Ion-Exchanged Glass Proppants for Fracture Resistance

Solution Overview

Problem

Glass and glass ceramic proppants used in hydrofracturing tend to fracture into fine fragments, which reduces permeability and well recovery due to 'blinding' of interstices between particles.

Innovation Solution

Ion-exchange treatment of spherically shaped glass particles to impart a compressive stress state, reducing fine fragment generation during failure, and using a multi-stage ion exchange process to create a graded stress profile for improved mechanical reliability and permeability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If glass spheres are used as proppants, then high strength and ease of manufacture are achieved, but fine fragment generation increases causing blinding of interstices and decreased permeability

Engineering Contradiction:

Improveproppant strengthVSAvoidfine fragment generation

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent applies preliminary action by subjecting glass spheres to ion exchange treatment before they are used as proppants. This pre-treatment modifies the glass structure to create a compressed state that prevents fine fragment generation during subsequent fracturing operations, thereby eliminating the harmful effect while preserving the strength benefits

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the physical-chemical parameters of the glass spheres through ion exchange treatment. By altering the ionic composition and internal stress state of the glass particles, the invention transforms them from a material that generates fine fragments to one that maintains structural integrity during fracturing operations

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If glass particles are used as proppants, then commercial abundance and low cost are achieved, but permeability decreases due to fine fragment blinding

Engineering Contradiction:

Improveease of manufactureVSAvoidpermeability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies preliminary action by subjecting glass spheres to ion exchange treatment before they are used as proppants. This pre-treatment modifies the glass structure to create a compressed state that prevents fine fragment generation during subsequent fracturing operations, thereby eliminating the harmful effect while preserving the strength benefits

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the physical-chemical parameters of the glass spheres through ion exchange treatment. By altering the ionic composition and internal stress state of the glass particles, the invention transforms them from a material that generates fine fragments to one that maintains structural integrity during fracturing operations

Inventive Principle:

Principle #35Parameter changes

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 ion-exchanged particles exhibit reduced fine fragment generation, maintaining higher permeability and production efficiency by minimizing 'blinding' of packed proppant beds and extending well production.

Implementation Method 1

molten salt ion exchange between the particle and a molten salt

Methodology Applied

Scientific EffectIon exchange: Ion Exchange

Data Source

PatentUS8193128B2Treatment of particles for improved performance as proppants

Publication Date: 2012.06.05 THE PENN STATE RES FOUND INC

AI summary

The disclosed invention relates to a process of using molten salt ion exchange to treat particles such as spherically shaped soda-lime-silica glass particles. The treated particles may be used as proppants in hydrofractured oil and natural gas wells.