Catalytic Proppant for In-Situ Hydrocarbon Refining
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Solution Overview
Problem
Subterranean formations with insufficient permeability hinder oil and gas recovery, and petroleum compositions with high densities or viscosities require additional energy for production, while heteroatoms like sulfur or nitrogen increase production costs and reduce market value.
Innovation Solution
Catalytic proppant particles with a ceramic support of silica and alumina, having specific pore distributions and surface areas, are used to facilitate downhole refining processes, reducing fluid viscosity and removing heteroatoms through hydrogenation reactions, thereby enhancing oil and gas recovery and refining hydrocarbons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If hydraulic fracturing is performed to improve permeability, then oil and gas flow is improved, but formation damage and heteroatom contamination increase
Solution Approach 1:
The patent applies preliminary action by incorporating catalyst particles into the proppant material before fracturing operations. This allows heteroatom removal to occur in-situ within the fracture as hydrocarbons flow through, preventing contamination rather than addressing it after the fact. The catalyst is positioned in advance to treat hydrocarbons as they pass through the fracture network.
Solution Approach 2:
The catalyst-coated proppant acts as an intermediary between the hydrocarbon flow and the fracture walls. The catalyst particles embedded in the proppant material serve as a mediating substance that facilitates chemical reactions to remove heteroatoms from the flowing hydrocarbons, transforming the proppant from a simple mechanical support to an active treatment medium.
2Productivity
If heat energy or CO2 gas pressure is applied to produce high density or viscosity petroleum compositions, then production is improved, but energy cost and complexity increase
Solution Approach 1:
The patent replaces mechanical/thermal energy input systems with a chemical catalysis system. Instead of applying external heat energy or CO2 gas pressure to reduce viscosity and improve production, the catalyst-coated proppant facilitates in-situ chemical reactions that modify hydrocarbon properties directly within the fracture, eliminating the need for expensive external energy inputs.
Solution Approach 2:
The system enables self-service by allowing the fracture itself to perform the treatment function. The catalyst particles within the proppant material facilitate automatic in-situ treatment of hydrocarbons as they flow through the fracture, making the fracture network self-treating without requiring external energy input systems or additional processing equipment.
3Reliability
If downstream surface facilities are used to remove heteroatoms, then hydrocarbon quality is improved, but production cost increases
Solution Approach 1:
The patent performs heteroatom removal as a preliminary action within the wellbore environment before hydrocarbons reach surface facilities. By placing catalyst-coated proppant in the fracture, the treatment occurs in-situ during production, eliminating the need for expensive downstream refining operations and reducing overall production costs while maintaining hydrocarbon quality.
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 catalytic proppant increases the productivity of the wellbore by lowering fluid viscosity and reducing sulfur, nitrogen, and metal content in hydrocarbons, improving estimated ultimate recovery and market value of hydrocarbons.
Implementation Method 1
reducing fluid viscosity and removing heteroatoms through hydrogenation reactions
Implementation Method 2
removing heteroatoms through hydrogenation reactions
Data Source
AI summary
Catalyst particles and methods for making same are disclosed herein. The catalyst particles can include a ceramic support containing silica and alumina. The ceramic support can have a macropore concentration of about 15% to about 45%, a mesopore concentration of about 20% to 50%, and a micropore concentration of about 8% to about 30% based on the total pore volume of the ceramic support. The ceramic support can also have a surface area of about 0.5 m2/g to about 50 m2/g. The catalyst particles can have a long term permeability at 7,500 psi of at least about 10 D in accordance with ISO 13503-5.