Crosslinked Proppant-Gel Matrix for Hydraulic Fracturing
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Solution Overview
Problem
In hydraulic fracturing, the loading of proppants is limited by their density, leading to high costs and inefficiencies due to settling issues, which can clog wellbores and hinder proppant distribution to fracture ends, affecting production rates.
Innovation Solution
A proppant-gel matrix is created by hydrating a gelling agent, adjusting its pH to 11.5-14.0 with a basic compound, mixing with proppants, and adding a crosslinking agent to enhance stability and viscosity, allowing for increased proppant loading with reduced gelling agent and energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If proppant loading is increased to reduce operation cost, then the amount of gelling agent needed decreases, but proppant settling increases causing wellbore clogging
Solution Approach 1:
The patent changes the pH parameter of the gelling agent to a basic range (pH 11.5-14.0) and introduces crosslinking agents to modify the gel's physical-chemical properties. This transforms the gel's interaction with proppants from passive suspension to active binding, enabling high proppant loading (up to 60-70% by weight) without immediate settling and wellbore clogging.
Solution Approach 2:
The patent creates a composite proppant-gel matrix where crosslinked gel forms a structured network that integrates with proppant particles. This composite structure provides both high proppant loading capacity and settling resistance, as the crosslinked gel matrix mechanically interlocks with proppants while maintaining suspension stability.
2Quantity of substance
If gel viscosity is increased to increase proppant loading, then more proppants can be suspended, but gelling agent loading and pump loading increase
Solution Approach 1:
Instead of increasing viscosity through more gelling agent, the patent changes the chemical parameter by introducing crosslinking agents at basic pH. This creates a crosslinked gel network that provides structural support and proppant suspension capability with much lower gelling agent concentrations, reducing both material cost and pump loading.
Solution Approach 2:
The patent replaces the mechanical viscosity-based suspension system with a chemical crosslinking-based suspension system. The crosslinked gel network provides structural framework that mechanically supports proppants through chemical bonding and physical entanglement rather than relying solely on viscous drag forces.
3Quantity of substance
If gel viscosity is increased to maintain proppant suspension, then proppant loading increases, but pump life decreases
Solution Approach 1:
The patent changes the rheological parameters of the gel by introducing crosslinking, which fundamentally alters the flow characteristics. The crosslinked gel provides suspension stability through network structure rather than high viscosity, resulting in lower pump pressures and extended pump life while maintaining high proppant loading.
4Quantity of substance
If crosslinking is used to increase proppant loading capacity, then material cost decreases, but the complexity of the formulation increases
Solution Approach 1:
The patent utilizes the inherent basic pH property of common crosslinking agents (like borax) to trigger crosslinking, eliminating the need for complex pH adjustment systems. The formulation complexity is minimized by selecting crosslinking agents that naturally provide the required basic environment, making the process straightforward despite the advanced chemistry involved.
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 method significantly reduces settling rates and maintains viscosity, enabling higher proppant loading with lower material and operational costs, improving fracture conductivity and hydrocarbon production.
Implementation Method 1
hydrating a gelling agent to form a hydrated gelling agent
Implementation Method 2
hydrating a gelling agent to form a hydrated gelling agent
Implementation Method 3
adding a basic compound to the hydrated gelling agent to form a basic hydrated gelling agent having a pH in the range of 11.5 to 14.0
Implementation Method 4
adding a crosslinking agent to the basic hydrated gelling system to form the proppant-gel matrix
Implementation Method 5
The method significantly reduces settling rates and maintains viscosity
Data Source
AI summary
A method of making a proppant-gel matrix comprising: a) hydrating a gelling agent to form a hydrated gelling agent; b) adding a basic compound to the hydrated gelling agent to form a basic hydrated gelling agent having a pH in the range of 11.5 to 14.0; c) mixing the basic hydrated gelling agent and a proppant to form a basic hydrated gelling system; and d) adding a crosslinking agent to the basic hydrated gelling system to form the proppant-gel matrix, is disclosed. The proppant-gel matrix can then be used as a fracturing fluid in a hydraulic fracturing process.