This paper presents methods, materials, and equipment that can be used to mix and apply viscous proppant-carrying fluids, on-the-fly, to support hydraulic fracturing processes using a dry-polymer blender. This dry-polymer blending system (DPBS) replaces the liquid-gel concentrate (LGC) mixing method, which requires premixing gel-producing powders with a hydrocarbon carrier fluid.The equipment and methods described have contributed to a cleaner environment without imposing any cost increases or wellsite expansion on the operating company. The on-the-fly dry-gel blending process is compatible with existing fracturing technology, and has helped enable environmentally responsible technology development.The fracturing fluid product used in this process is based on dry powders and does not contain hydrocarbon carrier fluids. Dry-polymer blending enables the use of new gel systems that work well in produced waters. This type of blending can be applied in any hydraulic fracturing operation requiring preparation, blending, and pumping of a viscous fluid to suspend proppant for transport to created fractures. The DPBS uses a trailer with a weigh system and continuous viscosity monitoring to help ensure job quality. Handling of the gel powder can be accomplished without dusting.
Offshore operators can more efficiently and effectively perform high-permeability and conventional hydraulic fracture treatments by blending treatment slurries under microprocessor control, adding undiluted acid on-the-fly, and altering sand concentrations and other slurry properties instantaneously. A two-skid system has been designed with these considerations in mind. The system, which can be shipped efficiently in 1S0 containers, has been tested on fluids up to 210-cp viscosity and can step or ramp sand concentrations up to a maximum of 20 lb/ gal. All additives, including acid treatments, are added on-thefly; leftover additives and acids may be stored for future jobs.The system may be applied in most conditions, including offshore wells requiring conventional orhigh-permeabil ity fracture treatments and certain land-based wells in remote areas where a compact skid is needed. Three significant benefits have resulted from using the compact-skid system:
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