Fly Ash Micro-Proppant Size Distribution for Fracture Stability

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Solution Overview

Problem

Existing proppants struggle to stabilize small fractures in oil and gas wells while maintaining high hydraulic conductivity and strength, as smaller size ranges are effective but result in lower permeability.

Innovation Solution

Development of fly ash particles with specific size distribution, roundness, and hydraulic conductivity to create a micro-proppant that prevents fracture healing and ensures efficient fluid flow, using classification methods to optimize particle size and density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If smaller size range proppants are used to stabilize smaller fractures, then the ability to prevent fracture healing is improved, but hydraulic conductivity is lowered

Engineering Contradiction:

Improvefracture stabilization abilityVSAvoidhydraulic conductivity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent applies parameter changes by precisely controlling particle size distribution parameters (d10, d50, d90, d98 values) and particle morphology parameters (roundness, sphericity) of fly ash particles to achieve optimal balance between fracture stabilization and hydraulic conductivity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite material approach by selecting specific fractions of fly ash particles with controlled size distribution and combining them to create a proppant mixture that achieves both small fracture stabilization and maintained hydraulic conductivity

Inventive Principle:

Principle #40Composite materials

2Reliability

If smaller size range proppants are used to stabilize smaller fractures, then the ability to prevent fracture healing is improved, but proppant strength is reduced

Engineering Contradiction:

Improvefracture stabilization abilityVSAvoidproppant strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies parameter changes by selecting and controlling particle size parameters (d50 between 45-150 μm) and particle morphology parameters (roundness and sphericity greater than 0.8) of fly ash particles to optimize the balance between fracture stabilization capability and mechanical strength

Inventive Principle:

Principle #35Parameter changes

3Productivity

If fly ash particles with specific size distribution are used, then hydraulic conductivity is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvehydraulic conductivityVSAvoidparticle size distribution control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by defining specific particle size distribution parameters (d10, d50, d90, d98) and morphology parameters (roundness, sphericity) that can be controlled through standard classification processes, achieving optimal hydraulic conductivity while maintaining feasible manufacturing precision

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10457859B2Proppant for use in hydraulic fracturing to stimulate a well

Publication Date: 2019.10.29 UNIVERSITY OF KENTUCKY RESEARCH FOUNDATION

AI summary

A proppant for use in hydraulic fracturing to stimulate a well is provided. The proppant is fly ash particles having a mean particle size (d50) of between 45 μm and 150 μm and a size distribution defined by (d10)≤5 μm and (d98)≤250 μm.