Geopolymerized Proppant Binding Composition for Fracture Conductivity
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Solution Overview
Problem
Current hydraulic fracturing treatments face challenges in maintaining fracture conductivity and proppant stability under high closure stresses due to limitations in strength-hardening temperatures and the need for external heat sources.
Innovation Solution
A binding composition comprising an aluminosilicate source, metal silicate, and alkali metal activator, which undergoes strength-hardening through curing, sintering, or geopolymerization, even at low temperatures, forming a strength-enhanced coated proppant that improves fracture conductivity without requiring external heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional binding compositions are used for proppants, then proppant strength can be enhanced, but external heat sources and high strength-hardening temperatures are required
Solution Approach 1:
The invention changes the chemical composition parameters of the binding composition by incorporating specific components (calcium silicate, aluminum source, alkali metal activator) that enable strength-hardening at lower temperatures. This compositional parameter change allows the binding composition to achieve adequate proppant strength without requiring external heat sources or high temperature environments, directly resolving the contradiction between strength enhancement and temperature requirement
Solution Approach 2:
The binding composition is designed to undergo strength-hardening through geopolymerization using the heat naturally present in the downhole environment, without requiring external heat sources. The chemical components work together to generate the necessary binding strength through self-contained chemical reactions, eliminating the need for additional heating equipment or processes
2Strength
If conventional binding compositions requiring external heat sources are used, then proppant strength can be enhanced, but device complexity and operational difficulty increase
Solution Approach 1:
The binding composition utilizes the natural thermal environment of the downhole setting to drive the strength-hardening process through geopolymerization. The chemical components (calcium silicate, aluminum source, alkali metal activator) are designed to react and bind proppant particles using the ambient heat already present in the formation, eliminating the need for external heating devices, heat generation equipment, or complex thermal management systems
Solution Approach 2:
By modifying the chemical composition to include geopolymerization-capable materials, the invention changes the hardening mechanism from heat-dependent to chemically-driven at lower temperatures. This parameter change in the binding chemistry eliminates the requirement for external heat sources and reduces device complexity while maintaining proppant strength enhancement
3Strength
If conventional binding compositions are used, then proppant strength can be enhanced, but fracture conductivity may be compromised under high closure stresses
Solution Approach 1:
The invention creates a composite binding system combining calcium silicate, aluminum source, and alkali metal activator that work synergistically to provide both strength enhancement and conductivity maintenance. The geopolymerization process forms a binding matrix that adheres to proppant particles while preserving their surface characteristics and flow properties, ensuring that enhanced strength does not come at the expense of fracture conductivity under closure stresses
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 binding composition effectively enhances proppant strength and fracture conductivity, allowing the proppants to withstand high closure pressures and maintain open fractures, thereby improving hydrocarbon production by forming a high-strength, conductive flow path in subterranean formations.
Implementation Method 1
The binding composition undergoes a strength-hardening process defined herein as involving one or more of curing, sintering or geopolymerization, wherein a strength-enhancing phase change occurs in at least a portion of the binding composition
Implementation Method 2
The binding composition undergoes a strength-hardening process defined herein as involving one or more of curing, sintering or geopolymerization
Data Source
AI summary
A downhole treatment fluid made up of a binding composition and a proppant, the binding composition including an aluminosilicate source, a metal silicate, an alkali metal activator. The binding composition may form a coated particulate or an aggregate with the proppant and provides strength-enhancing properties. The binding composition has easy handling properties facilitating on-the-fly preparation and downhole injection procedures. Furthermore, the binding composition has a low strength-hardening temperature and so may strength-harden in the presence of downhole temperatures.