Apparatus and method of delivering a fluid using direct proppant injection

Abstract

An apparatus and method for delivering a fluid mixture using direct injection to a mixing apparatus. The apparatus including a proppant storage vessel configured to contain therein a proppant material and output a proppant output flow at ambient pressure to a solid feed pump assembly. The apparatus further including a fracturing fluid storage vessel configured to contain therein a fracturing fluid and output a fracturing fluid output flow at a fracture fluid blending pressure. The solid feed pump assembly configured to output to a mixing apparatus, a proppant output flow at the fracture fluid blending pressure. The mixing apparatus configured to output a fluid mixture of the proppant and the fracturing fluid at the fracture fluid blending pressure. The mixing apparatus coupled to a high pressure pump assembly and configured to deliver the fluid mixture therein to a downstream component at an injection pressure.

1 . An apparatus for delivering a fluid mixture comprising:
 a proppant storage vessel configured to contain therein a proppant material and output a proppant output flow at ambient pressure;   a solid feed pump assembly coupled to the proppant storage vessel, the solid feed pump assembly including a proppant inlet in fluidic communication with the proppant storage vessel proppant output flow, the solid feed pump assembly configured to output a proppant output flow at a discharge pressure, wherein the discharge pressure is greater than the ambient pressure;   a fracturing fluid storage vessel configured to contain therein a fracturing fluid and output a fracturing fluid output flow at a fracture fluid blending pressure, wherein the fracture fluid blending pressure is greater than the ambient pressure;   a pressurized mixing apparatus coupled to the solid feed pump assembly, the pressurized mixing apparatus including a proppant inlet in fluidic communication with the solid feed pump assembly proppant output flow and a fracturing fluid inlet in fluidic communication with the fracturing fluid output flow, the pressurized mixing apparatus configured to mix the proppant output flow and the fracturing fluid output flow therein and output a fluid mixture of proppant and fracturing fluid, wherein the fracturing fluid of the fluid mixture of proppant and fracturing fluid is at the fracture fluid blending pressure; and   a pump assembly coupled to the pressurized mixing chamber and configured to deliver the fluid mixture of proppant and fracturing fluid therein to a downstream component at an injection pressure, wherein the injection pressure is greater than the fracture fluid blending pressure.   
     
     
         2 . The apparatus of  claim 1 , wherein the solid feed pump assembly is a solid feed pump assembly set forth by the Posimetric® standard. 
     
     
         3 . The apparatus of  claim 1 , wherein the solid feed pump assembly is an eductor pump assembly. 
     
     
         4 . The apparatus of  claim 1 , wherein the solid feed pump assembly is a rotary positive displacement pump assembly. 
     
     
         5 . The apparatus of  claim 1 , wherein the fracture fluid blending pressure is in a range of 200-400 psi. 
     
     
         6 . The apparatus of  claim 5 , wherein the fracture fluid blending pressure is approximately 300 psi. 
     
     
         7 . The apparatus of  claim 1 , wherein the injection pressure is in a range of 5000-12,000 psi or higher. 
     
     
         8 . The apparatus of  claim 1 , wherein the injection pressure is approximately 10,000 psi. 
     
     
         9 . The apparatus of  claim 1 , wherein the proppant material is sand. 
     
     
         10 . The apparatus of  claim 1 , wherein the fracturing fluid is at least one of liquid CO 2  or liquid propane. 
     
     
         11 . The apparatus of  claim 1 , wherein the solid feed pump assembly is configured to receive a continual supply of proppant material and output a continuous proppant output flow. 
     
     
         12 . An apparatus for delivering a fluid mixture comprising:
 a proppant storage vessel configured to contain therein a proppant material and output a proppant output flow at ambient pressure;   a solid feed pump assembly coupled to the proppant storage vessel, the solid feed pump assembly including a proppant inlet in fluidic communication with the proppant storage vessel proppant output flow, the solid feed pump assembly configured to output a proppant output flow at a discharge pressure, wherein the discharge pressure is greater than the ambient pressure, wherein the solid feed pump assembly is one of a solid feed pump assembly set forth by the Posimetric® standard, an eductor pump assembly or a rotary positive displacement pump assembly;   a fracturing fluid storage vessel configured to contain therein a fracturing fluid and output a fracturing fluid output flow at a fracture fluid blending pressure, wherein the fracture fluid blending pressure is greater than the ambient pressure;   a mixing apparatus coupled to the solid feed pump assembly, the mixing apparatus including a proppant inlet in fluidic communication with the solid feed pump assembly proppant output flow and a fracturing fluid inlet in fluidic communication with the fracturing fluid output flow, the mixing apparatus configured to mix the proppant output flow and the fracturing fluid output flow therein and output a fluid mixture of proppant and fracturing fluid, wherein the fracturing fluid is at the fracture fluid blending pressure; and   a pump assembly coupled to the mixing chamber and configured to deliver the fluid mixture therein to a downstream component at an injection pressure, wherein the injection pressure is greater than the fracture fluid blending pressure.   
     
     
         13 . The apparatus of  claim 12 , wherein the fracture fluid blending pressure is in a range of 200-400 psi. 
     
     
         14 . The apparatus of  claim 13 , wherein the fracture fluid blending pressure is approximately 300 psi. 
     
     
         15 . The apparatus of  claim 12 , wherein the injection pressure is in a range of 5000-12,000 psi. 
     
     
         16 . The apparatus of  claim 12 , wherein the proppant material is sand and the fracturing fluid is at least one of liquid CO 2  or liquid propane. 
     
     
         17 . The apparatus of  claim 12 , wherein the solid feed pump assembly is a solid feed pump assembly set forth by the Posimetric® standard coupled to the proppant storage vessel, the solid feed pump assembly comprising:
 a consolidation section configured to cause the proppant material to compact and act as a solid mass; 
 a rotating section configured to increase the pressure of the proppant material therein; and 
 a discharge section configured to discharge the proppant material at the increased discharge pressure. 
 
     
     
         18 . The apparatus of  claim 12 , wherein the solid feed pump assembly is an eductor pump assembly coupled to the proppant storage vessel and the fracturing fluid storage vessel, the eductor pump assembly comprising:
 a suction chamber in fluidic communication with the proppant output flow, the fracture fluid output flow and a motive fluid flow, the suction chamber configured to output a fluid mixture to a mixing chamber; and   an expansion feature coupled to the mixing chamber and configured to expand the fluid mixture therein for delivery to a downstream component.   
     
     
         19 . The apparatus of  claim 12 , wherein the solid feed pump assembly is rotary positive displacement pump assembly coupled to the proppant storage vessel, the rotary positive displacement pump assembly comprising:
 a pump body, including a feed inlet at a first end and a discharge point at a second end; a feed mechanism disposed within the pump body and configured to move the proppant material from the feed inlet to the discharge point while increasing a pressure of the proppant material from an ambient pressure to the discharge pressure.   
     
     
         20 . An apparatus for delivering a fluid mixture comprising:
 a proppant storage vessel configured to output a proppant output flow at ambient pressure;   a solid feed pump in fluidic communication with the proppant storage vessel, the solid feed pump assembly configured to output a proppant output flow at a  discharge pressure, wherein the discharge pressure is greater than the ambient pressure;   a fracturing fluid storage vessel configured to contain therein a fracturing fluid at a fracture fluid blending pressure, wherein the fracture fluid blending pressure is greater than the ambient pressure;   a mixing apparatus coupled to the solid feed pump assembly and the fracturing fluid storage vessel, the mixing apparatus configured to output a fluid mixture of proppant and fracturing fluid, wherein the fracturing fluid is at the fracture fluid blending pressure; and   a pump assembly coupled to the mixing chamber and configured to output a fluid mixture to a downstream component at an injection pressure, wherein the injection pressure is greater than the fracture fluid blending pressure.   
     
     
         21 . A method of delivering a fluid mixture, comprising:
 providing an input of a proppant material at ambient pressure to a proppant storage vessel, the proppant storage vessel configured to output a proppant output flow at ambient pressure;   providing an input of a fracture fluid at a fracture fluid blending pressure to a fracture fluid storage vessel, the fracture fluid storage vessel configured to output a fracture fluid output flow at the a fracture fluid blending pressure;   inputting the proppant output flow at ambient pressure from the proppant storage vessel into a solid feed pump assembly wherein the pressure of the proppant output flow is increased to a discharge pressure;   inputting the proppant output flow at the discharge pressure and a fracture fluid output flow at the fracture fluid blending pressure into a mixing apparatus;   mixing the proppant output flow and the fracturing fluid output flow therein the mixing apparatus and outputting a fluid mixture of proppant and fracturing fluid, wherein the fracturing fluid is at the fracture fluid blending pressure;   increasing the pressure of the output fluid mixture in a pump to output an increased pressure fluid mixture; and   delivering the increased pressure fluid mixture to one or more downstream components.