Coated Ceramic Proppant Particles for Fracture Support

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Solution Overview

Problem

Current proppants and gravel pack particles, such as sand and sintered ceramic particles, are costly, have high bulk densities, and cause wear in equipment due to their abrasive nature, while also producing fines and requiring high energy for production.

Innovation Solution

Development of coated particles with an inorganic substrate and an organic coating, where the substrate comprises silica and alumina in a specific weight ratio, achieving a bulk density of less than 1 g/cm3 and an apparent density of 1 to 2 g/cm3, which are used as proppants or in gravel packs to enhance oil and gas production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sand or sintered ceramic particles are used as proppants, then fracture holding capability is achieved, but cost increases and bulk density becomes high

Engineering Contradiction:

Improvefracture holding capabilityVSAvoidbulk density

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent uses composite particles consisting of a ceramic substrate (silica and alumina) coated with an organic material. This composite structure allows the particle to maintain the fracture holding capability of ceramic materials while reducing bulk density through the lower-density organic coating layer, achieving both reliability and weight reduction simultaneously

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the density parameters by controlling the thickness and composition of the organic coating layer. By adjusting the coating parameters (thickness, material composition), the bulk density can be reduced from conventional ceramic densities while maintaining the structural integrity and fracture holding capability required for reliable proppant performance

Inventive Principle:

Principle #35Parameter changes

2Reliability

If sintered ceramic particles are used as proppants, then fracture holding capability is achieved, but manufacturing cost increases due to high temperature sintering

Engineering Contradiction:

Improvefracture holding capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies a low-cost organic coating material to the ceramic substrate before final use. This preliminary coating step is inexpensive and can be done at low temperatures, avoiding the need for expensive high-temperature sintering processes while still achieving the required fracture holding capability through the ceramic substrate structure

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses inexpensive organic coating materials that can be applied at low cost and low temperature. These organic coatings serve as cost-effective alternatives to expensive high-temperature sintering processes, reducing manufacturing costs while maintaining adequate performance for the application

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If sintered ceramic particles are used as proppants, then fracture holding capability is achieved, but wear on equipment increases due to abrasive properties

Engineering Contradiction:

Improvefracture holding capabilityVSAvoidwear on equipment

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent uses a thin organic coating layer as a flexible protective shell around the ceramic proppant. This organic coating acts as a wear-resistant layer that reduces the abrasive effect of the ceramic substrate on equipment, while the underlying ceramic structure maintains the fracture holding capability

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent creates a composite structure where the organic coating material provides wear resistance and reduces abrasion on equipment, while the ceramic substrate maintains the mechanical strength and fracture holding capability. This composite approach simultaneously addresses both the harmful wear effect and the required functional performance

Inventive Principle:

Principle #40Composite materials

4Reliability

If conventional proppants are used, then fracture treatment is effective, but fines generation increases

Engineering Contradiction:

Improvefracture treatment effectivenessVSAvoidfines generation

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The organic coating acts as a protective shell that prevents the ceramic substrate from generating fines during handling and transport. This coating layer maintains the integrity of the proppant particles, reducing fines generation while allowing the fracture treatment to remain effective through the underlying ceramic structure

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS8227026B2Particles for use as proppants or in gravel packs, methods for making and using the same

Publication Date: 2012.07.24 HEXION INC

AI summary

Disclosed herein is a method for making a coated proppant particle including an inorganic material and a cold set thermosetting resin coating disposed upon the substrate. The proppants are suitable for treating a subterranean formation including injecting a fracturing fluid into the subterranean formation; wherein the fracturing fluid includes the coated particle. Methods for making and using gravel pack particles are also disclosed.