Hydrogel-Coated Proppants for Self-Suspension in Hydraulic Fracturing
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Solution Overview
Problem
Current proppant systems in hydraulic fracturing face challenges such as settling issues, high viscosity requirements, cost, health and safety concerns, and reduced fracture conductivity due to the use of resin-coated proppants and additives, which affect the efficiency and safety of oil and gas production.
Innovation Solution
Modified proppants with a hydrogel coating that localizes on the surface of proppant particles, providing self-suspension properties, reduced friction, and improved adhesion, while maintaining conductivity and resisting closure stresses, are used in conjunction with oxidative or enzymatic breakers to enhance their performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high viscosity fluid is used to suspend proppants, then proppant suspension stability is improved, but pumping energy requirements increase
Solution Approach 1:
The invention changes the physical-chemical parameters of proppant particles by coating them with hydrophilic polymers, transforming them from hydrophobic to hydrophilic. This parameter change allows proppants to remain suspended in low viscosity, water-based fluids without requiring high viscosity carriers, thereby reducing pumping energy while maintaining suspension stability
Solution Approach 2:
The hydrophilic polymer coating acts as an intermediary between the proppant particles and the aqueous fracturing fluid. This intermediary layer provides steric stabilization and prevents particle aggregation, enabling stable suspension in low viscosity fluids without requiring high viscosity carriers
2Productivity
If resin-coated proppants are used, then fracture conductivity is improved, but health and safety concerns increase due to fines formation
Solution Approach 1:
The invention uses composite proppant structures consisting of a proppant core coated with hydrophilic polymer materials. This composite structure provides both the mechanical strength needed for fracture conductivity and the surface properties that prevent fines generation, replacing the traditional resin coating approach
Solution Approach 2:
The invention employs oxidative breakers to accelerate the degradation of hydrocarbon contaminants and organic materials in the fracturing fluid and formation. This oxidation process eliminates harmful substances without requiring resin-coated proppants, thereby maintaining fracture conductivity while reducing fines formation and health safety concerns
3Strength
If high proppant loading levels are used, then fracture support is improved, but suspension stability deteriorates
Solution Approach 1:
By changing the surface properties of proppant particles through hydrophilic coating, the invention enables stable suspension at high proppant loading levels. The modified surface parameters prevent particle aggregation and settling, allowing high concentrations of proppant to remain suspended without requiring increased viscosity
4Use of energy by moving object
If slickwater fluid is used, then pumping energy is reduced, but proppant suspending capability deteriorates
Solution Approach 1:
The invention changes the surface parameters of proppant particles by applying hydrophilic polymer coatings, transforming them from hydrophobic sand grains to hydrophilic suspended particles. This parameter change enables effective suspension in low viscosity slickwater fluids, combining the energy efficiency of slickwater with the suspending capability of high viscosity fluids
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 hydrogel-coated proppants remain suspended in less viscous fluids, reduce equipment erosion, and improve well production efficiency, safety, and environmental impact by maintaining fracture conductivity and reducing fines formation, thus simplifying hydraulic fracturing operations.
Implementation Method 1
Modified proppants with a hydrogel coating that localizes on the surface of proppant particles
Implementation Method 2
The viscosity of the fluid is typically managed by addition of synthetic or naturally-based polymers
Implementation Method 3
Modified proppants with a hydrogel coating that localizes on the surface of proppant particles, providing self-suspension properties, reduced friction
Implementation Method 4
Modified proppants with a hydrogel coating that localizes on the surface of proppant particles, providing self-suspension properties, reduced friction, and improved adhesion
Implementation Method 5
Modified proppants with a hydrogel coating that localizes on the surface of proppant particles, providing self-suspension properties, reduced friction, and improved adhesion, while maintaining conductivity and resisting closure stresses, are used in conjunction with oxidative or enzymatic breakers
Implementation Method 6
Modified proppants with a hydrogel coating that localizes on the surface of proppant particles, providing self-suspension properties, reduced friction, and improved adhesion, while maintaining conductivity and resisting closure stresses, are used in conjunction with oxidative or enzymatic breakers
Data Source
AI summary
The invention provides for modified proppants, comprising a proppant particle and a hydrogel coating, wherein the hydrogel coating localizes on the surface of the proppant particle to produce the modified proppant, methods of manufacturing such proppants and methods of use.