Inorganic Flow Agent Coating for Hydraulic Fracturing Additives
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Solution Overview
Problem
Hydraulic fracturing operations face challenges with chemical additives that tend to clump or stick together due to polymeric coatings absorbing water, leading to increased production time and manufacturing expenses, and existing anti-caking agents like magnesium stearate are ineffective at preventing this issue.
Innovation Solution
The use of inorganic flow agents, such as metal salts of silicates or silica, applied to the surface of polymer-coated chemical additives to prevent clumping and improve the free-flowing character of the particles, allowing for more efficient storage and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymeric coatings are applied to chemical additives to control release, then the additives can be delivered to depth in the wellbore, but the coated particles tend to clump and stick together during storage and transport
Solution Approach 1:
The patent applies an inorganic flow agent as an intermediary substance between the polymeric coating and the environment. This flow agent coating prevents direct water absorption by the polymeric coating, thereby preventing clumping while maintaining the controlled release functionality of the original coating
Solution Approach 2:
The patent uses a thin inorganic flow agent film applied over the polymeric coating. This outer film acts as a protective barrier that prevents water from reaching the polymeric coating, maintaining particle separation during storage and transport while allowing the inner polymeric coating to perform its controlled release function
2Ease of operation
If existing anti-caking agents like magnesium stearate are used, then some prevention of clumping may occur, but they are ineffective at preventing this issue with polymer-coated particles
Solution Approach 1:
The patent changes the material parameter of the flow agent from organic (magnesium stearate) to inorganic (silica, metal salts of silicates). This parameter change fundamentally alters the interaction mechanism with water, providing effective clumping prevention where organic agents failed
3Duration of action of stationary object
If coated particles are stored in humid conditions or for prolonged periods, then water is absorbed by the polymeric coating, but this causes hardening and clumping that makes the particles difficult or impossible to use
Solution Approach 1:
The patent applies the inorganic flow agent coating beforehand as a protective cushion against water absorption. This pre-applied barrier prevents water from reaching the polymeric coating during storage, thereby preventing the clumping and hardening that would otherwise occur during prolonged or humid storage conditions
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
Inorganic flow agents significantly reduce clumping and sticking, enhancing the storage life and usability of coated particles, thereby increasing efficiency and reducing manufacturing costs in hydraulic fracturing operations.
Implementation Method 1
The inorganic flow agent is applied to the surface of the coated additive particles
Data Source
AI summary
Compositions, systems and methods for the prevention or reduction of clumping or sticking of particulate hydraulic fracturing chemical additives. In preferred examples the particulate hydraulic fracturing chemical additives may be coated with, for example, a coating comprising a polymeric component and with or without silica. Inorganic flow agents (IFA) may be applied to the exterior surface of the particulate hydraulic fracturing chemical additives to prevent hardening or clumping of the additives upon storage. Preferably the coating is permeable, but insoluble in an aqueous medium, whereupon the additive components are released into the medium.