherein the particles fall onto a film that flows along the inner wall of a mixer
    • 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
    • B01F27/05—Stirrers
    • B01F27/11—Stirrers characterised by the configuration of the stirrers
    • B01F27/19—Stirrers with two or more mixing elements mounted in sequence on the same axis
    • B01F27/192—Stirrers with two or more mixing elements mounted in sequence on the same axis with dissimilar elements
    • 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
    • B01F27/80—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis
    • B01F27/805—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis wherein the stirrers or the receptacles are moved in order to bring them into operative position; Means for fixing the receptacle
    • B01F27/807—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis wherein the stirrers or the receptacles are moved in order to bring them into operative position; Means for fixing the receptacle with the stirrer-head pivoting about a horizontal axis to bring it in and out of operative position, e.g. with receptacles pivoting about a horizontal axis for emptying
    • 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
    • B01F27/80—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis
    • B01F27/81—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis the stirrers having central axial inflow and substantially radial outflow
    • B01F27/811—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis the stirrers having central axial inflow and substantially radial outflow with the inflow from one side only, e.g. stirrers placed on the bottom of the receptacle, or used as a bottom discharge pump
    • B01F27/8111—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis the stirrers having central axial inflow and substantially radial outflow with the inflow from one side only, e.g. stirrers placed on the bottom of the receptacle, or used as a bottom discharge pump the stirrers co-operating with stationary guiding elements, e.g. surrounding stators or intermeshing stators
    • 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
    • B01F27/80—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis
    • B01F27/81—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis the stirrers having central axial inflow and substantially radial outflow
    • B01F27/812—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis the stirrers having central axial inflow and substantially radial outflow the stirrers co-operating with surrounding stators, or with intermeshing stators, e.g. comprising slits, orifices or screens
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F2101/00—Mixing characterised by the nature of the mixed materials or by the application field
    • B01F2101/49—Mixing drilled material or ingredients for well-drilling, earth-drilling or deep-drilling compositions with liquids to obtain slurries

Definitions

  • Mixers are generally employed to disperse powdered chemicals into fluids.
  • One application for mixers is in wellbore operations, for example, in preparing hydraulic fracturing fluid for injection into a subterranean formation.
  • the fracturing fluid includes gelling agents, powders and other granular material, e.g., guar gum, which are initially dispersed into the fluid via the mixer, and subsequently hydrated, e.g., in tanks, to result in the desired viscosity for the fluid.
  • Certain powder and granular material mixers include a centrifugal pump and eductor, or a centrifugal or high or low shear blender for dispersing the powder and granular material into fluid (e.g., water).
  • fluid e.g., water
  • the fluid is pumped by the pump into a mixing chamber.
  • the mixing chamber may be proximal to a throat of a converging-diverging nozzle such that the eductor draws the powder into the mixing chamber by the Venturi effect.
  • blender mixers the blender is located in the mixing chamber, and the powders and grains are fed thereto, e.g., by gravity.
  • the materials e.g., in the form of dry powder
  • Various devices are employed to avoid air entrainment during the dispersion process, or entrained air may be removed downstream, e.g., using a hydro-cyclone or another type of air separator.
  • the fluid mixture may then be sent to equipment downstream for further hydration.
  • the powders may tend to agglomerate into clumps, sometimes referred to as "fisheyes.”
  • the powders may have cohesive properties, such that partially-hydrated balls form, e.g., with dry powder surrounded by a "skin" of partially-hydrated powder. This skin prevents hydration of the dry powder within, resulting in a stable fisheye in the fluid, rather than an even dispersion of the powder.
  • suboptimal mixing may result, which can affect downstream application.
  • there is an additional risk of buildup and/or clogging of the material e.g., in the various throats of the system, if the materials are not sufficiently wetted at the point of introduction into the mixer.
  • a pre-wetter may be employed to mitigate the risk of such clumping.
  • Pre-wetters generally provide a fluid to the powder feed, upstream of the mixing.
  • pre-wetters require a separate pump to deliver the fluid to the powder, upstream of the mixing chamber.
  • additional pumping equipment i.e., centrifugal pumps to provide fluid to pre-wetter
  • the different pieces of equipment may limit the range of flowrates achievable for the system, limiting the applications for which a single size or configuration of mixer is suitable.
  • JP S5715828 describes a continuous type mixer for mixing a powder and liquid including an upper vessel provided with scraping vanes into which the powder is fed and a lower vessel with an impeller into which the liquid is fed.
  • the invention further resides in a method for dispersing an additive in a fluid as defined in claim 9.
  • FIG. 1 illustrates a schematic view of a mixing system 100, according to an embodiment.
  • the mixing system 100 may generally include a process fluid source 102, a mixer 104, and downstream equipment 106, among other potential components.
  • the process fluid source 102 may be or include a tank of water, a water-based solution of a suitable pH and/or any other type of solution, or any substantially liquid substance.
  • the source 102 may include or be coupled with one or more pumps for delivery of the fluid to the mixer 104; however, in other embodiments, such pumps may be omitted with the mixer 104 providing the pumping, for example.
  • the downstream equipment 106 may include any number of hydrating tanks, separators, other mixers/mixing systems, pumps, etc., so as to convert a slurry exiting the mixer 104 into a desired viscosity and/or composition fluid.
  • the mixer 104 includes a housing 107 as well as a fluid inlet 108 and an additive inlet 110 extending through the housing 107.
  • the fluid inlet 108 may be coupled with the fluid source 102 and may be configured to receive fluid (i.e., the process fluid) therefrom.
  • the additive inlet 110 may generally include an additive-receiving structure 111, which may be or include a cone, chamber, bowl, hopper, or the like, having an inner surface 115 configured to receive an additive 113, which may be a dry powder, and direct it into the housing 107, e.g. via gravity feed.
  • any dry, partially dry, crystalized, slurry, fluid, or pelletized, and/or packaged additive may be dispersed or otherwise mixed into the fluid using the mixer 104 via the additive inlet 110, as schematically depicted.
  • additives received through the additive inlet 110 may be pre-wetted into a partial slurry, e.g., to avoid fisheyes and/or any material buildup.
  • the mixer 104 may be configured for use in mixing sand, guar, other powders, etc. with the fluid. Further, in some cases, the mixer 104 may be configured for use as a macerator, which may tear apart fibers, pouches containing powders, pellets, etc.
  • the mixer 104 may be configured for use in creating gel for use in fracturing operations, e.g., in a wellbore; however, the mixer 104 may be employed for any number of different uses, consistent with the present disclosure.
  • the mixer 104 also includes an impeller/slinger assembly 112, which may be driven by a shaft 114.
  • the housing 107 defines a mixing chamber 118 therein that is in communication with the inlets 108, 110.
  • the impeller/slinger assembly 112 is disposed in the mixing chamber 118. Rotation of the impeller/slinger assembly 112 pumps the fluid from the source 102 through the mixing chamber 118 and into the outlet 121.
  • the shaft 114 may extend upwards, through the inlet 110 and out of the additive-receiving structure 111; however, this is but one example among many contemplated.
  • the impeller/slinger assembly 112 may extend downward through the bottom of the housing 116, may be magnetically driven, driven internally within the mixing chamber 118, or may be otherwise disposed in the housing 107.
  • the shaft 114 may be coupled with the impeller/slinger assembly 112, such that rotation of the shaft 114 rotates the impeller/slinger assembly 112.
  • the shaft 114 may be directly coupled to the impeller/slinger assembly 112, e.g. via a bolt; however, in other cases, gears, linkages, other speed-changing devices, or couplings may be employed to connect the shaft 114 to the impeller/slinger assembly 112.
  • the mixer 104 also includes a stator 120, which may be in the form of a ring, arcuate portion, etc., which is disposed around the impeller/stator assembly 112, as will be described in greater detail below. Further, the mixer 104 includes an outlet 121 and may include a flush line 122. The outlet 121 may receive a slurry formed from a combination of the additive received through the additive inlet 110 and the fluid received through the fluid inlet 108. The outlet 121 may direct the slurry to one or more conduits 124, which may carry the fluid to the downstream equipment 106.
  • the flush line 122 may communicate with an area of the mixing chamber 118 that is proximal to the impeller/slinger assembly 112 on one end, and with the additive-receiving structure 111 on the other end. Accordingly, the flush line 122 may tap the process fluid from the mixing chamber 118 at an area of relatively high pressure and deliver it to the inner wall of the additive-receiving structure 111, which may be at a reduced (e.g., ambient) pressure.
  • the fluid tapped by the flush line 122 may be relatively "clean" (i.e., relatively low additives content, as will be described below), so as to pre-wet fluid to the additive-receiving structure 111 and promote the avoidance of clumping of the additives.
  • the flush line 122 may provide the pre-wetting fluid without requiring additional pumping devices (apart from the pumping provided by the impeller/slinger assembly 112) or additional sources of fluid or lines from the source 102.
  • booster pumps, etc. may be provided in addition to or in lieu of tapping the fluid from the mixing chamber 118.
  • FIG 2 illustrates an exploded perspective view of the mixer 104, according to an embodiment.
  • the mixer 104 includes the housing 107, which is depicted in Figure 2 as formed from two portions: a first or “upper” housing portion 126 and a second or “lower” housing portion 128.
  • the upper and lower housing portions 126, 128 may be connected together, e.g., via bolts, clamps, other fasteners, adhesives, welds, etc., so as to define the mixing chamber 118 ( Figure 1 ) therebetween.
  • the lower housing portion 128 may define a mixing area 130
  • the upper housing portion 126 may define a mixing area 132 (shown in phantom), which may be generally aligned.
  • the mixing areas 130, 132 may together define the mixing chamber 118 ( Figure 1 ), in which the impeller/slinger assembly 112 and the stator 120 are disposed.
  • the lower housing portion 128 may also include an interior surface 139, e.g., defining the bottom of the mixing area 130. It will be appreciated that a variety of configurations of the housing 107, including unitary and segmented embodiments, embodiments with doors, etc. are contemplated.
  • the upper housing portion 126 may be coupled with the additive-receiving structure 111 and may provide the additive inlet 110.
  • the lower housing portion 128 may include the fluid inlet 108, which may extend through the lower housing portion 128 to a generally centrally-disposed opening 133.
  • the opening 133 may be defined in the interior surface 139.
  • the outlet 121 may extend from the mixing area 130, for example, including a substantially tangential conduit 135 extending from an opening 137 communicating with the mixing area 130.
  • the impeller/slinger assembly 112 includes a slinger 134 and an impeller 136.
  • the slinger 134 and the impeller 136 has inlet faces 134-1, 136-1, respectively, and backs 134-2, 136-2, respectively.
  • the inlet faces 134-1, 136-1 may be each be open (as shown) or at least partially covered by a shroud, which forms an inlet in the radial inner part of the slinger 134 and/or impeller 136.
  • the inlet faces 134-1, 136-1 are oriented in opposite directions, e.g., to receive fluid and/or dry components.
  • the backs 134-2, 136-2 are disposed proximal to one another and, e.g., coupled together, such that the impeller 136 and the slinger 134 are disposed in a "back-to-back" configuration.
  • the inlet face 134-1 of the slinger 134 may face the additive inlet 110 (e.g., the additive-receiving structure 111), while the inlet face 136-1 of the impeller 136 may face the fluid inlet 108 (e.g., the opening 133), as shown.
  • the inlet face 136-1 of the impeller 136 may face the interior surface 139, with the opening 133, defined on the interior surface 139, being aligned with a radial middle of the impeller 136.
  • the slinger 134 may face upwards, as shown, but in other embodiments may face downwards or in a lateral direction.
  • the impeller 136 may face downwards, as shown, but in other embodiments, may face upwards or in a lateral direction.
  • the slinger 134 and the impeller 136 may each have a radius, with the radius of the slinger 134 being larger than the radius of the impeller 136. The radii of the slinger 134 and impeller 136 may be dependent upon one another, so as to control a position of a fluid-air boundary, as will be described in greater detail below.
  • the slinger 134 may further define a saucer-shape, as shown, i.e., formed generally as a flatter (or flat) middle with arcuate sides and the inlet face 134-1.
  • the sides may be formed, for example, similar to, or as part of a torus that extends around the middle of the slinger 134.
  • the slinger 134 may be bowl-shaped (e.g., generally a portion of a sphere).
  • the slinger 134 may include slinger blades 138 on the inlet face 134-1. The number of blades 138 may range from about two blades to about 20 blades, for example, about nine blades.
  • the blades 138 may be curved circumferentially as proceeding radially outwards from the shaft 114, but in others the blades 138 may be straight, as shown.
  • the slinger 134 may be configured to propel fluid and/or dry additives received from the inlet 110 radially outwards by interaction with the blades 138 and upwards (as shown), e.g., as influenced by the shape of the slinger 134.
  • the impeller 136 may also include a plurality of blades on the inlet face 136-1, which may be generally aligned with the opening 133.
  • the impeller blades may draw fluid through the opening 133 of the fluid inlet 108, and then expel the fluid downwards and radially outwards.
  • a region of relative high pressure may develop between the lower housing portion 128 and the impeller 136, which may act to drive the fluid around the mixing chamber 118 and toward the slinger 134.
  • the flush line 122 may include an opening 140 defined in the lower housing portion 128 proximal to this region of high pressure.
  • the opening 140 may be defined in the interior surface 139 at a position between the outer radial extent of the impeller 136 and the opening 133 of the inlet 110.
  • the opening 140 may be disposed on the interior surface 139 and radially outside of the impeller 136 and/or elsewhere in the mixing chamber 118.
  • the flush line 122 may also include a conduit 142, which may be or include one or more pipes, tubes, hoses, flow restrictors, check valves, etc.
  • the conduit 142 may connect with a cone inlet 144 defined, for example, substantially tangent to the additive-receiving structure 111, such that fluid is transported from the opening 140 via the conduit 142, through the cone inlet 144, and into the additive-receiving structure 111.
  • the fluid may then take a generally helical path along the interior of the additive-receiving structure 111, until it is received through the additive inlet 110 to the slinger 134.
  • the fluid received through the cone inlet 144 may generally form a wall of fluid along the inner surface 115 of the additive-receiving structure 111.
  • a pressure gradient may develop between the impeller 136 and the lower housing portion 128, with the pressure in the fluid increasing as proceeding radially outwards from the opening 133.
  • Another gradient, related to the concentration of the additives in the fluid may also develop in this region, with the concentration of additives increasing as proceeding radially outward.
  • a high pressure head and low concentration may be desired, so as to provide a flow of relatively clean fluid through the flush line 122, propelled by the impeller/slinger assembly 112.
  • the opening 140 for the flush line 122 may be disposed at a point along this region that realizes an optimal tradeoff between pressure head of the fluid and concentration of the additives in the fluid received into the flush line 122. Additional details regarding the tradeoff are provided below.
  • stator 120 forms a shearing ring, which is received around the radial outside of the impeller/slinger assembly 112 and in the mixing chamber 118 ( Figure 1 ).
  • stator 120 may be coupled with the upper housing portion 126, e.g., via bolts, other fasteners, adhesives, welding, etc.
  • FIG 3 illustrates an enlarged sectional view of the stator 120 of Figure 2 , according to an embodiment.
  • the stator 120 includes first and second annular portions 146, 148, which are stacked together to form the stator 120.
  • the stator 120 may be held generally stationary with respect to the rotatable impeller/slinger assembly 112, e.g., via fastening with the upper housing portion 126.
  • the stator 120 may be supported by the impeller/slinger assembly 112 and may rotate therewith.
  • the stator 120 may ride on the inlet face 134-1 of the slinger 134, or may be separated therefrom.
  • the first annular portion 146 may be configured to minimize flow obstruction. As shown, in some cases, the first annular portion 146 may include a shroud 150 and posts 152 defining relatively wide slots 154, allowing relatively free flow of fluid therethrough. In other embodiments, the first annular portion 146 may omit the shroud 150, as will be described in greater detail below.
  • the second annular portion 148 may be configured to maximize flow shear, so as to promote turbulent mixing, and thus includes a series of stator vanes 156 that are positioned closely together around the stator 120.
  • Narrow flowpaths 158 may be defined between stator vanes 156; however, the sum of areas of the flowpaths 158 may be less than the sum of the areas of the stator vanes 156.
  • the ratio of the stator vane 156 cross-sectional area (i.e., the area that obstructs flow) to the area of the flowpaths 158 may be between about 1:2 and about 4:1, for example, about 1.5:1.
  • each of the stator vanes 156 may be greater than the area of each of the flowpaths 158.
  • the stator vanes 156 may be disposed at any pitch angle with respect to the circumference of the stator 120.
  • the stator vanes 156 may be oriented straight radial, against rotation (e.g., to increase shear), or with rotation.
  • the stator vanes 156 may have a shroud 157 that separates the sections 146, 148.
  • the stator120 may omit either or both of the shrouds 150, 157.
  • Figure 4 illustrates a perspective view of a section of the mixer 104, according to an embodiment.
  • Figure 5 illustrates a side cross-sectional view of the mixer 104, with the flush line 122 illustrated schematically, according to an embodiment.
  • the shaft 114 extends through the additive inlet 110 and is coupled with the impeller/slinger assembly 112.
  • the impeller 136 faces the opening 133, such that impeller blades 160 of the impeller 136 draw fluid through the inlet 108 via the opening 133.
  • Figure 6 schematically illustrates a simplified view of the cross-section of the mixer 104, according to an embodiment.
  • the impeller 136 draws the fluid upward from the interior surface 139, and then expels it downwards (toward the interior surface 139) and radially outward.
  • the fluid then moves upward in the mixing chamber 118, e.g., along an outer wall of the housing 107 to the top of the upper housing portion 126, where it is turned radially inwards.
  • the fluid then proceeds through the first annular portion 146 of the stator 120 to the slinger 134, and is then pushed radially outward, as well as upward, back toward the upper housing portion 126.
  • This may create a turbulent churning, as well as a hydrodynamically-stable interface between the fluid and the air, generally manifesting as a ring-shaped air-fluid boundary or "eye" 161 ( Figure 6 ) between a root 138-1 and a tip 138-2 of the slinger blades 138.
  • the slinger 134 thus tends to create a cyclonic separation effect, whereby air received through the inlet 110 is prevented from entrainment in the fluid received from the impeller 136.
  • the additives 113 are poured into or otherwise received through the inlet 110, e.g., propelled by gravity, but may also be propelled by pressure differentials, vacuums, blowers, pumps, etc.
  • the additives are then received onto the inlet face of the slinger 134, e.g., on the air side of the air-fluid boundary.
  • the additives collide with the blades 138 and are slung radially outward into the fluid received from the impeller 136, while producing a circumferential velocity component to the fluid and dry additives.
  • the circumferentially- and radially-driven dry additives and fluid then pass through the second annular portion 148 of the stator 120, where the combination is subjected to a high shear by interaction with the stator vanes 156 as it passes through the flowpaths 158.
  • the shearing provided by the interaction with the blades 138 and stator vanes 156 and the turbulent flow developed by the impeller/slinger assembly 112 may provide a generally uniform dispersion of the additives in the fluid from the source 102, resulting in a slurry.
  • the first section 146 of the stator 120 is disposed at a small radial clearance from the slinger blades 138 (e.g., radially outward therefrom) such that the slurry mixture of additives 113 (e.g., powdered chemicals) and fluid being slung outward by the slinger blades 136 is sheared in a first stage in the clearance, by the relative movement of the blades 134 and the stator vanes 156.
  • the slurry is then subjected to a second shear stage, as it is squeezed between the adjacent stator vanes 156 and pushed radially outwards through the flowpaths 158 by the action of the slinger 134.
  • the mixer 104 provides, in operation, a two-stage, high shearing and regional cavitation mixing.
  • the second section 148 of the stator 120 may have a substantially larger opening and be disposed above the slinger blades such that it allows the fluids to enter the slinger 134 through the slots 154, or otherwise minimizes flow obstruction through the stator 120.
  • the slurry may undergo such mixing multiple times, churning back through portions of the slinger 134 to effect further dispersion of the additives into the fluid, and eventually reaches the outlet 121, as shown in Figure 5 .
  • the slurry reaching the outlet 121 is channeled from the mixing chamber 118, e.g., to downstream equipment 106 ( Figure 1 ) for further hydration, deployment, treatment, etc.
  • the mixer 104 may also provide a self-regulating pre-wetter with the flush line 122.
  • the opening 140 may be disposed in the interior surface 139 of the lower housing portion 128, e.g., radially inside or outside of the outer radial extent of the impeller 136. This may represent an area of high pressure in the mixing chamber 118, which is "clean" relative to fluid in other parts of the mixing chamber 118, e.g., proximal to the outlet 121 and/or in the slinger 134.
  • the tapped, relatively clean fluid received via the opening 140 may flow through the flush line 122 to the additive-receiving structure 111.
  • the pre-wetting fluid may then flow, e.g., by gravity, along the interior surface of the additive-receiving structure 111 through the inlet 110 and back to the slinger 134.
  • the additives may be urged along the additive-receiving structure 111, toward the slinger 134, while being pre-wetted therein. This may serve to minimize clumping along the surface of the additive-receiving structure 111.
  • Figure 7 illustrates a plot of pressure and cleanliness in the fluid in the mixing chamber 118 versus the radius from the center of the opening 133, which is aligned with the center of the impeller 136.
  • the pressure may move from ambient (i.e., zero psig) to a maximum pumping pressure provided by the impeller 136.
  • the relationship between radial position and pressure head may be generally exponential, until the position reaches the radial extent of the impeller 136.
  • the "cleanliness,” that is, the inverse of the concentration of additives in the fluid, or, stated otherwise, the purity of the fluid, may decrease proceeding radially outward, as the fluid received through the inlet 108 is mixed with the additives. Accordingly, a tapping region 141 may be calculated, providing the optimal tradeoff between pressure head and cleanliness in the fluid tapped by the flush line 122 via the opening 140.
  • the flowrate of the relatively clean fluid through the flush line 122 may be controlled, for example, by matching a location or size of the opening 140, the conduit 142, and/or the cone inlet 144 to the pressure head developed by the impeller 136. With a known pressure drop through the flush line 122, such control may result in an optimized amount of fluid flowing through the flush line 122.
  • the flush line 122 may include one or more flow control devices, which may further allow for adjustment of the flowrate through the flush line 122.
  • FIG 8 illustrates a perspective view of the impeller/slinger assembly 112 and the stator 120, according to an embodiment.
  • the stator 120 includes the first and second annular portions 146, 148, as described above.
  • the second annular portion 148 may include a plurality of posts 170, which may extend upwards from the first annular portion 146, but may not include a shroud.
  • the posts 170 may be coupled to the upper housing portion 126 ( Figure 2 ).
  • the posts 170 may be any shape, including cylindrical, aerofoils, etc. and may be spaced apart so as to define wide channels therebetween. Accordingly, the second annular portion 148 may be configured to minimize flow obstruction therethrough.
  • stator vanes 156 may be pitched at an angle relative to the circumference of the stator 120, for example, opposite to rotation, so as to maximize shearing.
  • the slinger blades 138 may be curved circumferentially, e.g., to facilitate slinging the fluid and additives radially outwardly, and with a circumferential velocity component, so as to produce the shearing.
  • the stator 120 illustrated in Figure 8 may act as a diffuser.
  • the stator vanes 156, as illustrated, may be oriented to recover pressure and/or may facilitate air introduction into the slurry, for example, in foaming operations.
  • Figure 9 illustrates another perspective view of the impeller/slinger assembly 112, illustrating the inlet face 136-1 of the impeller 136, according to an embodiment.
  • the blades 160 of the impeller 136 which may be curved, straight, or any other suitable geometry, draws fluid upwards, and then expels it radially outwards into the mixing chamber 118 (e.g., Figure 3 ).
  • the impeller 136 may be configured for high-speed (e.g., between about 300 rpm and about 20,000 rpm) use, and may be capable of pumping of producing between about 34 kPa (about 5 psi) and about 1000 kPa (about 150 psi), e.g., about 414 kPa (about 60 psi) of head.
  • Figure 10 illustrates a perspective view of another slinger 200 of the mixer 104, according to an embodiment.
  • rotor blades such as blades 138 as shown in Figure 1
  • the slinger 200 may provide a low shear or controlled shear dispersion that can handle such delicate chemicals, which are prone to damage or otherwise unsuitable for use in the more-aggressive slinger embodiments.
  • the slinger 200 may effect a relatively gradual dispersion using generally concentric, annular disks 202, which are stacked one on top of the other upward from a hub 204.
  • the annular disk 202-1 closest to the hub 204 may have a smaller inner diameter than the annular disk 202-2 adjacent thereto, which in turn may have a smaller inner diameter than the annular disk 202-3. This may repeat as proceeding between adjacent disks 202 away from the hub 204, so as to provide an inlet face 205 for the slinger 200 through which fluid and/or additives may be received and propelled outwards. It will be appreciated that any number of annular disks 202 may be included.
  • the disks 202 may be held apart by vanes 206, providing narrow flowpaths between the disks 202.
  • the vanes 206 may provide slots, one for each of the annular disks 202, into which the annular disks 202 may be received and coupled to the vanes 206. Accordingly, the narrow paths may extend radially outwards, for example, obstructed in the radial direction only by the narrow vanes 206.
  • separate vanes may extend between each pair of adjacent disks 202, rather than or in addition to the vanes 206 that extend through the entire set of disks 202.
  • the vanes 206 may couple with one or more subsets of the total number of disks 202. In some cases, the vanes 206 may be omitted, with the disks 202 held together in a spaced-apart relation in any other suitable manner.
  • the large surface area of the annular disks 202 bordering the flowpaths, and the narrowness of the flowpaths, may result in shearing and turbulent flow of the fluid therethrough.
  • Such shearing may have a similar effect as the slinger 134 and stator 120 discussed above, and may promote dispersion of dry additives into fluid being slung radially outwards therethrough, while minimizing the impact forces from the vanes 204 which may damage more delicate material.
  • the shearing provided by the slinger 200 may result in the stator 120 being omitted; however, in other cases, the shearing effects of the stator 120 and the slinger 200 may be combined.
  • FIG 11 illustrates a perspective view of a shroudless stator 300, according to an embodiment.
  • the stator 300 includes first and second annular portions 302, 304, which may, as shown, both be shroudless.
  • the first annular portion 302 may include a base 306 and a series of vanes 308 extending upwards from the base 306 and disposed at intervals around the first annular portion 302.
  • Flowpaths 310 are defined between adjacent vanes 308.
  • the top of the flowpaths 310 may be open-ended, opening into the second annular portion 304 of the stator 120.
  • the second annular portion 304 may include tabs 312 extending upwards from the first annular portion 302.
  • the tabs 312 may be thicker, circumferentially, than the vanes 308, for example, each spanning two vanes 308 and one of the flowpaths 310; however, any relative sizing of the vanes 308 and tabs 312 may be employed.
  • the shroudless configuration may minimize obstruction of the flow from the impeller 136, increasing efficiency of the mixer 104.
  • Figure 12 illustrates a side, cross-sectional view of the mixer 104, according to another embodiment.
  • the embodiment shown in Figure 12 may be generally similar to the embodiment of the mixer 104 shown in one or more of Figures 1-8 , with similar components being referred to using like numerals and duplicative description being omitted herein.
  • the mixer 104 shown in Figure 12 may, however, have a stator 400 that is integrated with the housing 107, for example, with the lower housing portion 128. Accordingly, the stator 400 may be spaced radially apart from and may circumscribe the impeller/slinger assembly 112, with the outlet 121 being disposed radially outward of the stator 400.
  • stator 400 Supporting (and/or integrating) the stator 400 by the lower housing portion 128 may facilitate low friction rotation of the impeller/slinger assembly 112, since the stator 400 and the impeller/slinger assembly 112 may not be in contact with one another.
  • the stator 400 may be suspended from and/or integrated with the upper housing portion 126 to similar effect.
  • This embodiment of the mixer 104 may, in some cases, ensure all or substantially all of the incoming fluid is mixed with the additive chemical before exiting the mixer 104.
  • the mixer 104 may blend the powder uniformly, so as to avoid relying on the pipe turbulence downstream of the mixer 104 to effect such mixing.
  • the stator 400 may be shrouded or shroudless, and includes two or more annular portions (e.g., one for low flow disruption and one for high flow disruption).
  • the stator 400 may, however, be configured to receive substantially all fluid flow out of the volume of fluid, which may enhance bulk mixing.
  • Such a mixer 104 embodiment employing the stator 400 may be suited for powder dispersion into a very viscous fluid medium as well as when powder volume fraction in the mixture is high, e.g., with cement mixing.
  • embodiments of the mixer 104 shown in Figure 12 may include a flush line 122, e.g., as described above.
  • Figure 13 illustrates a flowchart of a method 1000 for dispersing an additive, such as a dry additive (e.g., powder, granules, etc.) into a fluid, according to an embodiment.
  • the method 1000 may proceed by operation of one or more embodiments of the mixing system 100 and/or the mixer 104 and, thus, is described herein with reference thereto. However, it will be appreciated that the method 1000 is not limited to any particular structure, unless otherwise expressly stated herein.
  • the method 1000 includes feeding a fluid into the mixing chamber 118 of the mixer 104 through the fluid inlet 108.
  • Reference 1002 in Figure 13 relates to feeding a liquid into the mixing chamber.
  • the mixing chamber 118 is defined within the housing 107, which may define the fluid inlet 108 that receives the fluid from the source 102.
  • the method 1000 also includes feeding the additive into the mixing chamber 118 through the additive inlet 110.
  • Reference 1004 in Figure 13 refers to feeding an additive into the mixing chamber.
  • the feeding at 1004 may be propelled by gravity, for example, by pouring the additive into the additive-receiving structure 111 of the additive inlet 110, although other methods for feeding the additive are also contemplated.
  • the method 1000 also includes rotating the impeller/slinger assembly 112 disposed in the mixing chamber 118.
  • Reference 1006 in Figure 13 relates to rotating an impeller/slinger assembly in the mixing chamber to generate a slurry.
  • Rotating the impeller/slinger assembly 112 draws fluid from the fluid inlet 108 (e.g., upwards) and radially outward, for example, by action of the impeller 136 disposed with its inlet face 136-1 proximal to the interior surface 139.
  • Rotating the impeller/slinger assembly 112 further causes the fluid, e.g., received from the impeller 136, along with the additive received through the additive inlet 110, to be slung radially outward.
  • the outward slinging may be caused by the slinger 134 of the impeller/slinger assembly 112, which may include blades 138 and/or disks 202.
  • the slinger 134 may include an inlet face 134-1, which may, for example, be oriented toward the additive inlet 110.
  • the additive When the additive is fed through the additive inlet 110, the additive may impinge on the blades 138 and/or disks 202 and be slug radially outward
  • the combination of the impeller 136 and the slinger 134 may result in an eye defined by a hydrodynamically-stable fluid-air boundary, to develop in the slinger 134.
  • the boundary may be present radially between a hub 138-1 and tip 138-2 of the blades 138 of the slinger 134.
  • the slinging of the additive (as well as the fluid received from the impeller 136) radially outwards by action of the slinger 134 may result in the additive crossing the air-fluid boundary, and thus being at least partially dispersed into the fluid, thereby forming a slurry.
  • the action of the impeller/slinger assembly 112 may create a hydrodynamically-stable eye, forming a fluid-air boundary, thereby preventing air from becoming entrained in the fluid.
  • air may be purposely introduced into the mixture, for example, in foaming applications, e.g., using the stator 120 of Figure 8 .
  • the additive may further be dispersed in the fluid, promoting increased homogenization of the slurry, by the slurry being received through the stator 120.
  • Reference 1008 in Figure 13 relates to receiving the slurry through a stator.
  • the stator 120 includes the plurality of vanes 156, defining flowpaths therebetween, through which the slurry is received. The interaction of the swirled, turbulent flow of the slurry with the stator vanes 156 may result in increased shearing of the fluid, which may increase mixing efficiency of the mixer 104.
  • the slurry with a certain concentration of additives is expelled from the mixer 104, via the outlet 121, which may be disposed radially outwards of the impeller/slinger assembly 112.
  • Reference 1010 in Figure 13 relates to expelling the slurry from the mixing chamber via an outlet.
  • the method 1000 may also include, e.g., as caused by rotation of the impeller/slinger assembly 112 at 1006, a portion of the fluid or slurry (e.g., with a relatively low concentration, relative to flow through the outlet 121) to flow into the flush line 122 and to the additive inlet 110, to pre-wet the additive.
  • Reference 1012 in Figure 13 relates to receiving a portion of the slurry at a low additive concentration through a flush line, to pre-wet the additive in the additive inlet.
  • the flush line 122 may include the opening 140, which may be positioned and/or sized so as to receive a slurry with a predetermined (e.g., minimized) concentration of additives at a predetermined (e.g., maximized) pressure in the mixing chamber 118.
  • a predetermined concentration of additives at a predetermined (e.g., maximized) pressure in the mixing chamber 118.
  • the sizing of the flush line 122, placement of the opening 140 thereof, and/or employment of flow control devices in the flush line 122, etc. may allow control of the amount of fluid that proceeds through the flush line 122 and the composition thereof.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dispersion Chemistry (AREA)
  • Mixers Of The Rotary Stirring Type (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Claims (9)

  1. Mélangeur (104), comprenant :
    un carter (107) comprenant une entrée de fluide (108), une entrée d'additif (110) et une sortie (121), le carter (107) définissant une chambre de mélange (118) en communication fluidique avec l'entrée de fluide (108), l'entrée d'additif (110) et la sortie (121) ;
    un rotor (136) disposé dans la chambre de mélange (118) dans lequel, lorsqu'il est en rotation, le rotor (136) aspire le fluide à travers l'entrée de fluide (108) ;
    un agitateur (134, 200) disposé dans la chambre de mélange (118) et conçu pour recevoir le fluide provenant du rotor (136) et pour recevoir un additif provenant de l'entrée d'additif (110), dans lequel, lorsqu'il est en rotation, l'agitateur (134, 200) défléchit le fluide et l'additif radialement vers l'extérieur et dans lequel le rotor (136) et l'agitateur (134, 200) forment un ensemble agitateur/rotor (112) ;
    un stator (120, 300, 400) disposé au moins partiellement autour de l'agitateur (134, 200), le stator (120, 300, 400) comprenant des aubes (156, 308) espacées de manière circonférentielle pour définir les passages d'écoulement (158, 310) entre elles ;
    l'agitateur (134, 200) et le rotor (136) présentent respectivement des faces d'entrée (134-1, 136-1) et des dos (134-2, 136-2), et dans lequel l'agitateur (134, 200) et le rotor (136) sont disposés en configuration dos à dos, de sorte que le rotor (136) entraîne le fluide radialement vers l'extérieur de l'agitateur (134, 200), vers le haut dans la chambre de mélange (118), puis radialement vers l'intérieur vers un milieu de l'agitateur (134, 200) ;
    caractérisé en ce que le stator (120) forme un anneau de cisaillement disposé radialement autour de l'ensemble rotor/agitateur (112), le stator (120) comprenant des première et seconde parties annulaires (146, 148) empilées ensemble, la première partie annulaire (146, 302) définissant une première zone de passage d'écoulement (158, 310) et la seconde partie annulaire (148, 304) définissant une seconde zone de passage d'écoulement (158, 310), dans lequel la première zone de passage d'écoulement (158, 310) est plus grande que la seconde zone de passage d'écoulement (158, 310) et dans lequel la seconde partie annulaire (148, 304) est disposée entre la première partie annulaire (146, 302) et le rotor (136).
  2. Mélangeur selon la revendication 1, comprenant en outre un arbre (114) accouplé avec l'agitateur (134, 200) et le rotor (136), pour faire tourner l'agitateur (134, 200) et le rotor (136).
  3. Mélangeur selon la revendication 1, dans lequel la première partie annulaire du stator (120, 300, 400) est décalée radialement par rapport aux lames (138) de l'agitateur (134), de manière à former un espace libre entre elles.
  4. Mélangeur selon la revendication 1, dans lequel la seconde partie annulaire (148, 304) du stator (120) est disposée autour d'au moins une partie de l'agitateur (134, 200) et est alignée de manière à recevoir le fluide provenant de celui-ci.
  5. Mélangeur selon la revendication 1, dans lequel la seconde partie annulaire (148) du stator (120) comprend une pluralité d'aubes (156) qui sont espacées pour définir une pluralité de passages d'écoulement (158) entre elles.
  6. Mélangeur selon la revendication 5, dans lequel la seconde partie annulaire (304) est sans carénage, de sorte que la pluralité de passages d'écoulement (310) définies dans celle-ci soient ouvertes.
  7. Mélangeur selon la revendication 1, dans lequel l'agitateur (134, 200) comprend une pluralité de lames d'agitateur (138) ou une pluralité de disques (202) espacés axialement.
  8. Mélangeur selon la revendication 1, dans lequel le carter (107) comprend une partie supérieure du carter (126) dans laquelle l'entrée d'additif (110) est au moins partiellement définie et une partie inférieure du carter (128) dans laquelle l'entrée de fluide (108) est au moins partiellement définie et dans lequel le stator (400) est au moins dans un état parmi : intégré à la partie inférieure du carter (128), à la partie supérieure du carter (126) ou aux deux (126, 128).
  9. Procédé destiné à disperser un additif dans un fluide, comprenant :
    l'alimentation (1002) d'un fluide à l'entrée de fluide (108) d'un mélangeur (104) selon l'une des revendications 1 à 8 ;
    l'alimentation (1004) d'un additif dans l'entrée d'additif (110) du mélangeur (104) ;
    la rotation (1006) de l'ensemble rotor/agitateur (112) disposé dans la chambre de mélange (118) pour produire une boue comprenant l'additif et le fluide ; et
    la réception (1008) de la boue à travers la sortie (121).
EP15755550.9A 2014-02-27 2015-02-24 Appareil de mélange avec stator et procédé de mélange Active EP3110539B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US14/192,821 US10137420B2 (en) 2014-02-27 2014-02-27 Mixing apparatus with stator and method
US14/192,838 US11819810B2 (en) 2014-02-27 2014-02-27 Mixing apparatus with flush line and method
PCT/US2015/017175 WO2015130619A1 (fr) 2014-02-27 2015-02-24 Appareil de mélange avec stator et procédé de mélange

Publications (3)

Publication Number Publication Date
EP3110539A1 EP3110539A1 (fr) 2017-01-04
EP3110539A4 EP3110539A4 (fr) 2017-11-08
EP3110539B1 true EP3110539B1 (fr) 2021-07-07

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EP (1) EP3110539B1 (fr)
CN (1) CN106457178B (fr)
CA (1) CA2939162C (fr)
EA (1) EA038757B1 (fr)
MX (2) MX2016011071A (fr)
NO (1) NO20161286A1 (fr)
SA (1) SA516371756B1 (fr)
WO (1) WO2015130619A1 (fr)

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CN111005710B (zh) * 2019-12-19 2022-03-18 中石化四机石油机械有限公司 输砂混排系统及控制方法
CN115298501A (zh) * 2020-01-23 2022-11-04 联邦科学和工业研究组织 用于制备金属基体复合物的设备和方法
CN112282983B (zh) * 2020-10-29 2023-05-12 东风商用车有限公司 天然气发动机用扰流式集成混合器
KR20240008321A (ko) * 2021-05-19 2024-01-18 포스 애널리터컬 에이/에스 식이 섬유를 결정하는 방법 및 장치 및 이에 사용하기 위한 샘플 용기 시스템

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FR2596290B1 (fr) * 1986-03-27 1990-09-14 Schlumberger Cie Dowell Dispositif pour le melange d'un materiau pulverulent et d'un liquide, ou liquide-liquide
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JP2013132572A (ja) * 2011-12-26 2013-07-08 Jtekt Corp 混合分散装置
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Also Published As

Publication number Publication date
EA201691737A1 (ru) 2016-12-30
EP3110539A4 (fr) 2017-11-08
CA2939162C (fr) 2023-10-24
NO20161286A1 (en) 2016-08-10
CN106457178B (zh) 2020-11-06
MX2019014917A (es) 2020-02-07
WO2015130619A1 (fr) 2015-09-03
CN106457178A (zh) 2017-02-22
MX2016011071A (es) 2016-11-30
EP3110539A1 (fr) 2017-01-04
CA2939162A1 (fr) 2015-09-03
SA516371756B1 (ar) 2021-09-06
EA038757B1 (ru) 2021-10-14

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