Continuous Acid Mixing Unit – On-Demand Acid Blending for Fracturing & Stimulation Operations

Product Overview

A continuous acid mixing unit (also known as a continuous acid blending unit or acid mixing skid) is a specialized piece of equipment designed to precisely blend raw acid, fresh water, and various chemical additives in real time to produce acid fracturing fluid-. Unlike traditional batch mixing methods that require pre-blending large volumes of acid before a job, a continuous acid mixing unit enables on-demand, “mix-as-you-go” acid preparation, delivering precisely formulated acid fluid directly to the fracturing pumps as the job progresses.

In acid fracturing and matrix acidizing operations, the quality and consistency of the acid fluid are critical to treatment success. Acid must be mixed to precise concentrations with specific additives—corrosion inhibitors, surfactants, friction reducers, and gelling agents—to achieve the desired reaction rate with the formation rock while protecting downhole equipment. Any inconsistency in acid concentration or additive content can compromise stimulation effectiveness or damage wellbore equipment.

The continuous acid mixing unit solves these challenges by providing automated, real-time acid blending with precise control over acid concentration, additive dosing, and fluid properties. Whether deployed as a truck-mounted unit for maximum mobility or a skid-mounted unit for offshore or permanent installations, our continuous acid mixing unit delivers reliable, high-quality acid fluid for even the most demanding stimulation operations.

How a Continuous Acid Mixing Unit Works

The continuous acid mixing unit operates on a straightforward but precise principle: continuously metering and mixing multiple fluid streams to produce a consistent, high-quality acid blend.

Step-by-Step Operation

Raw Materials Input – Raw acid (typically hydrochloric or hydrofluoric acid) is drawn from acid storage tanks, while fresh water and various liquid additives (corrosion inhibitors, surfactants, gelling agents, etc.) are supplied from their respective sources-. Optional dry powder additives can also be conveyed and metered into the mix.

Precise Metering – Each component is individually metered using high-accuracy flow meters and control valves. The acid supply centrifugal pump and water centrifugal pump deliver their respective fluids at controlled rates.

Mixing – All components are combined in the acid mixing tank, where the closed mixing system ensures thorough blending without exposure to the atmosphere. The mixing tank is equipped with agitation systems to achieve uniform fluid properties.

Quality Monitoring – The system continuously monitors acid concentration, viscosity, pH, and other critical parameters. Automatic controls adjust component feed rates in real time to maintain the target formulation.

Discharge – The finished acid fluid is discharged via the discharge centrifugal pump directly to the fracturing pumps for downhole injection.

The entire process is controlled by a PLC-based automation system, allowing the operator to select between automatic (fully computer-controlled) or manual operation modes depending on job requirements.

Key Features – Engineered for Safety, Precision, and Durability

1. Totally Enclosed Acid Mixing System

The closed acid mixing tank enables fully enclosed acid mixing, which maximally reduces the diffusion of corrosive acid mist into the surrounding environment. This protects personnel from hazardous acid vapors and minimizes environmental impact—a critical consideration in modern oilfield operations.

2. Multiple Acid Mist Removal Systems

The unit is equipped with spray-type and alkali-reaction type demisting systems that effectively capture and neutralize acid mist. This dual-layer approach to acid gas treatment ensures that even trace amounts of acid vapour are safely removed before they can reach the atmosphere, creating a safer and more compliant worksite.

3. Advanced Acid-Resistant Construction

The unit incorporates multiple acid-resisting processes including PTFE (Teflon) lining and FRP (fibreglass-reinforced plastic) components to ensure long-term equipment durability in the highly corrosive acid environment. All wetted parts—pumps, tanks, piping, and valves—are constructed from acid-resistant materials to withstand prolonged exposure to concentrated acids and chemical additives.

4. High Automation with Precise Control

The system achieves high automation with automatic control of chemical additive concentration, acid mixing concentration, and acid tank level. The PLC-based control system continuously adjusts feed rates to maintain target fluid properties, minimizing operator intervention and reducing the risk of human error.

5. Integrated Dry Powder Additive System

The unit includes two dry powder conveyors for metering and introducing dry chemical additives into the mix. This enables the use of dry gelling agents or other powdered additives alongside liquid chemicals, providing formulation flexibility for different treatment designs.

6. Flexible Mounting Options

Available as truck-mounted (on a Sinotruck chassis with CAT C15 engine) or skid-mounted configurations, our continuous acid mixing unit can be deployed in virtually any operational setting—from remote onshore locations to offshore platforms.

Technical Specifications – Model GYC100

Applications

Our continuous acid mixing unit is suitable for a wide range of acid stimulation and well intervention operations:

Acid Fracturing – Continuous blending of gelled or emulsified acid for fracture stimulation in carbonate and sandstone reservoirs

Matrix Acidizing – Precise mixing of acid formulations for near-wellbore stimulation to remove formation damage

Squeeze Acidizing – Controlled acid blending for treating entire production intervals

Offshore Stimulation Vessels – Skid-mounted configurations for offshore fracturing and acidizing campaigns

Multi-Well Pad Operations – Truck-mounted units for high-volume acid stimulation programs in shale and tight gas plays

Why Choose Our Continuous Acid Mixing Unit

On-demand acid blending – Eliminates pre-mixing and waste; mix only what you need, when you need it

Superior acid mist control – Totally enclosed system with multiple demisting systems protects personnel and environment

Corrosion-resistant construction – PTFE and FRP components ensure long service life in aggressive acid environments

High automation – PLC-based control with automatic additive dosing and concentration monitoring reduces labour and errors

High capacity – Up to 2,650 gpm (10 m³/min) discharge flowrate supports large-scale fracturing operations

Flexible deployment – Truck-mounted or skid-mounted options to match your operational needs

Dual additive capability – Handles both liquid chemical additives and dry powder additives

Proven performance – Based on field-proven technology with successful deployments in major oilfield regions

Contact us to learn more about our continuous acid mixing unit and how it can enhance the safety, efficiency, and fluid quality of your acid stimulation operations.