新型雾化消泡智能加注技术

New Atomization Defoaming Intelligent Filling Technology

摘要: 针对页岩气田泡沫排水采气过程中常规雾化装置存在的喷嘴易堵塞、药剂混合不均、用量偏高及自动化程度不足等难题，研究优化了压力式喷嘴结构参数(孔径1.2 mm、入口角度30˚)，提升了高压环境下消泡剂的微米级雾化均匀性；采用双重密封结构设计，确保装置在35 MPa高压工况下长期稳定无泄漏；开发了在线自动定量配液、隔膜式计量泵、冲程调节系统及传感器–云平台–终端三级物联网管控系统，研制出新型雾化消泡智能加注装置，实现了消泡剂精准配液、稳定泵注、远程调控与实时监测，系统响应时间 ≤ 3 s。川南页岩气荣239井、自232井现场试验结果表明：装置在35 MPa下累计稳定运行182天，雾化粒径D₅₀ = 45 μm、均匀性系数RSD = 18%，药剂与泡沫液体积比1:1.1时即可实现稳定消泡，单井消泡剂用量降低45%以上，药剂接触效率提升至85%以上，喷嘴堵塞频次显著降低。

Abstract: Aiming at the problems of nozzle clogging, uneven mixing of reagents, high dosage, and insufficient automation in the conventional atomization device in the process of foam drainage and gas recovery in the shale gas field, the structural parameters of the pressure nozzle are optimized. The nozzle aperture is 1.2 mm, and the inlet angle is 30˚, which improves the micron-level atomization uniformity of defoamer in a high-pressure environment. The double sealing structure design is adopted to ensure the long-term stability of the device under 35 MPa high-pressure conditions without leakage. An online automatic quantitative liquid dispensing, diaphragm metering pump, stroke adjustment system, and sensor-cloud platform-terminal three-level Internet of Things control system were developed. A new type of atomization and defoaming intelligent filling device was developed, which realized accurate liquid dispensing, stable pumping, remote control, and real-time monitoring of defoamers. The system response time does not exceed 3 ms. The field test results of Rong 239 well and Zi 232 well in southern Sichuan shale gas show that the device runs stably for 182 days under 35 MPa high pressure. The atomization particle size D₅₀ is 45 μm, the uniformity coefficient RSD is 18%, and the elimination ratio is 1:1.1. Stable defoaming can be achieved. The amount of single well defoaming agent decreased by more than 45%, the utilization rate of the agent increased to 85%, and the number of nozzle blockages decreased significantly.