Delayed Coke Proppant Particulates for Hydraulic Fracturing
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Solution Overview
Problem
Hydraulic fracturing operations face challenges with the deposition of dense proppant particulates in fractures, leading to reduced fluid conductivity and increased production costs due to high settling rates and the formation of fines, which restrict fluid flow and necessitate additional wellbore cleanout and restimulation operations.
Innovation Solution
The use of proppant particulates composed of delayed coke, which have a lower apparent density and specific chemical properties, improving transport and conductivity within fractures, and are derived from a readily available and cost-competitive petroleum refinery process stream, reducing CO2 emissions by replacing higher-BTU fuel sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional dense proppant particulates are used, then proppant strength and fracture support are improved, but settling rate increases and transport efficiency deteriorates
Solution Approach 1:
The invention changes the density parameter of the proppant material from traditional dense materials (sand, gravel) to low-density delayed coke material. This parameter change reduces the settling rate while maintaining sufficient proppant strength to support fractures, thereby resolving the contradiction between strength and settling rate.
Solution Approach 2:
The invention uses delayed coke, a composite carbonaceous material derived from petroleum refinery processes, as the proppant particulate. This composite material provides both the necessary mechanical strength for fracture support and the low density required for improved transport and reduced settling.
2Reliability
If high-density proppant particulates are used, then fracture conductivity is improved, but fines production increases and fluid conductivity deteriorates
Solution Approach 1:
The invention changes the material composition parameter from traditional dense proppants to delayed coke, which has different mechanical properties. This change reduces fines production while maintaining fracture conductivity, as the delayed coke particles are more resistant to fragmentation into fine particles that would clog fractures.
3Productivity
If delayed coke proppant is used, then transport efficiency and settling performance are improved, but material availability and cost competitiveness may deteriorate
Solution Approach 1:
The invention utilizes delayed coke, a byproduct of petroleum refinery operations, as the proppant material. This approach converts a waste or lower-value stream from the refinery process into a valuable proppant product, improving transport efficiency while maintaining cost competitiveness through resource utilization.
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 delayed coke proppant particulates exhibit improved transport and conductivity within fractures, reducing settling rates and fines production, thereby enhancing hydraulic fracturing efficiency and reducing operational costs while offering an environmentally friendly carbon sequestration option.
Implementation Method 1
the proppant particulates may have one or more of: (1) an apparent density in the range of about 1.0 g/cm3 to about 2.0 g/cm3
Implementation Method 2
reducing CO2 emissions by replacing higher-BTU fuel sources
Data Source
AI summary
A fracturing fluid including proppant particulates formed from delayed coke, as well as a method for utilizing such fracturing fluid, are provided herein. The fracturing fluid includes a carrier fluid, as well as proppant particulates composed of delayed coke material. The method includes introducing the fracturing fluid into a subterranean formation and (optionally) depositing at least a portion of the proppant particulates within one or more fractures in the subterranean formation.