3D Printed Proppant Core-Shell Structure for Deep Well Strength
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Solution Overview
Problem
Conventional proppants, such as sand and resin-coated sand, fail to withstand increased closure stresses in deeper wells due to insufficient crush resistance, and high-density ceramic proppants face challenges with settling and cost, necessitating a proppant with lower density and higher crush strength for effective hydraulic fracturing.
Innovation Solution
3D printed proppants with a core and shell structure, made from materials like metal, polymer, or ceramic, offering a particle size range of 8 to 140 mesh and porosity of 10% to 75%, which can be optimized for mechanical strength and density through post-printing processing such as sintering or curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-density ceramic proppants are used to increase crush resistance, then strength is improved, but density increases causing faster settling rate in carrier fluids
Solution Approach 1:
The patent uses composite materials by combining a ceramic outer shell (providing crush resistance) with a lower-density inner core (reducing settling rate). The core can be made from materials like polymer, metal, or ceramic with density less than 2.5 g/cc, while the shell is made from ceramic or other high-strength materials. This composite structure allows the proppant to achieve both high strength and low settling rate simultaneously.
Solution Approach 2:
The patent applies the nesting principle by placing a lower-density core inside a higher-density shell. The core is positioned within the shell cavity, creating a nested structure where the inner core reduces overall density while the outer shell provides mechanical strength. This nested configuration directly addresses the contradiction between strength and settling rate.
2Ease of manufacture
If conventional sand proppants are used, then cost is reduced, but crush resistance is insufficient for deeper wells
Solution Approach 1:
The patent changes the material parameters by using 3D printing technology to create proppants with customized density and strength properties. By controlling the materials used in the core and shell, and adjusting parameters like particle size (8-140 mesh) and porosity (10%-75%), the proppant can be optimized for both cost-effectiveness and sufficient crush resistance for deep well applications.
3Stability of the object's composition
If high viscosity fracturing fluids are used to prevent proppant settling, then proppant suspension is improved, but formation damage increases and fracture network is reduced
Solution Approach 1:
The patent changes the density parameter of the proppant by incorporating low-density cores, which reduces the proppant's settling rate without requiring high viscosity fluids. This allows the use of low viscosity slickwater fracturing fluids that generate better fracture networks and cause less formation damage while still maintaining proppant suspension through the reduced density of the 3D printed proppants.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The 3D printed proppants achieve a crush resistance strength of over 40 Mega Pascals and a density of less than 2.5 grams per cubic centimeter, enhancing fracture conductivity and permeability while reducing formation damage and production costs.
Implementation Method 1
which can be optimized for mechanical strength and density through post-printing processing such as sintering or curing
Data Source
AI summary
A method of producing a 3D printed proppant comprises providing a 3D printing apparatus that produces the 3D printed proppant; distributing a layer of build material within a build chamber of the 3D printing apparatus, wherein the build material comprises metal, polymer, ceramic, composite, or combinations thereof; depositing a layer of binder material on the layer of build material; curing the binder material within the 3D printing apparatus; and repeating as necessary to produce the 3D printed proppant, wherein the 3D printed proppant has a particle size from 8 mesh to 140 mesh.