Patent Publication Number: US-9884300-B2

Title: Multi chamber mixing manifold

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This is a continuation of U.S. patent application Ser. No. 14/869,070, filed on Sep. 29, 2015 (issuing as U.S. Pat. No. 9,457,326 on Oct. 4, 2016) which is a continuation of U.S. patent application Ser. No. 14/487,733, filed on Sep. 16, 2014 (issuing as U.S. Pat. No. 9,144,775 on Sep. 29, 2015), which is a continuation of U.S. patent application Ser. No. 13/458,526, filed Apr. 27, 2012 (issued as U.S. Pat. No. 8,834,016 on Sep. 16, 2014), which claims benefit of U.S. Provisional Patent Application Ser. No. 61/479,641, filed on Apr. 27, 2011, each of which is hereby incorporated herein by reference, and priority of each is hereby claimed. 
     Priority of U.S. Provisional Patent Application Ser. No. 61/479,641, filed on Apr. 27, 2011, incorporated herein by reference, is hereby claimed. 
    
    
     BACKGROUND 
     One embodiment relates generally to systems and methods for optimal mixing and distribution of two or more fluids, and more particularly, to systems and methods for optimal mixing and distribution of two or more fluids, including fracturing (frac) fluids and completion fluids, used in oil and gas operations. 
     In a variety of applications, the proper mixing and distribution of two or more fluids is a critical performance-affecting factor. 
     Many conventional manifold designs provide insufficient mixing and/or distribution of the subject fluids. For example, one conventional manifold design comprises a first pipe having inlets disposed thereon arranged in a first linear array pattern. The first pipe is connected via one or more conduits to a second pipe disposed substantially parallel to the first pipe, the second pipe having outlets disposed thereon arranged in a second linear array pattern. Fluids injected through the inlets travel through the first pipe to the connecting conduits and then into the second pipe where the fluid can then exit through the outlets. This flow path would ideally provide the means by which the injected fluids can thoroughly mix before exiting the manifold. 
     However, a typical scenario results in the fluid(s) injected through the outermost inlets of the first linear array pattern (i.e., the inlets disposed closest to the ends of the first pipe) being substantially absent from the outermost outlets of the second linear array pattern (i.e., the outlets disposed closest to the ends of the second pipe) positioned on the opposite side. A fluid injected through an inlet at one end of the first pipe is unlikely to travel in a flow path in which it will make it to an outlet at the opposite end of the second pipe. 
     While certain novel features of this invention shown and described below are pointed out in the annexed claims, the invention is not intended to be limited to the details specified, since a person of ordinary skill in the relevant art will understand that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation may be made without departing in any way from the spirit of the present invention. No feature of the invention is critical or essential unless it is expressly stated as being “critical” or “essential.” 
     SUMMARY 
     The apparatus of the present invention solves the problems confronted in the art in a simple and straightforward manner. What is provided is a multi chamber mixing chamber method and apparatus. 
     One or more embodiments of the invention provide systems and methods for optimal mixing and distribution of two or more fluids. 
     The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein: 
         FIG. 1  shows a top view of the exterior of a multi-chamber manifold in accordance with one or more embodiments of the invention. 
         FIG. 2  shows a rear perspective view of the exterior of a multi-chamber manifold in accordance with one or more embodiments of the invention. 
         FIG. 3  shows a perspective view taken from the right side of the rear interior portion of a multi-chamber manifold in accordance with one or more embodiments of the invention. 
         FIG. 4  shows a perspective view taken from the left side of the rear interior of a multi-chamber manifold in accordance with one or more embodiments of the invention. 
         FIG. 5  is a front perspective view (taken from the right side) showing the multi-chamber manifold of  FIGS. 1-4  mounted on a skid which in turn is mounted on a trailer. 
         FIG. 6  is a front perspective view (taken from the left side) showing the multi-chamber manifold of  FIGS. 1-4  mounted on a skid which in turn is mounted on a trailer. 
         FIG. 7  shows a flowchart illustrating a method in accordance with one or more embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Detailed descriptions of one or more preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in any appropriate system, structure or manner. 
       FIGS. 1-2  illustrate a top view and a perspective view, respectively, of the exterior of a multi-chamber manifold  100  in accordance with one or more embodiments of the invention. 
     The multi-chamber manifold  100  comprises an elongate housing  104  having a first end  116   a  and a second end  120   a . The ends  116   a ,  120   a  may be sealably capped with blocking end flanges  116   b ,  120   b  to prevent fluid from escaping therethrough. A plurality of fluid inlets  108   a - 108   d  may be disposed along housing  104  in a first linear array pattern. Outermost fluid inlet  108   a  may be disposed proximate the first end  116   a  and the first linear array pattern may extend towards the second end  120   a . A plurality of fluid outlets  112   a - 112   j  may also be disposed along housing  104  in a second linear array pattern. Outermost fluid outlet  112   a  may be disposed proximate the second end  120   a  and the second linear array pattern may extend towards the first end  116   a . Flow control valves (not shown) may be used to regulate fluid flow through the fluid inlets  108   a - 108   d  and the fluid outlets  112   a - 112   j . In one embodiment, carbon steel may be used to construct the multi-chamber manifold  100 . However, any material suitable for constructing a manifold for optimal mixing and distribution of two or more fluids may be used. While housing  104  is shown as having an annular cross-section, other configurations could be used in other embodiments. 
     Inlets  108   a - 108   d  may each be connected to one or more sources of fluid so that at least two different types of fluid may be fed or supplied to the multi-chamber manifold  100  for mixing and distribution. The fluids may include liquids and gases. In one embodiment, the fluids may comprise frac water blends obtained from a plurality of sources, or mixtures of frac fluids, chemical additives, and brines. Methods for facilitating the delivery of optimal volumes of a frac fluid containing optimal concentrations of one or more additives to a well bore are disclosed in United States Patent Publication No. 2010/0059226 A1, which is incorporated herein by reference in its entirety. Where a definition or use of a term in the incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply. The systems and methods of the present invention may be used to provide a homogeneous fluid blend for use in conjunction with the incorporated reference. 
     Referring now to  FIG. 3 , an inside view of housing  104  according to one or more embodiments of the present invention is shown. Within housing  104  of the multi-chamber manifold  100 , there may be provided a plurality of chambers. In one embodiment, the multichamber manifold  100  comprises two chambers: a primary mixing chamber  124  (referred to hereinafter as “vortex chamber  124 ”) and a secondary mixing chamber  128 . 
     As shown in  FIGS. 3-4 , the vortex chamber  124  may comprise a chamber separation structure  132  separating the vortex chamber  124  from the secondary mixing chamber  128 . An upper portion of the inner wall of housing  104  may define upper and lateral boundaries of the vortex chamber  124 . The vortex chamber  124  may be disposed proximate the first end  116   a  of housing  104  such that the vortex chamber  124  may receive fluid entering the multi-chamber manifold  100  through the inlets  108   a - 108   d.    
     The chamber separation structure  132  may comprise a horizontal chamber separation plate  136  defining a lower boundary of the vortex chamber  124  and one or more vertical chamber separation plates  140   a ,  140   b  defining lateral boundaries of the vortex chamber  124 . The horizontal chamber separation plate  136  comprises side walls  144   a ,  144   b  that may be sealably coupled to the inner wall of housing  104 . The one or more vertical chamber separation plates  140   a ,  140   b  may be oriented substantially perpendicular to the horizontal chamber separation plate  136 . The one or more vertical chamber separation plates  140   a ,  140   b  may be disposed at and sealably coupled to the ends  148   a ,  148   b  of the horizontal chamber separation plate  136 . In one embodiment, a portion of vertical chamber separation plate  140   a  may be shaped to conform to the geometry of the inner wall of housing  104  so as to create a sealed barrier, preventing the fluid mixture inside the vortex chamber  124  from flowing laterally in a direction towards the second end of housing  120   a.    
     Inlets  108   a - 108   d  may protrude both outwardly and inwardly with respect to housing  104 , each outward-inward protrusion combination forming an inlet nozzle defining a passage through which a fluid may be injected to the vortex chamber  124 . The outwardly protruding portions  152   a - 152   d  of the inlet nozzles allow for fluids to commence its flow path into the multichamber manifold  100  such that the fluids flow substantially radial to housing  104 . The inwardly protruding portions  156   a - 156   d  of the inlet nozzles are angled to affect an angular velocity on the fluids, projecting the fluids into the vortex chamber  124  in a manner causing the fluids to swirl rapidly about a center. This induced swirl, or vortex, provides turbulent flow that facilitates thorough mixing of the injected fluids, producing a substantially homogeneous blend. The specific angle of each inlet nozzle is determined based on the particular application. 
     The chamber separation structure  132  may further comprise a plurality of baffle plates  160   a ,  160   b  that extend upwardly from and substantially perpendicular to the horizontal chamber separation plate  136 . As previously described, the inlet nozzles are angled to induce a vortex that facilitates the mixing of the injected fluids. The upwardly extending baffle plates  160   a ,  160   b  serve to guide the mixture of fluids through a gate  164  disposed between the upwardly extending baffle plates  160   a ,  160   b , the gate  164  defining an opening in the horizontal chamber separation plate  136 . The gate  164  directs the mixture of fluids to flow to the secondary mixing chamber  128 . 
     One or more inlet nozzles may be disposed at either side of the upwardly extending baffle plates  160   a ,  160   b . For example, in one embodiment, a first set of two inlet nozzles may be disposed at a lateral distance from upwardly extending baffle plate  160   a , proximal to the first end  116   a  of housing  104 . In this configuration, a second set of two inlet nozzles may also be disposed at a lateral distance from upwardly extending baffle plate  160   b , distal to the first end  116   a  of housing  104  relative to first set of inlet nozzles. The inwardly protruding portions  156   a - 156   d  of the inlet nozzles may be angled upward relative to the horizontal chamber separation plate  136  and inward relative to the one or more vertical chamber separation plates  140   a ,  140   b . Thus, the two sets of inlet nozzles may provide a mirror image trajectory of vectored fluid flow allowing the fluids to coincide and induce the vortex above the gate  164 . Gravity causes substantially all of the fluid mixture to flow downwardly through gate  164 , guided, in part, by upwardly extending baffles  160   a ,  160   b.    
     The chamber separation structure  132  may further comprise an L-shaped baffle plate  168  connected to the bottom surface of the horizontal chamber separation plate  136  and disposed below the gate  164 . Upon passing through gate  164 , the fluid mixture encounters the L-shaped baffle plate  168 , which guides the fluid mixture flow in a first direction towards the first end  116   a  of housing  104 . The change in flow direction of the fluid mixture caused by the L-shaped baffle plate  168  may further enhance the mixture quality. 
     Another change in flow direction is caused by the fluid mixture encountering the first end  116   a  of housing  104 , which forces the fluid mixture to flow in a second direction opposite the first direction. This change in flow direction may also further enhance the mixture quality. Moreover, as the fluid mixture flows in the second direction, it flows past the L-shaped baffle plate  168  towards the second end  120   a  of housing  104  where the fluid mixture can then be evenly distributed among fluid outlets  112   a - 112   j.    
     Although  FIGS. 3-4  show multi-chamber manifold  100  having two chambers (vortex chamber  124  and secondary mixing chamber  128 ), it is envisioned that other embodiments may have additional chambers for further mixing. A secondary spill over plate (not shown) may be incorporated in the secondary mixing chamber  128  in order to capture solids or perform a two-stage fluid separation prior to the fluid mixture exiting through outlets  112   a - 112   j . For example, in one or more embodiments, a two-stage fluid separation may involve the separation of oil and water. 
     The multi-chamber manifold  100  illustrated in  FIGS. 1-4  may be designed and constructed to be lightweight, compact, and portable. In one or more embodiments of the invention, the multi-chamber manifold  100  may be mounted on a trailer, truck, or any other suitable vehicle for transporting the manifold  100  to various work sites. However, in other embodiments of the invention, the manifold  100  may be fixed to a particular location. 
     One or more embodiments of the present invention relate to methods for enhanced mixing of fluids, as shown by the flow chart in  FIG. 5 . The methods involve providing a multichamber manifold  500 , the manifold comprising a housing, a plurality of fluid inlets, a plurality of fluid outlets, a vortex chamber, and a secondary mixing chamber. 
     The methods further involve supplying two or more input fluids to the manifold through the fluid inlets of the manifold  502 . The fluids may flow through inlet nozzles and into the vortex chamber. The fluid nozzles may be angled to induce a vortex in the vortex chamber  504 . The vortex serves the purpose of stirring the input fluids for thorough mixing, producing a fluid mixture. 
     The fluid mixture may be directed downwards from the vortex chamber through a gate to a secondary mixing chamber  506  for further mixing. Baffles may be used to guide the flow path of the fluid mixture in various directions. The fluid mixture may be directed in a first direction towards a first end of the manifold  508 . The fluid mixture may also be directed in a second direction opposite the first direction towards a second end of the manifold  510 . Changing the direction of the fluid mixture flow path facilitates further mixing of the fluids. 
     The resulting homogeneous fluid blend may be distributed among the plurality of fluid outlets to discharge from the manifold  512 . The destination of the fluid mixture after discharging from the manifold depends on the particular application. Fluid flow can be directed in its entirety to one destination or distributed either evenly or proportionally to multiple destinations. 
     It is to be understood that the invention is not to be limited or restricted to the specific examples or embodiments described herein, which are intended to assist a person skilled in the art in practicing the invention. For example, the number of fluids to be mixed, the number of inlets, the number of outlets, the number of spill over plates, and the number of chambers may vary according to the desired results of a particular application. Also, the dimensions of the various components of the multi-chamber manifold may be scaled to achieve the desired results of a particular application. Accordingly, numerous changes may be made to the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims. 
     The following is a list of reference numerals: 
     
       
         
           
               
            
               
                   
               
               
                 LIST FOR REFERENCE NUMERALS 
               
            
           
           
               
               
            
               
                 (Part No.) 
                 (Description) 
               
               
                   
               
               
                 100 
                 multi-chamber manifold 
               
               
                 104 
                 elongate housing 
               
               
                 116a 
                 first end 116a 
               
               
                 120a 
                 second end 
               
               
                 116b 
                 blocking end flange 
               
               
                 120b 
                 blocking end flange 
               
               
                 108 
                 fluid inlets (108a-108d) 
               
               
                 112 
                 plurality of fluid (outlets 112a-112j) 
               
               
                 124 
                 a primary mixing chamber (vortex chamber) 
               
               
                 128 
                 secondary mixing chamber 
               
               
                 132 
                 chamber separation structure 
               
               
                 136 
                 horizontal chamber separation plate 
               
               
                 140a 
                 vertical chamber separation plate 
               
               
                 140b 
                 vertical chamber separation plate 
               
               
                 144a 
                 side wall 
               
               
                 144b 
                 side wall 
               
               
                 152 
                 outwardly protruding portions (152a-152d) of  
               
               
                   
                 the inlet nozzles 
               
               
                 156 
                 inwardly protruding portions (156a-156d) of the  
               
               
                   
                 inlet nozzles are angled to affect an angular  
               
               
                   
                 velocity on the fluids 
               
               
                 160a 
                 baffle plate 
               
               
                 160b 
                 baffle plate 
               
               
                 164 
                 gate 
               
               
                 168 
                 L-shaped baffle plate 
               
               
                 500 
                 step of providing a multichamber manifold 
               
               
                 502 
                 step of supplying two or more input fluids to the manifold 
               
               
                 504 
                 step of inducing a vortex in the vortex chamber 504 
               
               
                 506 
                 step of directing fluids from the vortex chamber to a 
               
               
                   
                 secondary mixing chamber 
               
               
                 508 
                 step of directing the mixture of fluids in a first direction 
               
               
                   
                 towards a first end of the manifold 
               
               
                 510 
                 step of directing mixture of fluids in a second  
               
               
                   
                 direction, which second direction is substantially  
               
               
                   
                 the opposite direction as the first direction, and  
               
               
                   
                 towards a second end of the manifold 
               
               
                 512 
                 step of distributing the mixture of fluids among  
               
               
                   
                 outlets to discharge from the manifold 
               
               
                   
               
            
           
         
       
     
     All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise. 
     It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above. Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention set forth in the appended claims. The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.