Low-Temperature Coated Proppants for Hydraulic Fracturing
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Solution Overview
Problem
Current proppants used in hydraulic fracturing and gravel packing face challenges such as high energy costs, expensive raw materials, and risk of borehole wall collapse due to pressure fluctuations, with existing solutions having technical and cost limitations for sand control and production efficiency.
Innovation Solution
Development of free-flowing coated particles with a substrate coated using a curable resole phenolic-formaldehyde resin and reactive or non-reactive powders, applied at low temperatures to create a high-performance proppant that can be produced efficiently and used in remote locations, reducing energy consumption and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sintered ceramic particles are used as proppants, then strength and flow capacity are improved, but energy costs and raw material costs increase due to high-temperature sintering
Solution Approach 1:
The invention changes the temperature parameter from high-temperature sintering to low-temperature coating and curing. The coating is applied at ambient temperature and cured at temperatures below 350°F, dramatically reducing energy consumption while maintaining proppant strength through the resin coating rather than thermal processing
Solution Approach 2:
The invention creates a composite proppant structure with a substrate core (sand or ceramic) and a resin coating layer. This composite structure provides the strength and fracture resistance of ceramics without requiring high-temperature sintering, as the resin coating bonds particles together and provides structural integrity
2Adaptability or versatility
If curable resin coatings are applied to proppant substrates, then the coating remains flexible and can be cured downhole, but the coating may not provide sufficient immediate strength protection
Solution Approach 1:
The invention applies a protective resin coating to the proppant substrate before injection into the wellbore. This preliminary coating provides immediate protection and strength enhancement during handling and injection, while the curable nature allows for additional downhole curing to enhance properties later
Solution Approach 2:
The resin formulation is designed to cure at temperatures below 350°F, changing the curing temperature parameter from traditional high-temperature curing to low-temperature curing. This allows the coating to remain flexible during application and injection, then cure effectively in the downhole environment
3Strength
If precured resin coatings are applied to proppant substrates, then immediate strength and structural integrity are improved, but the proppants cannot be cured or adjusted downhole
Solution Approach 1:
The invention uses a curable resin formulation that remains uncured or partially cured during coating application and injection. The curing process is triggered or completed downhole at temperatures below 350°F, providing both immediate handling strength from the coating application and final structural integrity from downhole curing
4Stability of the object's composition
If traditional high-temperature coating processes are used, then complete resin curing and coating stability are achieved, but energy consumption and environmental emissions increase
Solution Approach 1:
The invention changes the curing temperature parameter from traditional high-temperature processes to low-temperature curing below 350°F. The resin formulation is specifically designed to achieve complete curing and stable coating properties at these lower temperatures, reducing energy consumption and environmental emissions while maintaining coating stability
Solution Approach 2:
The invention uses a composite resin system combining resole phenolic-formaldehyde resin with reactive powder particles. This composite material system provides complete curing and stable coating properties at low temperatures through chemical reaction, eliminating the need for high-temperature thermal curing
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 provide improved unconfined compressive strength and can be used to form a stable proppant pack or gravel pack, enhancing production efficiency and reducing costs by minimizing energy usage and environmental impact.
Implementation Method 1
a coating disposed upon the substrate, the coating comprising a continuous phase comprising curable resole phenolic-formaldehyde resin
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 resole resin and reactive powder particles embedded or adhered to the continuous phase. The reactive powder particles typically include resole resin, novolak resin, polyester, acrylic and/or urethane. A method including applying a coating including the continuous phase including resole resin and reactive or non-reactive powder particles embedded or adhered to the continuous phase.