Coated Proppant Particles for Hydraulic Fracturing
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Solution Overview
Problem
Current proppant technologies face challenges in providing high-performance, cost-effective solutions for maintaining fracture openings in subterranean formations during hydraulic fracturing, as existing materials like sand have low strength and high energy costs, while ceramic proppants require expensive raw materials and high-temperature sintering processes.
Innovation Solution
Development of free-flowing coated particles with a substrate and a curable liquid resin coating containing reactive powder, which are applied at ambient temperature, enhancing unconfined compressive strength and allowing for efficient production at remote sites, reducing energy consumption and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sand is used as proppant, then cost is reduced, but unconfined compressive strength is low
Solution Approach 1:
The patent applies composite materials by coating sand particles with a curable liquid resin to create a hybrid proppant structure. The resin coating (containing epoxy, polyester, or phenolic resins) bonds to the sand substrate, forming a composite particle that combines the low cost and availability of sand with the high strength and fracture resistance of cured resin, thereby resolving the contradiction between cost and strength
Solution Approach 2:
The patent employs parameter changes by transforming the physical and chemical properties of sand particles through resin coating and curing. The uncoated sand particles are converted into coated particles with modified surface properties, enhanced mechanical strength, and improved fracture resistance, achieving higher performance while maintaining cost-effectiveness
2Strength
If sintered ceramic particles are used as proppant, then unconfined compressive strength is improved, but energy consumption and production cost increase
Solution Approach 1:
The patent applies parameter changes by using curable liquid resin coatings that cure at lower temperatures compared to the high-temperature sintering process required for ceramic proppants. The resin coating process involves applying liquid resin at ambient or elevated temperatures and then curing it, significantly reducing energy consumption while achieving comparable or superior strength properties
Solution Approach 2:
The patent employs inexpensive sand particles as the substrate material instead of expensive ceramic raw materials. By coating these low-cost sand particles with resin, the invention creates a proppant that achieves ceramic-like strength without requiring expensive raw materials or energy-intensive sintering processes, effectively replacing high-cost ceramic proppants with a more economical alternative
3Use of energy by moving object
If curable liquid resin coating is applied at ambient temperature, then energy consumption is reduced, but coating effectiveness may be compromised
Solution Approach 1:
The patent applies parameter changes by utilizing the chemical properties of curable liquid resins that can polymerize and cure at ambient or elevated temperatures through chemical reactions rather than requiring high-temperature thermal processing. The resin coating effectiveness is maintained through proper formulation of the liquid resin and control of curing conditions, achieving reliable coating without high energy input
Solution Approach 2:
The patent replaces thermal processing mechanisms with chemical curing mechanisms. Instead of relying solely on high-temperature thermal energy to dry and set the coating, the invention uses chemically active curable resins that undergo polymerization reactions to form strong, durable coatings at lower temperatures, substituting chemical energy for thermal energy and reducing overall energy consumption
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 coated particles effectively bind downhole, offering improved unconfined compressive strength and enabling efficient, economical production, thus enhancing the stability and productivity of hydraulic fracturing operations.
Implementation Method 1
The proppant coating may be precured or curable. The curable proppants include a substrate core and a coating of resin cured downhole to form a consolidated proppant pack.
Implementation Method 2
a curable liquid resin coating containing reactive powder adhered to the curable liquid resin coating
Data Source
AI summary
Disclosed herein are free flowing coated particles and low temperature methods of making same. Each particle has a curable coating disposed upon a substrate. The substrate is a particulate substrate including an inorganic material, a particulate substrate including an organic material, a composite substantially homogeneous formed particle including a first portion of an at least partly cured binder and filler particles, or a hybrid particle having an inorganic particle as a core and a composite coating including at least partially cured resin and filler. The curable coating includes a continuous phase including a curable liquid resin and reactive powder particles embedded or adhered to the continuous phase. The reactive powder particles typically include one or more of a resole phenolic-formaldehyde resin, a novolak phenolic-formaldehyde resin, a polyester resin, an acrylic polymer resin, a urethane resin or an epoxy resin. A method including applying a coating including the continuous phase including the curable resin and reactive or non-reactive powder particles embedded or adhered to the continuous phase.