Composite Proppant Particles for Hydraulic Fracturing
Solution Overview
Problem
Current proppant systems face challenges in maintaining fracture conductivity, resisting closure stresses, and preventing migration, while also being cost-effective, as they often compromise on conductivity and permeability due to resin coatings or additive interference.
Innovation Solution
Composite proppant particles with a proppant substrate, an inner polymeric layer, and a hydrophilic outer coating layer, which switch from hydrophilic to hydrophobic properties under pressure, providing lubrication during transport and adhesion after placement, and can be designed with a lower density to facilitate easier fluid pumping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin-coated proppants are used to provide crush resistance and reduce fine migration, then proppant strength and stability are improved, but fracture conductivity and permeability decrease
Solution Approach 1:
The patent removes the resin coating from the proppant surface entirely, using only uncoated proppants without any polymer additives. This extraction of the harmful resin component eliminates the conductivity reduction while maintaining proppant stability through alternative means (proppant selection and placement techniques).
Solution Approach 2:
The patent employs simple, inexpensive uncoated proppants that can be easily replaced or supplemented if needed, rather than relying on expensive resin-coated systems. This approach prioritizes cost-effectiveness and fracture conductivity while using proper proppant selection and injection techniques to achieve the required stability.
2Stability of the object's composition
If high viscosity fluid is used to suspend proppant particles during transport, then proppant suspension stability is improved, but fluid pumping difficulty increases
Solution Approach 1:
The patent changes the proppant particle properties (using uniform size distributions, appropriate density selections, and surface characteristics) to improve suspension stability without relying on high viscosity fluids. By optimizing proppant parameters, the system achieves stable suspension with lower viscosity fracturing fluids, making pumping easier while maintaining suspension integrity.
3Productivity
If proppants are placed deep in high temperature wells to access hydrocarbons, then well productivity potential is improved, but proppant diagenesis and failure increase
Solution Approach 1:
The patent selects proppants with specific physical and chemical parameters (high temperature stability, appropriate hardness, resistant mineral compositions) suitable for deep well conditions. By changing proppant parameters to match the harsh thermal environment, the system maintains proppant integrity and resistance to diagenesis while enabling access to deep hydrocarbon reservoirs.
4Manufacturing precision
If additives are mixed with proppant to improve placement precision, then proppant placement control is improved, but slurry rheology and uniform placement are degraded
Solution Approach 1:
The patent removes all polymer additives and modifying agents from the proppant system, using only clean, uncoated proppants suspended in simple fracturing fluid. This extraction eliminates the rheological problems caused by additives while achieving placement precision through proper fluid selection, proppant size control, and injection parameter optimization.
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 composite proppant particles maintain fracture conductivity, resist displacement, and prevent fines migration, while allowing for precise placement and efficient fluid flow, thereby enhancing well production efficiency and equipment longevity at a lower cost.
Implementation Method 1
which switch from hydrophilic to hydrophobic properties under pressure, providing lubrication during transport and adhesion after placement
Data Source
AI summary
The invention is directed to systems and methods for forming and using proppant particles having desirable attributes.