Hydraulic Fracturing Flowback Design Using Critical Filtration Velocity
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Solution Overview
Problem
Existing methods for minimizing proppant flowback during hydraulic fracturing operations are inadequate, leading to reduced fracture conductivity, equipment damage, and increased processing costs due to proppant flowback, with existing solutions like resin-coated proppants and fibers having limitations such as lower conductivity and operational complexity.
Innovation Solution
A computer simulation model is developed to predict proppant flowback by determining the critical filtration velocity, allowing for optimized fracturing and flowback job design to minimize proppant mobilization and maintain fluid production rates, using a model-based workflow for both pre-fracturing and post-fracturing treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin-coated proppant (RCP) is used to prevent proppant flowback, then proppant flowback is reduced, but near-wellbore conductivity decreases
Solution Approach 1:
The patent changes the physical-chemical parameters of proppant by applying resin coating, which bonds particles together to prevent flowback. However, this coating reduces the conductivity parameter, creating the observed contradiction between reliability and productivity.
2Reliability
If resin-coated proppant is used to prevent proppant flowback, then proppant flowback is reduced, but operational complexity increases
Solution Approach 1:
The resin coating process introduces additional operational parameters and steps, including coating application, curing conditions, and compatibility considerations with fracturing fluids, thereby increasing operational complexity while achieving flowback prevention.
3Reliability
If fibers are used as PFB prevention measure, then proppant flowback is reduced, but near wellbore conductivity decreases
Solution Approach 1:
The patent uses fiber materials as a composite addition to the proppant system to prevent flowback. The fibers create a matrix structure that holds proppant particles in place, but this composite structure reduces the overall conductivity of the near-wellbore zone.
4Productivity
If rapid pressure release is used during flowback, then fluid production rate increases, but proppant mobilization increases
Solution Approach 1:
The patent addresses the dynamic relationship between pressure release rate and proppant stability. Rapid pressure release increases fluid production but creates high velocity flows that mobilize proppant. The solution involves controlling the dynamics of pressure release to balance these competing effects.
5Productivity
If proppant concentration is increased to maintain fracture conductivity, then fracture conductivity is improved, but proppant flowback risk increases
Solution Approach 1:
The patent explores the parameter relationship between proppant concentration and flowback risk. Higher concentrations improve conductivity but increase the amount of proppant available for flowback. The solution involves optimizing concentration parameters and using bonding mechanisms to decouple these relationships.
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 model effectively reduces proppant flowback, maintains fracture conductivity, and minimizes non-productive time and workover expenses by optimizing fracturing and flowback processes, ensuring stable fluid production rates.
Implementation Method 1
A critical filtration velocity uc is determined for each computation cell for a final fracture geometry
Data Source
AI summary
Design method for hydraulic fracturing of a reservoir is presented that maximize well production rates and minimize proppant flowback. The method comprises employing computer simulators that analyze a fracturing treatment design in the context of well properties, reservoir properties, fluids and proppants, and calculates a critical filtration velocity for a proppant pack. If the fluid flow velocity in the fracture exceeds the critical filtration velocity, there is a risk for proppant flowback. The method is applicable to wells that have not yet been fractured, as well as those that have previously undergone a fracturing treatment.