Flowable Proppant Composition for High-Pressure Fracture Conductivity
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Solution Overview
Problem
Current proppant technologies face challenges in maintaining fracture conductivity and permeability due to closure pressures, proppant breakage, and low porosity limitations, which restrict hydrocarbon recovery in hydraulic fracturing operations, especially at greater depths.
Innovation Solution
The use of flowable propping compositions comprising a hardenable external phase and an immiscible internal phase, where the external phase hardens to create a permeable conduit with increased porosity and interconnectivity, reducing the presence of the internal phase to enhance fracture conductivity and withstand high subterranean stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional solid proppant particulates are used to maintain fracture openness, then fracture closure resistance is improved, but fracture conductivity and permeability deteriorate due to low porosity and proppant breakage
Solution Approach 1:
The patent employs a porous proppant material with controlled porosity (30-70%) that maintains fracture openness while allowing fluid flow. The porous structure enables the proppant to resist closure pressures while preserving conductivity, eliminating the trade-off between strength and reliability present in traditional solid proppants.
Solution Approach 2:
The invention uses a composite proppant system combining a load-bearing outer shell with an inner porous core. This composite structure provides mechanical strength to withstand closure pressures while the porous interior maintains high porosity and interconnectivity for fluid flow, simultaneously achieving both fracture closure resistance and conductivity.
2Strength
If proppant load bearing strength is increased to withstand closure pressure, then fracture openness is maintained, but proppant breakage increases under high subterranean stresses
Solution Approach 1:
The composite proppant structure with a load-bearing outer shell and porous inner core allows the system to withstand high closure pressures and subterranean stresses. The outer shell provides mechanical strength while the inner porous structure remains stable and intact, preventing proppant breakage even under extreme conditions.
Solution Approach 2:
The porous proppant material maintains structural integrity while withstanding high stresses. The controlled porosity (30-70%) and interconnected pore network provide both mechanical stability and fluid flow capability, preventing breakage under high subterranean stresses while maintaining fracture openness.
3Strength
If conventional proppant packs are used to prevent fracture closure, then fracture openness is maintained, but hydrocarbon recovery is limited due to low porosity and poor interconnectivity
Solution Approach 1:
The patent employs a porous proppant material with controlled porosity (30-70%) and interconnected pore network that simultaneously maintains fracture openness and enables high hydrocarbon recovery rates. The porous structure allows fluid flow while preventing fracture closure, eliminating the trade-off between fracture openness and productivity.
Solution Approach 2:
The composite proppant system combines a load-bearing outer shell with an inner porous core that provides both fracture openness and high porosity for hydrocarbon flow. This composite structure maintains fracture openness while achieving high productivity through the porous interior's interconnected pore network.
4Strength
If traditional solid proppants are used to maintain fracture conductivity, then fracture openness is maintained, but embedment and debris issues reduce long-term performance
Solution Approach 1:
The porous proppant material prevents embedment and debris generation while maintaining fracture openness. The controlled porosity (30-70%) and interconnected pore network allow fluid flow without creating debris that would reduce long-term performance, ensuring durable fracture conductivity throughout the well's operational life.
Solution Approach 2:
The composite proppant structure with load-bearing outer shell and porous inner core eliminates embedment and debris issues. The outer shell prevents proppant breakage and embedment, while the inner porous structure maintains fracture openness and fluid flow, ensuring long-term fracture performance without the degradation caused by traditional solid proppants.
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
This approach increases fracture conductivity and permeability, leading to higher hydrocarbon recovery rates and longer-term economic benefits by creating well-interconnected pores and reducing embedment and debris issues, while withstanding high stresses and closure pressures.
Implementation Method 1
a hardenable external phase and an internal phase wherein the internal phase is immiscible with the external phase. The fracturing fluid and the flowable propping composition are introduced into a subterranean formation where the hardenable external phase is hardened to form a hardened external phase in the fracture
Implementation Method 2
an internal phase wherein the internal phase is immiscible with the external phase. After the external phase is hardened, the presence of the internal phase is reduced from the hardened external phase thereby leaving a void volume
Data Source
AI summary
Propping compositions comprising: a hardenable, liquid external phase comprising an element selected from the group consisting of: a cement, a cement foam, a polymer, a resin, an aluminum, a flowable carrier fluid, and any combination thereof; and an internal phase that is either gas or liquid and that is immiscible with the external phase; wherein the internal phase exits the propping composition as the hardenable external phase hardens, leaving behind an hardened, interconnected porous network. Some propping compositions may require contact with a treatment for removal from the hardenable external phase and the treatment for removal may comprise at least one material selected from the group consisting of: an acid, a base, a chelant, an oxidizer, a solvent, and any combination thereof.