System, method and apparatus for entraining air in concrete

Abstract

A method of preparing a concrete composition for downhole injection includes utilizing a controller to control a process including circulating process water in a process water supply loop for a predetermined period while monitoring and controlling the temperature and flow rate of the process water, circulating aqueous-based air entrainment solution in an aqueous-based air entrainment solution supply loop for the predetermined period and controlling the flow rate of the aqueous-based air entrainment solution and after the predetermined period of time in which the flow of process water and aqueous-based air entrainment solution have stabilized, simultaneously actuating valves to divert and mix the process water, the aqueous-based air entrainment solution and compressed air to produce an air-entrained foam and mixing the foam with a concrete composition to be deployed downhole.

1 . A foam production system comprising:
 a set of mixers;   a water supply circuit switchably connected to the set of mixer;   an air entrainment solution supply circuit switchably connected to the set of mixers;   an air supply switchably connected to the set of mixers;   a controller connected to the set of mixers, the water supply circuit, the air entrainment solution supply circuit, and the air supply;   a process water circulated in the water supply circuit in a non-integrated mode;   an air entrainment solution circulated in the air entrainment solution supply circuit in the non-integrated mode;   a regulated air maintained in the air supply in the non-integrated mode;   an air-entrained foam generated by the set of mixers from the regulated air, the process water, and the air entrainment solution in an integrated mode;   a set of process parameters stored in the controller;   a set of process data received by the controller; and,   a set of control signals generated by the controller based on the set of process parameters and the set of process data.   
     
     
         2 . The foam production system of  claim 1 , further comprising:
 a set of non-integrated mode parameters stored in the controller;   a set of non-integrated mode data received by the controller; and,   a set of non-integrated mode control signals generated by the controller based on the set of process parameters and the set of process data.   
     
     
         3 . The foam production system of  claim 1 , further comprising:
 a set of integrated mode parameters stored in the controller;   a set of integrated mode data received by the controller; and,   a set of integrated mode control signals generated by the controller based on the set of process parameters and the set of process data.   
     
     
         4 . A method for generating a foam comprising the steps of:
 circulating a water supply independently and simultaneously in a non-integrated mode;   circulating an air entrainment solution independently and simultaneously in the non-integrated mode;   maintaining a regulated air supply independently and simultaneously in the non-integrated mode; and,   mixing the water supply, the air entrainment solution, and the regulated air supply together in an integrated mode to generate the foam when a batch process command is received.   
     
     
         5 . The method of  claim 4 , further comprising the steps of:
 receiving a set of non-integrated mode parameters;   receiving a set of non-integrated mode data;   comparing the set of non-integrated mode data to the set of non-integrated mode parameters; and,   generating a set of non-integrated mode control signals if the set of non-integrated mode data is outside the set of non-integrated mode parameters.   
     
     
         6 . The method of  claim 5 , further comprising the step of circulating the water supply based on the set of non-integrated mode control signals. 
     
     
         7 . The method of  claim 5 , further comprising the step of circulating the air entrainment solution based on the set of non-integrated mode control signals. 
     
     
         8 . The method of  claim 5 , further comprising the step of maintaining the air supply based on the set of non-integrated mode control signals. 
     
     
         9 . The method of  claim 4 , further comprising the steps of:
 receiving a set of integrated mode parameters;   receiving a set of integrated mode data;   comparing the set of integrated mode data to the set of integrated mode parameters; and,   generating a set of integrated mode control signals if the set of integrated mode data is outside the set of integrated mode parameters.   
     
     
         10 . The method of  claim 9 , further comprising the step of circulating the water supply based on the set of integrated mode control signals. 
     
     
         11 . The method of  claim 9 , further comprising the step of circulating the air entrainment solution based on the set of integrated mode control signals. 
     
     
         12 . The method of  claim 9 , further comprising the step of maintaining the air supply based on the set of integrated mode control signals. 
     
     
         13 . The method of  claim 9 , wherein the step of mixing further comprises the steps of:
 discharging the water supply into a set of mixers if the set of integrated mode data is within the set of integrated mode parameters;   discharging the air entrainment solution into the set of mixers if the set of integrated mode data is within the set of integrated mode parameters; and,   discharging the air supply into the set of mixers if the set of integrated mode data is within the set of integrated mode parameters.