Dry on the Fly Equipment
ZL has been a manufacture of polymer dispersion equipment for dry polymer hydration at the well-site, since its it's establishment in 1995. The evolution of our polymer dispersion equipment has evolved extensively since this time. Early generations of polymer dispersion equipment, used up until 2010, where massive in size, requiring station type facilities, where polymer hydration could take as long as 300 minutes.
Driven to reduce the CAPEX requirements of polymer flooding and the personnel required to operate the equipment, ZL developed a smaller unit for polymer dispersion that reduced the hydration time by more than half that of the station types and fit it on a skid and later enclosed in containers for easy mobilization between well-sites.
ZL's third generation of polymer dispersion equipment incorporated a Polymer Splicing Unit (PSU), with an improved hydration residence time of 30 minutes.
In ZL's fourth generation of polymer dispersion equipment, ZL was able to further compact the equipment by developing a system that provides instantaneous polymer hydration using a proprietary Venturi system into what is now known as ZL's CPDU, Compact Polymer Dispersion Unit. ZL has deployed over 14 fourth generation CPDUs since 2014.
In 2020, ZL's fifth and latest generation was modified for use in hydraulic fracturing operations.
ZL's CPDU can be broken into three main sections:
Dry Polymer Silo
temporary dry polymer storage, equipped with a vibrator and dust collector,
with a screw type metering system
Dry Polymer Transmission System
proprietary transfer process of dry polymer to the dispersion and wetting system
Dispersion and Wetting System
high efficiency water jetting dispersion system and mother solution tank
CPDU Specifications for Polymer Flooding
Dry Polymer Powder Feed Rates: 880 - 4410 lb/hr (400 - 2000 kg/hr)
Mother Solution Concentration: 0.3 - 1.5 %
Water Injection Rate (@ 1,000 ppm): 60,380 - 289,330 bbl/day (9,600 - 48,00 m /day)
CPDU Dimensions (smallest available): 11.8 ft x 8.5 ft x 11.8 ft (3.6 m x 2.6 m x 3.6)
CPDU Dimensions (largest available): 17 ft x 11.1 ft x 12.5 ft (5.2 m x 3.4 m x 3.8)
Power Generation Requirement: 30 - 150 kW
Operation Up Time: > 90 %
CPDU Specifications for Hydraulic Fracturing
Dry Polymer Powder Feed Rate: < 50 lbs/min (22.7 kg/min)
Mother Solution Concentration: 1.0 - 2.5 %
FR Feed Rate: 2.0 - 5.3 bbl/min (0.32 - 0.4 m /min)
Dry FR Dosage Range: <1.0 - 11 PPT (lbs dry FR/1000 gallons)
Dry FR Dosage Equivalency to Emulsion: < 5 GPT
CPDU Trailer Dimensions: 29.5 ft x 7.9 ft x 8.7 ft (9 m x 2.4 m x 2.7 m)
Dry FR Storage Size: 2,500 lbs (1,134 kg)
Liquid FR Storage Size: 350 gallons (1.3 m )
Power Generation Requirement: 70 kW
Operation Up Time: > 90 %