Metathesis-Radically Cross-Linked Proppant for High-Temperature Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current proppant materials used in hydraulic fracturing lack sufficient thermal resistance and compressive strength, leading to inadequate performance in high-temperature and aggressive environments, with existing solutions exhibiting high technological complexity, material fragility, and inefficient production processes.
Innovation Solution
A metathesis-radically cross-linked mixture of oligocyclopentadienes and methacrylates is developed, with specific polymer stabilizers, radical initiators, and catalysts added to enhance thermal strength, achieving compressive strength of at least 150 MPa at temperatures above 100°C and improved mechanical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mineral materials or hollow pellets are used as proppants, then the proppant can be delivered to fracture sites, but the compressive strength and thermal resistance are insufficient
Solution Approach 1:
The patent uses a composite polymer system combining polydicyclopentadiene (PDCP) base polymer with thermoplastic elastomers (TPE) and cross-linking agents. This composite structure achieves compressive strength exceeding 150 MPa at temperatures above 100°C while maintaining flexibility and resistance to thermal degradation, resolving the contradiction between strength and thermal resistance.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the proppant material by controlling the glass transition temperature (Tg) to be above 100°C through selective polymer blending and cross-linking. This parameter change enables the material to maintain its mechanical properties and dimensional stability under high-temperature reservoir conditions, simultaneously improving both compressive strength and thermal resistance.
2Strength
If polymeric coatings are applied to proppants, then the compression strength increases, but the thermal resistance remains insufficient
Solution Approach 1:
The patent creates an integrated composite polymer matrix rather than a separate coating system. The combination of PDCP, TPE, and cross-linking agents forms a unified structure where the thermoplastic elastomer phase provides thermal stability while the cross-linked network delivers high compression strength, achieving both properties simultaneously in a single material system.
Solution Approach 2:
The patent introduces localized cross-linked regions within the polymer matrix through controlled cross-linking reactions. These cross-linked zones provide high compression strength and thermal resistance at critical stress points, while the bulk polymer matrix maintains flexibility and processability, resolving the contradiction between strength enhancement and thermal stability.
3Ease of manufacture
If existing polymer materials are used for proppants, then the material can be processed, but the resistance to aggressive environments and thermal strength are inadequate
Solution Approach 1:
The patent employs a composite polymer system where PDCP provides chemical inertness and resistance to aggressive hydrocarbon environments, while TPE additives maintain processability and ease of manufacture. The cross-linked structure further enhances environmental resistance without significantly complicating the processing, as the cross-linking occurs during or after forming operations.
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 resulting material exhibits significantly higher glass transition temperatures, increased compressive strength, and reduced linear thermal expansion, providing enhanced resistance to organic solvents and minimal swelling, thus addressing the limitations of existing proppant materials.
Implementation Method 1
a metathesis-radically cross-linked mixture of oligocyclopentadienes and methacrylates
Implementation Method 2
at least one of radical initiators selected from the following group: di-tert-butyl peroxide (B), dicumyl peroxide (BC-FF), 2,3-dimethyl-2,3-diphenylbutane (30), triphenylmethane (TPM)
Implementation Method 3
at least one of polymer stabilizers as which compounds selected from the following group are used: tetrakis[methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate)]methane (1010), 2,6-di-tert-butyl-4-(dimethylamino)phenol (703)
Implementation Method 4
a catalyst as which a compound of the following general formula is used: where a substituent L is selected from the following group
Data Source
AI summary
The material for proppant and method for producing the same relate to the chemistry of high-molecular weight compounds, and more particularly, to polymer materials with high requirements for physical and mechanical properties, for instance, for the production of proppants, i.e., propping granules, used in the oil and gas production by a method of hydraulic fracturing of formation. The technical result achieved by implementation of the present invention is an increase in thermal strength of the proppant material providing for a compressive strength of at least 150 MPa at a temperature of not less than 100° C. The method consists in the following. A mixture of oligocyclopentadienes is obtained by heating dicyclopentadiene (DCPD) to a temperature of 150-220° C. and holding at this temperature for 15-360 minutes. The oligomerization of dicyclopentadiene occurs. The mixture of oligomers is cooled down to 20-50° C., and polymer stabilizers, radical initiators, methacrylates and a catalyst are sequentially added thereto. The resultant polymer matrix is heated up to a temperature of 50-340° C. and is held at this temperature for 1-360 minutes, and thereafter is cooled down to room temperature. A metathesis polymerization (MP) and radical polymerization (RP) cross-linkage of the mixture of oligocyclopentadienes with methacrylic esters occurs.