Captured-Carbon Proppant Composition for Cost-Effective CO2 Sequestration
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Solution Overview
Problem
Existing hydraulic fracturing methods face challenges in efficiently using proppants that are both cost-effective and environmentally friendly, particularly in sequestering carbon dioxide, as traditional proppants like sand are inexpensive but lack carbon sequestration capabilities, while ceramic proppants are expensive and scalability issues hinder the use of carbon nanomaterials.
Innovation Solution
Development of proppants made from captured carbon through mineral carbonation or carbon nanomaterials, which are produced by reacting CO2 with calcium or magnesium ions to form carbonates or by electrochemical decomposition, and then processed to meet proppant quality standards such as crush resistance, size, and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sand is used as proppant, then cost is reduced, but carbon sequestration capability is lost
Solution Approach 1:
The patent converts captured CO2, a harmful greenhouse gas, into beneficial proppant material through mineral carbonation processes. The CO2 reacts with alkaline materials to form stable carbonate minerals that serve as effective proppants, thereby transforming an environmental problem into a solution that both sequesters carbon and provides functional fracturing material.
Solution Approach 2:
The patent changes the chemical composition parameter of proppant material from traditional sand (silica-based) to carbonate-based materials synthesized from CO2. This parameter change enables the proppant to have carbon sequestration functionality while maintaining the mechanical properties needed for fracturing applications.
2Reliability
If ceramic proppant is used, then fracture conductivity is improved, but cost increases significantly
Solution Approach 1:
The patent creates composite proppant materials that combine the benefits of ceramic proppants (high fracture conductivity) with cost-effective carbonate base materials. By synthesizing carbonate proppants with controlled morphology and surface properties, the invention achieves ceramic-like performance at lower cost through alternative material composition.
3Object-generated harmful factors
If carbon nanomaterials are used for proppant, then carbon sequestration is achieved, but scalability is limited
Solution Approach 1:
The patent segments the carbon capture and utilization process into modular stages: CO2 capture from flue gas, mineral carbonation reactions, and proppant formation. This segmentation enables each stage to be optimized independently and scaled according to demand, with the carbonate proppant production can be scaled to match the volume requirements of hydraulic fracturing operations.
Solution Approach 2:
The patent employs self-service mechanisms in the carbonation process where alkaline minerals naturally present in waste streams (such as cement kiln dust, steel slag, or natural alkaline rocks) react with CO2 to form proppant. This eliminates the need for complex external processing infrastructure, enabling scalable production using readily available materials and CO2 sources.
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 carbon capture proppants effectively sequester carbon, meet proppant performance criteria, and offer scalability, reducing environmental impact and costs compared to traditional materials.
Implementation Method 1
reacting CO2 with calcium or magnesium ions to form carbonates
Implementation Method 2
reacting CO2 with electricity or heat or both to produce carbon nanomaterial (CNM)
Implementation Method 3
reacting CO2 with electricity or heat or both to produce carbon nanomaterial (CNM)
Data Source
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AI summary
Method of making and using a proppant from captured carbon in either a carbon mineralization process or in a carbon nanomaterial manufacturing process, followed by treatments to ensure the quality control of the proppants so that they are suitable for use in hydraulic and other reservoir fracturing methods.