Research Projects
Vorticity Muffler Project
Originally designed as a weapon sound suppression technology (a silencer) by the US Army Combat Capabilities Development Command (DEVCOM) – Army Research Laboratory (DEVCOM ARL). The novel principle was later adapted and applied to muffler applications.
This technology uses the principle of “vorticity” (advanced fluid dynamic principles to adaptively & reactively control the released sound by modifying the duration, phasing and amplitudes of exhaust pressure fluctuations), which results in a muffler design that reduces of the overall sound output, while attempting to minimize engine backpressure.
Recognizing that this technology could be applied to engines in the oil field to meet new and tighter noise pollution regulations, and improve noise hazards that effect worker safety and hearing, NHF selected this DEVCOM ARL invention for an NHF research and development project. NHF entered into a Cooperative Research and Development Agreement (CRADA) and a subsequent Patent License Agreement (PLA) with DEVCOM ARL.
Expanding on the Army’s early-stage research, NHF has facilitated the production of a number of “vorticity” muffler prototypes. The first prototypes were geared towards reducing the noise of engines used in the oilfield. Prototypes were designed and developed for both a pulling unit and a fracking unit used in the industry. Work is ongoing in this
area, and initial testing on both types of engines showed significant amplitude reductions in key exhaust frequencies. Concurrently, NHF has worked to develop a smaller version of the vorticity muffler that can be used on small to midsized generators. This prototype is currently undergoing testing, however all measurements to date show a significant improvement in noise reduction over the generator’s standard muffler.
From a business development perspective, NHF had a market analysis performed to better understand the potential markets for the vorticity muffler. The analysis identified the potential demand for the muffler in a number of areas, including:
- Portable generators
- Outdoor power equipment
- Diesel power engines
Importantly, NHF holds the US patent license rights needed to fully develop and commercialize this technology. The vorticity muffler is currently available for further licensing opportunities. Please contact NHF if you are interested in learning more about this opportunity.
Cold Spray Technology
Cold Spray technology is an enhanced particle deposition technique, which provides for the spontaneous attachment of desired particles to a wide variety of surfaces. The US Army Combat Capabilities Development Command (DEVCOM) – Army Research Laboratory (DEVCOM ARL) has conducted much research and established significant expertise in the practical application of this technology.
This process can be used in the field to repair and/or create a variety of equipment parts.
NHF collaborated with DEVCOM ARL to leverage their expertise in this field. Based on the knowledge gained from working with DEVCOM ARL, NHF purchased a cold spray unit and provided it to a local company for use in exploring applications of the technology in the oilfield (i.e., coatings and equipment repair applications). While ultimately the cold spray unit was returned to the manufacturer, there were several key developments in assessing cold spray’s potential for future use in the field.
Downhole Well Cleanout Tool – “Hydrotool”
Locally designed and patented oilfield tool that works to clean out existing wells. The invented “Hydrotool” removes scale, calcium, barite, paraffin or other obstructions from the inside of the casing and clears the casing perforations. The tool is designed to provide a pulsating, cyclonic action of high-pressure fluid (primarily water) in either a 45° down and/or a 90° perpendicular side flow. It is expected that the Hydrotool can be scaled and adapted for other uses such as: pipelines, flow lines, heat exchangers, tanks, and other enclosures.
In this case, NHF worked with the US Army Combat Capabilities Development Command (DEVCOM) – Armaments Center (DEVCOM AC) to perform advanced computer modeling & simulation related the Hydrotool design. This modeling resulted in an enhanced spray head design that delivers improved cleaning performance.
From a business perspective, NHF funded the development and production of a number of demonstration prototypes of the Hydrotool. The demonstration units are currently being used in real-world applications (in New Mexico and Texas) and performance data is being captured. This data will be made available to prospective licensing partners and will measure the effectiveness of the tool in a number of areas, including:
- Success in increasing production in existing oil wells (Note: Data captured to date shows an average 50% increase in overall production.)
- Safety metrics related to the use of the Hydrotool
- Minimal downtime
NHF is the patent licensing representative and is actively marketing the Hydrotool. The invention has both issued and pending patents in the US, with additional coverage in a number of foreign countries.
"Pima started using the Hydrotool by Wellnu, LLC in the early spring of 2023 in the oilfields of West Texas. When we first saw the Hydrotool tested it was in our yard, where we invited 4 of our clients to see this new downhole tool. Everyone was impressed by the cyclonic action of the Hydrotool, providing a controlled force of water. It was quite easy for us to get the producers to try the Hydrotool on their wells after showing them the demonstration of how the tool worked. I asked the Wellnu team if we could have the tool fitted for use in a horizontal well, and they got started on making the necessary design changes.
Over the past 6 months, we have used the Hydrotool ten times. All ten uses of the tool were to clean out sand, scale, and stimulate oil production...increasing production in every well by at least 50%.
A number of our producers have used the Hydrotool for cleanout purposes where more traditional down-hole tools failed. In one instance, the Hydrotool completed in 27 minutes what a competitor didn’t complete in 10 hours. We have used the same single Hydrotool on all 10 wells, with no downtime because of a faulty tool or safety concerns. "
Coating Sucker Rods
NHF collaborated with DOD laboratories to utilized a coating process that can be extended the life of sucker rods and couplings used in the oil field by 17x.
Many working oil wells depend on the sucker rods and couplings to transfer the vertical motion on the surface mounted drive system to the pump assembly located own down bore in the well. This process can extend the life of sucker rods and couplings used in the oil field by 17x.
While ultimately not utilized, the NHF experience with surface coatings provided numerous insights into addressing corrosion and maximization of critical parts for energy production.
Future Initiatives
Metal Coatings
Chemicals that decrease or stop metal corrosion.
Batteries
New technology makes them small, lighter, longer lasting, and more powerful.
Paint
For metal that changes color when the metal is under stress; this could be used in metal fabrication, or to find equipment in the field where equipment may weaken from continued contact with corrosive fluids, or gasses.
Water Quality Enhancement
Produced water is a naturally occurring, saline water recovered during oil and gas production. Produced water includes formation water, hydraulic fracturing fluid flow back, and any chemicals added during routine production operations.
Oil and gas operations generate an abundance of produced water. For every barrel of oil produced, for example, three to six barrels of water are produced, giving this water its name of “produced water.”
Most produced water is disposed of by injecting it into geologic formations that are thousands of feet below the surface and useable groundwater. The water is injected through water disposal wells. However, reinjecting the water can have unintended consequences. Research has linked deep underground injection of produced water to increases in seismicity in several states, including New Mexico.
Instead of reinjecting produced water into disposal wells, produced water has the potential to help New Mexico preserve its surface and underground freshwater resources.
Private industry and government agencies at the state and federal levels are researching and investing in technology to reduce the cost of treating and reusing produced water to transform produced water from a waste to a resource.
NHF has the ability to find technologies that currently exist within several federal labs, that may be available to the private sector, and develop them for use in several scenarios that can help enhance the ability to develop practical solutions.
Through NHF research we may also be able to find was to use the metals and/or chemicals in the produced water. Lithium, iodine, and any number of other products may be able to be mined from the produced water.