Native Drilling Cuttings as Proppant for Hydrofracturing

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Solution Overview

Problem

The increasing cost of conventional proppants used in hydrofracturing due to high demand poses a challenge in maintaining wellbore permeability, as fractures formed during the process are susceptible to closure without effective propping agents.

Innovation Solution

Utilizing native drilling cuttings, separated from drilling fluid and dried to minimize base fluid content, in a hydrofracturing slurry with conventional proppants to enhance fracture propping without additional processing, thereby reducing the reliance on expensive conventional proppants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional proppants are used to keep fractures open, then wellbore permeability is maintained, but the cost of hydrofracturing increases due to rapidly rising proppant prices

Engineering Contradiction:

Improvefracture opennessVSAvoidproppant cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent substitutes expensive conventional proppants with cheap drilling cuttings that are normally discarded as waste. The drilling cuttings serve as a disposable, low-cost propping agent that can keep fractures open during production without requiring the high material costs of traditional proppants made from sand, kaolin, or bauxite

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent converts the harmful waste product (drilling cuttings that must be disposed of) into a beneficial propping agent. By repurposing the cuttings from a waste stream into a functional component of the fracturing process, the invention simultaneously reduces waste disposal costs and eliminates the need to purchase expensive conventional proppants

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Quantity of substance

If drilling cuttings are used as proppant substitute, then proppant cost is reduced, but the effectiveness of keeping fractures open may be compromised

Engineering Contradiction:

Improveproppant costVSAvoidfracture openness

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent applies parameter changes by controlling the particle size distribution of drilling cuttings to match the specifications of conventional proppants. The cuttings are screened to ensure they fall within the 20/40 mesh size range, and their physical properties are adjusted through the hydrofracturing process to provide adequate fracture propping capability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite propping system by combining drilling cuttings with conventional proppants in a slurry mixture. This composite approach allows the drilling cuttings to provide bulk volume and cost reduction while the conventional proppants ensure adequate fracture support, achieving both cost efficiency and technical reliability

Inventive Principle:

Principle #40Composite materials

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 effectively keeps fractures open, enhancing wellbore permeability and reducing the environmental impact and costs associated with conventional proppant usage, while leveraging abundant drilling byproducts.

Implementation Method 1

Hydrofracturing involves pumping a fracturing liquid into the wellbore under high pressure such that fractures form in the rock formation surrounding the wellbore

Methodology Applied

Scientific EffectHydraulic fracturing: Fracture Mechanics

Implementation Method 2

proppant is injected into the fractures to prop the fractures open while allowing fluid to flow through its interstitial space

Methodology Applied

Scientific EffectProppant packing: Porosity

Implementation Method 3

obtaining native drilling cuttings that have been separated from a drilling fluid

Methodology Applied

Scientific EffectSolid-liquid separation: Sedimentation

Implementation Method 4

removing hydrocarbons and residual fluid from the native drilling cuttings

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS11828152B2Hydrofracturing applications utilizing drilling cuttings for enhancement of wellbore permeability

Publication Date: 2023.11.28 CHEVRON USA INC

AI summary

The present disclosure provides methods and systems for hydrofracturing processes utilizing native drilling cuttings to enhance wellbore permeability. The native drilling cuttings are obtained during drilling operations and may be used in hydrofracturing applications without further grinding or processing. The native drilling cuttings can be combined into a slurry and injected into a well for the hydrofracturing application. In some cases, the native drilling cuttings are dried before combining them with the slurry.