Thermal Post-Treated Coke Proppants for Stronger Fracture Conductivity
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Solution Overview
Problem
Existing proppants used in hydraulic fracturing, such as sand, suffer from high cost and limited hydrocarbon recovery rates, necessitating the development of high-performance proppants and fracturing fluids.
Innovation Solution
The use of thermally post-treated fluid coke and flexicoke proppant particles, treated at temperatures between 400°C to 1200°C for durations ranging from 1 minute to 24 hours, which are then mixed with a carrier fluid and optionally other additives, to enhance mechanical properties and improve fracture conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional sand proppant is used in hydraulic fracturing, then the fracture conductivity is maintained, but the cost is high and hydrocarbon recovery rate is limited
Solution Approach 1:
The invention applies parameter changes by thermally treating coke particles at temperatures between 400°C to 1200°C for durations of 1 minute to 24 hours. This thermal treatment modifies the physical and chemical properties of the coke proppant, enhancing its mechanical strength and fracture conductivity characteristics, thereby improving hydrocarbon recovery while using a cost-effective material
Solution Approach 2:
The invention uses composite materials by combining coke particles with optional additives and carrier fluids to create a enhanced proppant system. The coke-based proppant can be mixed with other materials to optimize performance characteristics, achieving both cost-effectiveness and high productivity
2Strength
If thermally post-treated fluid coke and flexicoke proppant particles are used, then strength and conductivity are improved, but the treatment process complexity increases
Solution Approach 1:
The thermal treatment process applies controlled parameter changes (temperature and time) to transform the coke particles into high-strength proppant. By systematically varying temperature (400°C to 1200°C) and duration (1 minute to 24 hours), the process achieves desired strength and conductivity improvements through well-understood thermal transformation mechanisms
3Reliability
If thermally post-treated fluid coke and flexicoke proppant particles are used, then fracture conductivity is improved, but the treatment time and energy consumption increase
Solution Approach 1:
The invention uses parameter changes to optimize the thermal treatment process, allowing flexibility in balancing treatment time and energy consumption against the achieved fracture conductivity. Higher temperatures can achieve the desired properties in shorter times, while lower temperatures require longer durations, enabling process optimization based on specific application requirements
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 thermally treated proppant particles demonstrate improved strength and conductivity, enabling more effective propping of fractures and enhancing hydrocarbon production by maintaining high hydraulic conductivities under stress conditions.
Implementation Method 1
The thermally post-treated fluid coke and/or flexicoke proppant particles are produced by heat-treating the fluid coke and/or flexicoke particles, respectively, to a temperature in a range from 400° C. to 1200° C. for a predetermined duration that is in range from 1 minute to 24 hours
Data Source
AI summary
A fracturing fluid comprises a carrier fluid and thermally post-treated fluid coke and/or flexicoke proppant particles, comprising fluid coke and/or flexicoke particles, respectively, that have been thermally post-treated to a temperature in a range from 400° C. to 1200° C. for a predetermined duration. A method of utilizing such fracturing fluid comprises introducing the fracturing fluid into a subterranean formation. A method of making such fracturing fluid comprises producing the thermally post-treated fluid coke and/or flexicoke proppant particles by thermally post-treating the fluid coke and/or flexicoke particles, respectively, to the temperature in the range from 400° C. to 1200° C. for the predetermined duration and mixing the thermally post-treated fluid coke and/or flexicoke proppant particles with the carrier fluid, optionally along with one or more other types of proppant particles and/or one or more additives.