Disperse non-polyalphaolefin drag reducing polymers
A drag reducing composition comprising at least one non-polyalphaolefin polymer having an average particle size in the range of from about 5 to about 800 micrometers. The non-polyalphaolefin polymer can initially be formed via emulsion polymerization. The initial polymer particles can then be at least partially consolidated and then reduced in size and suspended in a carrier fluid. The resulting drag reducing composition can be added to a hydrocarbon-containing fluid to decrease the pressure drop associated with the turbulent flow of the hydrocarbon-containing fluid through a conduit.
1. A drag reducer, comprising:
a plurality of first non-polyalphaolefin latex polymer particles, wherein the plurality of first non-polyalphaolefin latex polymer particles have a weight average molecular weight of at least about 1×10 6 g/mol and an average particle size ranging from about 5 micrometers to about 800 micrometers; and
a plurality of second non-polyalphaolefin latex polymer particles having an average particle size of less than about 1 micrometer.
2. The drag reducer of claim 1 , wherein the average particle size of the plurality of first non-polyalphaolefin latex polymer particles ranges from about 10 micrometers to about 600 micrometers.
3. The drag reducer of claim 1 , wherein the plurality of first non-polyalphaolefin latex polymer particles is dispersed in a carrier fluid.
4. The drag reducer of claim 3 , wherein the carrier fluid comprises water, alcohol, or a combination thereof.
5. The drag reducer of claim 1 , wherein the plurality of first non-polyalphaolefin latex polymer particles comprises repeating units of residues of C4-C20 alkyl, C6-C20 substituted or unsubstituted aryl, or aryl-substituted C1-C10 alkyl ester derivatives of methacrylic acid or acrylic acid.
6. The drag reducer of claim 1 , wherein the plurality of first non-polyalphaolefin latex polymer particles comprises repeating units of residues of 2-ethylhexyl methacrylate monomers.
7. The drag reducer of claim 1 , wherein the plurality of first non-polyalphaolefin latex polymer particles comprises repeating units of residues of 2-ethylhexyl methacrylate monomers and residues of butyl acrylate monomers.
8. The drag reducer of claim 7 , wherein the plurality of first non-polyalphaolefin latex polymer particles is dispersed in a carrier fluid, and the carrier fluid comprises water, alcohol, or a combination thereof.
9. A drag reducer, comprising:
a plurality of first non-polyalphaolefin latex polymer particles, wherein the plurality of first non-polyalphaolefin latex polymer particles have a weight average molecular weight of at least about 1×10 6 g/mol and an average particle size ranging from about 20 micrometers to about 400 micrometers; and
a plurality of second non-polyalphaolefin latex polymer particles having an average particle size ranging from about 10 nm to about 500 nm.
10. The drag reducer of claim 9 , wherein the plurality of first non-polyalphaolefin latex polymer particles is dispersed in a carrier fluid.
11. The drag reducer of claim 10 , wherein the carrier fluid comprises water, alcohol, or a combination thereof.
12. The drag reducer of claim 9 , wherein the plurality of first non-polyalphaolefin latex polymer particles comprises repeating units of residues of C4-C20 alkyl, C6-C20 substituted or unsubstituted aryl, or aryl-substituted C1-C10 alkyl ester derivatives of methacrylic acid or acrylic acid.
13. The drag reducer of claim 9 , wherein the plurality of first non-polyalphaolefin latex polymer particles comprises repeating units of residues of 2-ethylhexyl methacrylate monomers.
14. The drag reducer of claim 9 , wherein the plurality of first non-polyalphaolefin latex polymer particles comprises repeating units of residues of 2-ethylhexyl methacrylate monomers and residues of butyl acrylate monomers.
15. A process for forming a drag reducer, comprising:
forming a first plurality of polymer particles, wherein the first plurality of particles have a first average particle size of less than about 1 micrometer;
consolidating at least a portion of the first plurality of polymer particles to form a second plurality of polymer particles, wherein the second plurality of polymer particles have a second average particle size greater than the first average particle size; and
forming a third plurality of polymer particles from the second plurality of polymer particles, wherein the third plurality of polymer particles have a third average particle size less than the second average particle size and greater than the first average particle size.
16. The process of claim 15 , wherein the first average particle size ranges from about 10 nm to about 500 nm.
17. The process of claim 15 , wherein the second average particle size is greater than 0.75 inches.
18. The process of claim 15 , wherein the third average particle size ranges from about 5 micrometers to about 800 micrometers.
19. The process of claim 18 , wherein the third average particle size ranges from about 20 micrometers to about 400 micrometers.
20. The process of claim 15 , wherein the first plurality of polymer particles is formed by emulsion polymerization.
21. The process of claim 15 , wherein the consolidating at least portion of the first plurality of particles comprises adding a water-miscible solvent to the first plurality of polymer particles.