Patent Application
20080037361
This application claims priority from U.S. Provisional Patent Application Ser. No. 60/773,496 filed Feb. 15, 2006, the entire specification of which is hereby incorporated by reference in its entirety.
1. Field of the Invention
The present invention relates in general to mixers, and more particularly to a mixer apparatus for use in association with, for example, mixing of solids with a working fluid. For example, the mixer apparatus of the present invention discloses pumper impellers which are well suited for the mixing of oil well drilling mud and the like as the mixer both mixes and shears the material. The invention, however, is not limited to the mixing of solids with a working fluid, or limited to use in association with the oil drilling industry. It is contemplated that the mixer apparatus of the present invention is well suited for a number of different applications.
2. Background Art
Many industrial processes and other methods require the combining or mixing of various materials together, such as, for example, solids within a working fluid. Typically, with many such applications, as the dispersion of the solids within the working fluid increases, the resulting mixture exhibits improved performance. There is often a struggle properly mix various materials together. Difficulty is likewise encountered relative to the maintenance of solids within a mixture.
By way of example, the oil drilling industry typically uses what is commonly referred to as “mud” which is a mixture of a number of solids with a working fluid. Generally, the solids are introduced into a stream of water or other working fluid (such as diesel fuel) through any number of different methods. Once introduced, the solids and the working fluid mix to some extent as they are directed to a holding tank. In certain applications, the tank may include recirculation pumps which re-circulate the mixture so as to limit separation.
While such mixing systems have been employed for many years with some success, there are nevertheless drawbacks to such systems. In particular, solids are often not well dispersed within the working fluid. As such, it is generally necessary to continuously agitate the mixture to preclude undesirable separation thereof. Second, such a mixture often lacks the desired viscosity which leads to poor or reduced performance during use in the well drilling operation. Typically, the result is increased wear and maintenance to equipment coupled with an increased operating cost. Third, increased quantities of solids may be required to achieve a desired performance in a inadequately mixed material. In addition to the cost of materials, certain drilling operations are in remote locations place a premium on storage and inventory space.
Accordingly, it is an object of the present invention to provide a mixer apparatus which can disperse a solid within a working fluid.
It is another object of the present invention to provide for a more uniform mixture of solids with a working fluid.
It is another object of the present invention to improve the mixture of solids within a fluid.
It is another object of the present invention to improve the performance of mud used in association with oil drilling, while the invention is not limited to such use.
Additional objects will be understood with reference to the drawings and claims appended hereto.
The invention is directed to a mixer apparatus which overcomes the shortcomings of the prior art. In particular, such a mixer comprises a mixing chamber assembly, a mixing agitation assembly and an orifice assembly. The mixing chamber assembly comprises a housing defining a cavity, an inlet providing fluid communication with the cavity and an outlet providing fluid communication with the cavity. The mixing agitation assembly comprise a motor assembly, a drive shaft coupled to the motor assembly and at least one impeller coupled to the drive shaft. The at least one impeller and at least a portion of the drive shaft are positioned within the housing and are also positioned between the inlet and the outlet. The orifice assembly includes at least one orifice positioned between the inlet and the at least one impeller. As fluid is directed into the cavity through the inlet and through the at least one orifice, at least a portion of the fluid is mixed by the impeller and exhausted through the outlet.
In a preferred embodiment, the outlet is positioned above the inlet such that fluid directed through the inlet extends in a generally vertically upward direction as it progresses from the inlet, through the at least one orifice, the at least one impeller and the outlet.
In another preferred embodiment, the orifice assembly further comprises a first orifice and a second orifice in a spaced apart configuration within the housing so as to define a first region between the second orifice and the housing and a second region between the first and second orifices. The at least one impeller comprises a first impeller positioned in the first region and a second impeller positioned in the second region.
In another preferred embodiment, the orifice assembly further comprises a frame coupled to each of the first orifice and the second orifice. The frame is removably positionable within the cavity so as to facilitate the positioning of the first and second orifice in a proper special orientation.
In one such embodiment, the second orifice is spaced apart from the housing so as to define a third region between the housing and second orifice, opposite the second region.
In one such embodiment, the inlet is directed into the third region of the cavity. In another such embodiment, the first and second regions are substantially identical in volume.
In a preferred embodiment, the at least one orifice is substantially circular.
In another embodiment, the at least one orifice is spaced apart from the at least one impeller.
In a preferred embodiment, the drive shaft rotates about an axis that is parallel to the flow of fluid through the mixer.
In yet another aspect of the invention, the invention is directed to a method of mixing mud suitable for use in oil well drilling applications. The method comprises the steps of: providing the mud through an inlet; directing the mud through an orifice; mixing the mud with an impeller; directing the mud through a second orifice; mixing the mud with a second impeller; and directing the mud through an outlet.
The invention will now be described with reference to the drawings wherein:
While this invention is susceptible of embodiment in many different forms, there is shown in the drawings specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments illustrated.
It will be understood that like or analogous elements and/or components, referred to herein, are identified throughout the drawings by like reference characters. In addition, it will be understood that the drawings are merely representations of the present invention, and some of the components may have been distorted from actual scale for purposes of pictorial clarity.
Referring now to the Figures, and in particular to
Mixing agitation assembly 12 is shown in
Drive shaft 22 includes first end 36 and second end 38. The first end is coupled to motor 30. The second end of drive shaft 22 extends into mixing chamber 14. First impeller 24 is shown as comprising a bar-turbine type of impeller which includes disk 40 and blades, such as blades 42. The impeller is coupled to the drive shaft spaced apart from the second end of the drive shaft. The particular configuration of the disk and the blades can be varied depending on the particular material that is to be mixed. In the present embodiment, six blades are spaced apart form each other uniformly equally about the disk, three on one side of the disk and three on the other side of the disk. Generally the blades comprise an elongated member having a substantially square cross-sectional configuration. In other embodiments, there may be fewer (such as three, for example) blades, whereas in other embodiments there may be greater blades (for example twelve blades). The blades may or may not extend beyond the circumference of the disc. Of course, the invention is not limited to any particular construction or configuration of the disk or the blades of the impeller. In certain embodiments, the size of the disk may be minimized and the blades may be provided with varying configurations. Of course, other impeller types, including, but not limited to disperser blades, axial blades and radial blades.
Second impeller 26 is shown in
In the embodiment shown, the two impellers are substantially identical and the disks of the impellers are parallel to each other. In other embodiments, one impeller disc can be offset at an angle such that, upon rotation the disc appears to wobble. Additionally, while the two impellers are shown to be substantially equally spaced along the drive shaft, it is contemplated that the impellers may be positioned at substantially different positions relative to each other. Furthermore, it is contemplated that a single impeller may be utilized or a number of impellers greater than three can be employed.
Mixing chamber assembly 14 is shown in
In the embodiment shown, the housing has approximate dimensions of 11″×16″×24″. Of course, the invention is not limited to such a configuration. For example, and as is shown in
Inlet 60 is shown in
Outlet 62 is shown in
It is likewise contemplated that in place of the exhaust chamber, an outlet opening can be positioned proximate the top wall in any one of the opposing sidewalls and the end walls, or within the top wall itself. In such a configuration, wall 65 can be eliminated which can decrease the size of the housing. In other embodiments, the outlet may be positioned proximate the bottom of the housing. Finally, multiple outlets are contemplated for use.
Orifice assembly 16 is shown in
With reference to
To facilitate proper mixing, and to provide a framework upon which to achieve the proper positioning of the two orifices within the housing baffle member 72 is provided. Referring again to
As is shown in
To assemble the mixing apparatus of the present invention, the mixing chamber is first provided. Inlet 60 and outlet 62 can be coupled to existing piping such that the passage of fluid from the inlet will be directed through the mixing assembly and eventually through the outlet. As set forth above, the invention is not limited to any particular manner of coupling the inlet and the outlet to existing equipment.
With the top wall 56 removed, the inside of the mixing housing is accessible. As is shown in
Next, it is necessary to introduce the mixing agitation assembly to the mixing chamber assembly. In particular, a portion of the drive shaft, the impellers and a portion of the motor assembly is attached to top wall 56. The impellers are carefully manipulated such that the second impeller 26 passes through first orifice 68 into a position between the first and second orifices.
Once the second impeller is positioned between the two orifices, top wall 56 is secured. Specifically, the top wall is secured to the remainder of the housing through the use of fasteners such as nuts and bolts. As set forth above, to facilitate portability of the device, handles can be provided in a spaced apart orientation about the top wall. The same nuts and bolts can be utilized to couple the handle to the mixing chamber that are utilized to attach the top wall to the side wall and the front and back wall. In another embodiment, as is shown in
Once the top wall 56 is positioned and secured, motor assembly 20 can be attached to the mixing chamber assembly. When fully assembled, the mixer apparatus is ready for utilization.
In operation, a material is provided at a particular flow rate through inlet 60. In the embodiment contemplated, the material comprises a mixture of various solids in a working fluid (for example, water or diesel fuel) which together form what is commonly referred to as mud used in association with oil well drilling. The initial introduction of the solids with the working fluid can be accomplished through a number of different means. For example, the solids can be pulled into passing the working fluid through a venturi-type mixing apparatus. Other methods of introduction of the solids is likewise contemplated. Indeed, the invention is not limited to any particular manner in which to provide material to inlet 60.
Once the material enters housing 50 through inlet 60, the material is directed in an upward direction toward and into the third region of the mixing chamber. As additional material enters, the material is driven upward through second orifice 70 and into second impeller 26. As the material passes against and around the second impeller, the solids become dispersed within the working fluid. The material continues through this second region and eventually passes through first orifice 68. At this stage, the material is introduced into first impeller 24 within the first region.
The contact with the first impeller further disperses the solids through the working fluid. As the material continues beyond the first impeller, the material reaches top wall 56 and is directed to the outlet. Specifically, at top wall 56, the material (now thoroughly mixed) is directed through upper passageway 67 into exhaust chamber 64 and finally through outlet opening 66. Unlike the material that was introduced at the inlet, the material at the outlet is thoroughly mixed (i.e., the solids are fully dispersed within the liquid). Such a fine dispersion requires less agitation when directed to a holding tank and typically exhibits substantially greater viscosity.
Certain tests were performed with pump having the configuration disclosed herein. In a first series of tests, an oil based “mud” product was prepared. The “mud” included 2.5 gallons of diesel fuel, 7.5 pounds of MI Barite, 2.7 liters of water, 0.95 liters of CaCl2, 3 ounces of lime, 3 ounces of VG supreme and 3 ounces of HRP.
A total for four separate tests were performed utilizing the mixture. The first test included a five inch Cowles blade at 2655 fpm for a run time of 60 seconds. The second test included a six inch Cowles blade at 2048 fpm for a run time of 60 seconds. The third test included a five inch Cowles blade at 3186 fpm for a run time of 30 seconds. Finally, the fourth test included a five inch Cowles blade at 3186 fpm for 30 seconds and 3412 fpm for 30 seconds. The results of the tests, expressed as Brookfield Viscosity Readings with #4 spindle, are shown in the table below.
In a second series of tests, a water based “mud” product was prepared. The “mud” included 4 gallons of tap water, 1.5 pounds of MI Gel (Bentonite), 1 ounce lime, 1 ounce caustic and 0.7 ounces xanthium gum for the first test of the second series. In the second, third and fourth tests, an additional 0.5 pounds of MI Gel (Bentonite) was added to the product.
The two tests included a five inch Cowles blade at 2655 fpm for a run time of 55 seconds. The third test included a six inch Cowles blade at 2048 fpm for a run time of 30 seconds. The fourth test included a six inch Cowles blade at 1830 fpm for a run time of 45 seconds. The results of the tests, expressed as Brookfield Viscosity Readings with #4 spindle, are shown in the table below.
With each of the series of tests, it was determined that the mixer of the present invention exhibited superior performance over a conventionally utilized mixer for such products. In particular, whereas such mixtures retain fluid properties when mixed with a conventional mixer for such products, the mixtures achieve a pseudo-plastic configuration with a greatly enhanced viscosity, and a gel-like consistency.
The foregoing description merely explains and illustrates the invention and the invention is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications without departing the scope of the invention.
| Number | Date | Country | |
|---|---|---|---|
| 60773496 | Feb 2006 | US |
