Crosslinked Aromatic Resin Beads for Spherical Proppant Scale-Up
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Solution Overview
Problem
Existing synthetic methods for producing proppants suffer from drawbacks such as foaming, use of expensive catalysts, slow kinetics, and difficulty in scaling up production, leading to the generation of undesirable aspherical particles with reduced fracture conductivity and increased contact stresses.
Innovation Solution
A method involving suspension polymerization is used to directly synthesize highly spherical crosslinked aromatic resin beads by reacting a linker agent and catalyst with an aromatic feedstock, forming a pre-polymer mixture, combining it with an antisolvent, and heating to create crosslinked beads, which can incorporate fillers like coke to enhance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If crosslinkers are used to form aromatic resins from polyaromatic-rich refinery streams, then proppant particles can be produced, but small molecular weight products such as water or HCl are generated leading to foaming in the product during the reaction
Solution Approach 1:
The patent removes the problematic crosslinking step that generates small molecular weight byproducts (water or HCl) causing foaming. Instead, it uses a two-stage process where prepolymers are first formed, then crosslinked in situ within the bead structure during suspension polymerization, eliminating the need for separate high-pressure autoclave curing that causes foaming.
Solution Approach 2:
The patent performs preliminary formation of prepolymer mixtures before the actual crosslinking and bead formation steps. By pre-forming the reactive mixture and then conducting suspension polymerization with in situ crosslinking, the process avoids subsequent high-pressure curing steps that would generate foaming, while still achieving the desired crosslinked structure.
2Object-generated harmful factors
If pressure-curing is used as a finishing step to combat bubble formation and foaming, then foaming is reduced, but the process requires a pressure vessel or autoclave that is difficult to scale to large volumes
Solution Approach 1:
The patent replaces the mechanical pressure-curing system (autoclave) with a chemical in situ crosslinking system that occurs during suspension polymerization. The crosslinking reaction is initiated within the bead structure itself using appropriate catalysts and conditions, eliminating the need for expensive and difficult-to-scale high-pressure equipment while maintaining control over bubble formation.
Solution Approach 2:
The patent changes the curing parameters from high-pressure autoclave conditions to controlled-temperature suspension polymerization conditions. By adjusting temperature, catalyst type, and reaction time parameters during the polymerization process, the crosslinking occurs in situ without requiring high-pressure equipment, enabling easy scale-up to large production volumes.
3Manufacturing precision
If grinding and sizing is used to obtain particles of interest, then particle size can be controlled, but material is lost that is crushed beyond the size range and jagged aspherical particles are generated
Solution Approach 1:
The patent performs preliminary formation of spherical beads with controlled size distribution during the suspension polymerization process itself, before any grinding or sizing operations. By controlling droplet size and polymerization conditions, the final bead size is predetermined, minimizing or eliminating the need for subsequent size reduction and associated material losses.
Solution Approach 2:
The patent maintains spherical geometry throughout the process by forming beads directly as spheres during suspension polymerization. The spherical droplets serve as templates for bead formation, ensuring high sphericity is retained in the final product without requiring grinding operations that would create jagged, aspherical particles and result in material loss.
4Manufacturing precision
If grinding is used to size particles, then particle size can be adjusted, but highly aspherical particles are produced that reduce fracture conductivity and amplify contact stresses
Solution Approach 1:
The patent performs preliminary size and shape control during the suspension polymerization process itself, where spherical droplets of predetermined size serve as templates for bead formation. This eliminates the need for subsequent grinding operations that would destroy the spherical shape and create aspherical particles with poor fracture conductivity and high contact stresses.
Solution Approach 2:
The patent maintains spherical geometry throughout the entire process by using suspension polymerization where spherical droplets are the precursors to final beads. The spherical shape is inherent to the process mechanism, ensuring high sphericity in the final product without requiring size reduction operations that would compromise particle shape and performance.
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 method produces proppants with high compressive strength, spherical shape, and low density, suitable for hydraulic fracturing, allowing for scaled-up production without high-pressure curing and reducing particle degradation, thus improving fracture conductivity and mechanical resilience.
Implementation Method 1
contacting a linker agent and a catalyst with an aromatic feedstock at a first temperature effective to react the linker agent with molecules in the aromatic feedstock to form a pre-polymer mixture
Implementation Method 2
the pre-polymer mixture is dispersed as droplets in the antisolvent
Implementation Method 3
agitating the pre-polymer mixture and the antisolvent
Implementation Method 4
heating the pre-polymer mixture and antisolvent to a second temperature to react the pre-polymer mixture to form crosslinked aromatic resin beads
Implementation Method 5
form crosslinked aromatic resin beads
Data Source
AI summary
A variety of methods are disclosed, including, in one embodiment, a method of making crosslinked aromatic resin beads comprising: contacting a linker agent and a catalyst with an aromatic feedstock at a first temperature effective to react the linker agent with molecules in the aromatic feedstock to form a pre-polymer mixture; combining the pre-polymer mixture with an antisolvent; agitating the pre-polymer mixture and the antisolvent; and heating the pre-polymer mixture and antisolvent to a second temperature to react the pre-polymer mixture to form crosslinked aromatic resin beads, wherein the pre-polymer mixture is dispersed as droplets in the antisolvent.