One-Step Furan Resin Coating for Proppant Stabilization
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Solution Overview
Problem
Hydraulic fracturing operations in subterranean formations often result in loose particles that can plug proppant packs, making it difficult to recover fluids, and existing stabilizing methods like gravel packing and furan resin treatments face challenges with handling, temperature limitations, and corrosion issues.
Innovation Solution
A one-step furan resin composition comprising a furan polymer, hydrolyzable ester, silane coupling agent, surfactant, and solvent is introduced into the wellbore to coat proppant particulates and form a consolidated permeable proppant pack, stabilizing the formation without the need for sequential treatments and addressing temperature and corrosion concerns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If furan resin is used to stabilize loose particles, then particle stabilization is achieved, but handling difficulty and corrosion issues worsen due to internal catalysis and acid requirements
Solution Approach 1:
The patent extracts and removes the problematic internal catalysis function from the furan resin composition. By eliminating the internal catalyst that causes stickiness and handling difficulties, the resin becomes easier to handle while maintaining its particle stabilization capability through alternative curing mechanisms initiated by external factors like water or atmospheric moisture.
Solution Approach 2:
The patent introduces an intermediary substance or mechanism that enables furan resin polymerization without requiring corrosive acid catalysts. This intermediary allows the resin to cure and stabilize particles while avoiding the corrosion issues associated with traditional acid-catalyzed furan resin systems.
2Reliability
If traditional gravel packing is used to control loose particles, then particle migration is prevented, but treatment complexity and time increase due to sequential operations required
Solution Approach 1:
The patent merges the particle stabilization function directly into the proppant particulates themselves by coating them with furan resin. This combines the proppant placement and particle stabilization operations into a single simultaneous treatment, eliminating the need for sequential gravel packing operations and significantly reducing treatment time.
Solution Approach 2:
The furan resin-coated proppant particulates serve multiple functions simultaneously: they act as both the proppant material needed to hold fractures open and the stabilization agent needed to control loose particles. This multi-functional approach eliminates the need for separate gravel packing operations.
3Reliability
If sequential fluid systems with corrosion inhibitors are used, then furan resin polymerization is activated, but system complexity and temperature limitations worsen due to inhibitor effectiveness ranges
Solution Approach 1:
The patent extracts and removes the corrosion inhibitor component from the furan resin system. By eliminating the need for corrosion inhibitors, the system becomes simpler and free from temperature limitations associated with inhibitor effectiveness ranges, while polymerization is initiated by alternative mechanisms such as water or moisture.
Solution Approach 2:
The patent changes the activation parameters for furan resin polymerization from requiring acid catalysts and corrosion inhibitors to being initiated by water, atmospheric moisture, or other non-corrosive triggers. This parameter change simplifies the system and removes temperature constraints related to inhibitor performance.
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 method effectively stabilizes loose particles in subterranean formations by forming a consolidated permeable pack, enhancing fluid recovery and simplifying the treatment process while avoiding handling and temperature-related issues of traditional methods.
Implementation Method 1
The one-step furan resin composition comprises a furan polymer, a hydrolyzable ester, a silane coupling agent, a surfactant, and a solvent
Implementation Method 2
furan resins require an acid catalyst to help activate the polymerization of the resin in temperatures less than about 250° F.
Implementation Method 3
the one-step furan resin composition comprises a furan polymer, a hydrolyzable ester, a silane coupling agent, a surfactant, and a solvent
Data Source
AI summary
Methods including providing at least one target interval in a wellbore, wherein the at least one target interval has a temperature of at least about 70° F. to at least about 290° F.; providing a pad fluid; providing a treatment fluid comprising proppant particulates coated with a one-step furan resin composition, wherein the one-step furan resin composition comprises a furan polymer, a hydrolyzable ester, a silane coupling agent, a surfactant, and a solvent; introducing the pad fluid into the wellbore at a rate and pressure sufficient to create or enhance at least one fracture within the target interval; introducing the treatment fluid into the wellbore so as to deposit the proppant particulates coated with the one-step furan resin composition into the at least one fracture; and setting the one-step furan resin composition so as to form at least a partially consolidated permeable proppant pack in the at least one fracture.