Expandable Proppant Fracture Support
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Solution Overview
Problem
Conventional proppants are ineffective in maintaining large fractures near the wellbore, leading to inefficient hydrocarbon production due to their inability to hold open larger channels and unreliable wellbore connectivity.
Innovation Solution
The use of expandable proppants with an outer shell layer that expands at least 10% greater in an open position than in a closed position, combined with a proppant delivery system that includes an expandable injector and internal expandable portions, to effectively hold open fractures and maintain connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional proppants are used, then the fracture can be held open to some extent, but the fracture width is insufficient and wellbore connectivity is unreliable
Solution Approach 1:
The proppant is designed with an expandable structure that transitions from a compressed delivery state to an expanded deployed state. The proppant body includes expandable components such as balloons or membranes that can be inflated with fluid or gas to increase the proppant size by a factor of 10 or more, thereby achieving both large fracture width and reliable wellbore connectivity
Solution Approach 2:
The proppant's physical parameters (size, volume, shape) are changed after deployment through expansion mechanisms. The proppant is injected in a compressed state and then expanded in situ using internal pressure from fluid or gas, transforming it from a small deliverable particle to a large fracture-holding structure that ensures reliable connectivity
2Length of moving object
If proppant size is increased to hold open large fractures, then fracture support improves, but delivery and injection becomes more difficult
Solution Approach 1:
The proppant is segmented into a collapsible structure that can be divided into compressible components. The proppant body is designed with foldable or collapsible walls that allow it to be compressed into a small size for delivery through standard injection equipment, then expanded at the target location to provide large fracture support
Solution Approach 2:
The proppant structure employs a nested configuration where internal components are housed within outer shells that can be collapsed. The expandable proppant can be nested within the delivery system's injection line, compressed to fit through small openings, and then deployed to expand into the fracture zone
3Ease of operation
If conventional proppants are used, then injection is straightforward, but they cannot maintain large fracture widths near the wellbore
Solution Approach 1:
The proppant is prepared in advance in a compressed, injectable state that can be easily delivered through standard fracturing equipment. The expansion mechanism is pre-loaded within the proppant structure, allowing it to be injected first and then expanded in sequence, maintaining the simplicity of injection while achieving large fracture widths
Solution Approach 2:
The proppant transitions dynamically from a static compressed delivery state to an active expanded fracture-supporting state. This dynamic transformation allows the system to maintain ease of injection during delivery, then automatically expand at the target location to achieve and maintain large fracture widths near the wellbore
Data Source
AI summary
A method of increasing hydrocarbon production, the method including fracturing downhole formation and disposing an expandable proppant into the downhole formation. The method further includes expanding the expandable proppant into contact with the downhole formation and holding open the downhole formation with the expandable proppant. A proppant having an expandable outer shell layer, wherein the expandable outer shell layer is configured to expand outwardly to a size at least 10 percent greater in an open position than in a closed position. A proppant delivery system having a tool body, an expandable injector disposed on the side of the tool body, and an expandable proppant disposed within the tool body.