Hollow Proppant With Internal Flow Paths
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Solution Overview
Problem
Conventional proppants used in hydraulic fracturing can impede hydrocarbon flow due to their solid nature, leading to reduced permeability and increased costs associated with material usage and shipping.
Innovation Solution
Development of proppants with internal flow paths, such as space frames and cylindrical shapes with circular cross-sectional areas, which increase permeability by allowing fluid to flow through and around the proppants, and are made from materials with compressive strengths greater than 9,000 psi to withstand fracturing stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional solid proppants are used to hold fractures open, then fracture support is achieved, but hydrocarbon flow is impeded and permeability is reduced
Solution Approach 1:
The proppant is designed with a porous structure containing internal flow channels that allow hydrocarbons to flow through the proppant itself. This porous design reduces flow impedance while maintaining structural integrity and fracture support capability, directly resolving the contradiction between providing mechanical support and impeding fluid flow.
Solution Approach 2:
The invention transitions from traditional solid proppants to hollow cylindrical proppants with internal flow paths, adding a dimensional aspect (internal volume) that enables fluid passage. This dimensional change allows the proppant to function both as a mechanical support element and as a flow-conducting element, eliminating the harmful flow impedance effect.
2Strength
If traditional solid proppants are used, then sufficient compressive strength is achieved, but material usage and shipping costs increase
Solution Approach 1:
The invention extracts material from the solid proppant structure to create internal flow channels, resulting in a hollow cylindrical design. This extraction reduces the total material quantity required for each proppant while maintaining sufficient compressive strength through optimized wall thickness and structural design, thereby reducing both material usage and associated shipping costs.
Solution Approach 2:
The proppant utilizes a composite structure combining a hollow cylindrical shell with internal flow channels, optimizing the material distribution. This composite design achieves the required mechanical strength with reduced material quantity by concentrating material where structurally necessary while creating voids for fluid flow.
3Productivity
If proppants with internal flow paths are designed, then permeability is enhanced, but structural complexity increases
Solution Approach 1:
The proppant structure is segmented into distinct functional zones: an outer cylindrical shell providing structural strength and internal flow channels providing fluid passage. This segmentation allows each zone to be optimized independently for its specific function while maintaining overall structural simplicity through regular geometric forms.
Solution Approach 2:
The proppant employs a cylindrical geometry with curved surfaces, which provides structural efficiency and strength while facilitating fluid flow through the internal channels. The curved geometry is simpler to manufacture than complex irregular shapes and naturally distributes stress, maintaining structural integrity without excessive complexity.
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
These proppants enhance fracture permeability by 2 to 7 times compared to traditional designs, reduce material needs, and lower shipping costs while maintaining sufficient strength to support fracturing pressures.
Implementation Method 1
The plurality of openings allowing fluid to flow through the proppant thereby increasing permeability
Data Source
AI summary
Embodiments of proppants are described herein. In one embodiment, a proppant for hydraulic fracturing includes a proppant body. The proppant body has a length (L) and an outside diameter (D), and the proppant body length (L) to the proppant body outside diameter (D) ratio (L/D) is about 0.3 to about 5.0. The proppant body includes a space frame, and the space frame includes a plurality of rigid members creating a plurality of openings allowing fluid to flow through the proppant thereby increasing permeability. In another embodiment, a proppant for hydraulic fracturing includes a substantially cylindrical proppant body with a substantially circular cross-sectional area and an internal flow path with a substantially circular cross-sectional.