Hydration apparatus and method

Abstract

Vessels including an enclosure having an outer perimeter and an interior space, a channel disposed in the interior space, a first port disposed on a surface of the first enclosure at or proximate to a first end of the channel, and a second port disposed on a surface of the first enclosure at or proximate to a second end of the channel, where the channel has a length greater than the shortest distance between the first port and the second port, and where the first port and the second port are in fluid communication with one another. In some cases, the length of the channel is greater than a length of the outer perimeter. Optionally, the vessel may have a second enclosure having an outer perimeter and an interior space with a second channel disposed in the interior space, a third port disposed on a surface of the second enclosure at or proximate to a first end of the second channel, and a fourth port disposed on a surface of the second enclosure at or proximate to a second end of the second channel, where the second port, the third port and fourth port are in fluid communication. In yet some other optional variations, the vessel further includes a plurality of enclosures each having an outer perimeter and an interior space, a channel disposed in the interior space, a port disposed on a surface of the enclosure at or proximate to a first end of the channel, and a port disposed on a surface of the enclosure at or proximate to a second end of the channel, where the channel has a length greater than a shortest distance between the ports, and the second port and the ports disposed on the surface of the plurality of enclosures are in fluid communication. The perimeter shape of the enclosure(s) may be any suitable shape, including, but not limited to, substantially circular, ovate or rectangular.

What is claimed is: 
     
         1 . A method for treating at least a portion of a subterranean formation penetrated by a wellbore, the method comprising:
 a) introducing into at least one reaction vessel a mixture comprising:
 i) a liquid component comprising a first chemical reactant; 
 ii) a second chemical reactant; 
   b) passing the mixture through the at least one reaction vessel;   c) preparing a treatment fluid which comprises the mixture and an optional insoluble particle; and   d) introducing the treatment fluid into the wellbore;   
       wherein the reaction vessel comprises:
 a) a first enclosure having an outer perimeter and an interior space defined therein; 
 b) a channel disposed in the interior space; 
 c) a first port disposed on a surface of the first enclosure at or proximate to a first end of the channel; and, 
 d) a second port disposed on a surface of the first enclosure at or proximate to a second end of the channel; 
 wherein the channel has a length greater than a shortest distance between the first port and the second port, and wherein the first port and the second port are in fluid communication. 
 
     
     
         2 . The method of  claim 1  wherein the first chemical reactant is water and the second chemical reactant is a water reactable material. 
     
     
         3 . The method of  claim 1  wherein the channel has a length greater than a length of the outer perimeter. 
     
     
         4 . The method of  claim 1  further comprising a second enclosure having an outer perimeter and an interior space defined therein, the second enclosure comprising a second channel disposed in the interior space, a third port disposed on a surface of the second enclosure at or proximate to a first end of the second channel, and a fourth port disposed on a surface of the second enclosure at or proximate to a second end of the second channel, wherein the second port, the third port and fourth port are in fluid communication. 
     
     
         5 . The method of  claim 1  further comprising a plurality of enclosures, wherein each of the plurality of enclosures comprise an outer perimeter and an interior space defined therein, a channel disposed in the interior space, a port disposed on a surface of the enclosure at or proximate to a first end of the channel, and a port disposed on a surface of the enclosure at or proximate to a second end of the channel, and wherein the channel has a length greater than a shortest distance between the ports, and wherein the second port and the ports disposed on the surface of the plurality of enclosures are in fluid communication. 
     
     
         6 . The method of  claim 1  wherein the mixture undergoes a rate limited chemical reaction requiring residence time, while flowing the mixture through the reaction vessel under the influence gravity, pressure or combination thereof. 
     
     
         7 . The method of  claim 2  wherein the concentration of water reactable material is greater than or equal to about 40 pounds per 1000 gallons of liquid component. 
     
     
         8 . The method of  claim 1  wherein the mixture is passed through a plurality of reaction vessels. 
     
     
         9 . The method of  claim 8  wherein one or more additional chemical components are injected into the plurality of reaction vessels at one or more points downstream from the first port. 
     
     
         10 . The method of  claim 1  wherein the reaction vessel further comprises at least one static mixing element, an axial mixer, or combination thereof. 
     
     
         11 . The method of  claim 1  further comprising measuring pressure change of the mixture across the at least one reaction vessel to monitor a reaction of the first chemical reactant with the second chemical reactant. 
     
     
         12 . The method of  claim 1  decreasing the concentration of the first chemical reactant, the second chemical reactant, or both, during the treating. 
     
     
         13 . The method of  claim 1  wherein the channel has an archimedian spiral pattern. 
     
     
         14 . The method of  claim 13  wherein the mixture is injected into a high pressure fluid stream. 
     
     
         15 . The method of  claim 14  wherein the mixture injected into a high pressure fluid stream is a pill comprising a high concentration of the second chemical reactant. 
     
     
         16 . The method of  claim 4  wherein the channel and the second channel have an archimedian spiral pattern, and wherein a first fluid flowpath is in a progressively inward direction through the channel of the first enclosure, and wherein a second fluid flowpath is in a progressively outward direction through the second channel. 
     
     
         17 . The method of  claim 4  wherein the channel and the second channel have an archimedian spiral pattern, and wherein a first fluid flowpath is in a progressively outward direction through the channel of the first enclosure, and wherein a second fluid flowpath is in a progressively inward direction through the second channel. 
     
     
         18 . A method for treating at least a portion of a subterranean formation penetrated by a wellbore, the method comprising:
 a) introducing into at least one hydration vessel a mixture comprising:
 i) a liquid component comprising water; 
 ii) a second component comprising a hydratable material; 
   b) passing the mixture through the at least one hydration vessel in a continuous manner to form a slurry;   c) preparing a treatment fluid which comprises the slurry and an optional insoluble particle; and   d) introducing the treatment fluid into the wellbore;   
       wherein the hydration vessel comprises:
 a) an inlet chamber comprising a spiraling first fluid passageway; and, 
 b) a discharge chamber comprising a spiraling second fluid passageway; 
 
       wherein the first fluid passageway and the second fluid passageway are in fluid communication. 
     
     
         19 . The method of  claim 18  further comprising at least one intermediate chamber disposed between the inlet chamber and the discharge chamber, wherein the at least one intermediate chamber comprises a spiraling first intermediate fluid passageway, wherein the first fluid passageway, the second fluid passageway, and the first intermediate fluid passageway are in fluid communication. 
     
     
         20 . The method of  claim 19  wherein the at least one intermediate chamber is at least one pair of intermediate chambers disposed between the inlet chamber and the discharge chamber, the pair of intermediate chambers comprising:
 i) a first intermediate chamber comprising a spiraling first intermediate fluid passageway; and, 
 ii) a second intermediate chamber comprising a spiraling second intermediate fluid passageway; 
 
       wherein the first fluid passageway, the second fluid passageway, the first intermediate fluid passageway and the second intermediate fluid passageway are in fluid communication. 
     
     
         21 . The method of  claim 19  wherein the at least one intermediate chamber comprises a first and a second fluid passageway, wherein the fluid passageways are partitioned by a plate having a hole therein, and wherein the first and the second fluid passageways are in fluid communication. 
     
     
         22 . The method of  claim 19  wherein the first outer chamber and the second outer chamber each comprise a first and a second fluid passageway, wherein the fluid passageways are partitioned by a plate having a hole therein, and wherein the first and the second fluid passageway are in fluid communication. 
     
     
         23 . The method of  claim 22  wherein a first fluid flowpath is in a progressively inward direction through the first fluid passageway, and wherein a second fluid flowpath is in a progressively outward direction through the second fluid passageway. 
     
     
         24 . The method of  claim 19  wherein a first fluid flowpath is in a progressively inward direction through the first fluid passageway, and wherein a second fluid flowpath is in a progressively inward direction through the second fluid passageway. 
     
     
         25 . The method of  claim 18  wherein the hydration vessel further comprises an inlet port disposed on a perimeter of the inlet chamber, and a discharge port disposed on a perimeter of the discharge chamber. 
     
     
         26 . The method of  claim 19  wherein the hydration vessel further comprises a second pair of intermediate chambers disposed between the at least one pair of intermediate chambers and the discharge chamber. 
     
     
         27 . The method of  claim 26  wherein the hydration vessel further comprises a third pair of intermediate chambers disposed between the second pair of intermediate chambers and the discharge chamber. 
     
     
         28 . The method of  claim 27  wherein the hydration vessel further comprises a fourth pair of intermediate chambers disposed between the third pair of intermediate chambers and the discharge chamber. 
     
     
         29 . The method of  claim 20  wherein the inlet chamber, the at least one intermediate chamber, and the discharge chamber are substantially circular or ovate in outer perimeter shape. 
     
     
         30 . The method of  claim 20  wherein the inlet chamber, the at least one intermediate chamber, and the discharge chamber are substantially rectangular in outer perimeter shape. 
     
     
         31 . The method of  claim 19  wherein the hydration vessel further comprises at least one pair of intermediate chambers disposed between the first intermediate chamber and the discharge chamber, the pair of intermediate chambers comprising:
 i) a second intermediate chamber comprising a spiraling second intermediate fluid passageway; and, 
 ii) a third intermediate chamber comprising a spiraling third intermediate fluid passageway; 
 
       wherein the first fluid passageway, the second fluid passageway, the first intermediate fluid passageway, the second intermediate fluid passageway and the third intermediate passageway are in fluid communication. 
     
     
         32 . The method of  claim 31  wherein the hydration vessel further comprises a second pair of intermediate chambers disposed between the at least one pair of intermediate chambers and the discharge chamber. 
     
     
         33 . The method of  claim 32  wherein the hydration vessel further comprises a third pair of intermediate chambers disposed between the second pair of intermediate chambers and the discharge chamber. 
     
     
         34 . The method of  claim 33  wherein the hydration vessel further comprises a fourth pair of intermediate chambers disposed between the third pair of intermediate chambers and the discharge chamber. 
     
     
         35 . The method of  claim 18  wherein the at least one hydration vessel is a plurality of hydration vessels connected in a series configuration. 
     
     
         36 . The method of  claim 18  wherein the at least one hydration vessel is a plurality of hydration vessels connected in a parallel configuration. 
     
     
         37 . A method comprising:
 a) providing an apparatus, the apparatus comprising:
 i. an inlet chamber having an outer perimeter and a first fluid passageway formed therein, wherein the first fluid passageway has a length greater than a shortest distance between the outer perimeter and center of the inlet chamber; and, 
 ii. a discharge chamber having an outer perimeter and a second fluid passageway formed therein, wherein the second fluid passageway has a length greater than a shortest distance between the outer perimeter and center of the discharge chamber; 
   wherein the first fluid passageway and the second fluid passageway are in fluid communication;   b) introducing into the apparatus, an admixture comprising:
 i) a liquid component comprising a first chemical; and, 
 ii) a second component; 
   c) flowing the admixture through the apparatus; and,   d) discharging from the apparatus a product formed from the first chemical and the second component.