Ultra-Lightweight Composite Proppants for Low-Settling Fracturing

Solution Overview

Problem

Conventional proppants used in hydraulic fracturing have high density, leading to settling issues and increased power consumption, and residual materials can decrease reservoir permeability.

Innovation Solution

Production of ultra-lightweight proppants using a microfluidic system, combining plant-based fillers like lignin and cellulose with a thermoplastic polymer matrix, formed through a solvent-based emulsion process in a microfluidic chip.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional high-density proppants are used to resist high closure pressure, then mechanical strength is improved, but proppant settling increases and pumping power consumption increases

Engineering Contradiction:

Improvemechanical strengthVSAvoidproppant density

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining a polymer matrix (providing mechanical strength and elasticity) with plant-based fillers (reducing density). This composite structure allows the proppant to maintain sufficient strength to resist closure pressure while achieving ultra-low density (接近 water density), thereby reducing settling and pumping power requirements

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the density parameter of proppants from conventional high-density materials to ultra-low-density composite materials with density接近 water. This parameter change fundamentally alters the proppant behavior in fracturing fluid, reducing settling velocity and allowing for lower viscosity fluids and lower pumping rates

Inventive Principle:

Principle #35Parameter changes

2Reliability

If viscosifiers are added to fracturing fluid to keep proppants suspended, then proppant transport is improved, but power consumption increases and reservoir permeability decreases

Engineering Contradiction:

Improveproppant suspensionVSAvoidpumping power

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

By changing the density parameter of proppants to be接近 water density, the patent eliminates the need for high-viscosity fracturing fluids. The ultra-lightweight proppants remain suspended naturally without requiring heavy viscosifiers, thereby reducing pumping power requirements and avoiding permeability damage from viscosifier residues

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent extracts or removes the need for viscosifiers from the fracturing system by using ultra-lightweight proppants that naturally suspend in low-viscosity fluids. This eliminates the harmful side effects of viscosifiers while maintaining proppant transport and suspension

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If viscosifiers are used to improve proppant transport, then proppant suspension is improved, but reservoir permeability is decreased

Engineering Contradiction:

Improveproppant suspensionVSAvoidreservoir permeability

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent extracts or removes the need for viscosifiers from the fracturing system by using ultra-lightweight proppants that naturally suspend in low-viscosity fluids. This eliminates the harmful side effects of viscosifiers while maintaining proppant transport and suspension

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

By changing the density parameter of proppants to be接近 water density, the patent eliminates the need for high-viscosity fracturing fluids. The ultra-lightweight proppants remain suspended naturally without requiring heavy viscosifiers, thereby reducing pumping power requirements and avoiding permeability damage from viscosifier residues

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

Reduces proppant settling, allows lower viscosity fracturing fluids, minimizes flood loss, and decreases pumping rates, thereby enhancing hydraulic fracturing efficiency and reducing environmental impact.

Implementation Method 1

dissolving a polymer in a solvent, mixing the particles into the solvent. The solvent is injected into a microfluidic chip, and the polymer-precipitating phase is injected into the microfluidic chip. Emulsified solvent droplets are formed in the polymer-precipitating phase in the microfluidic chip and particles of the proppant are collected after the polymer has precipitated

Methodology Applied

Scientific EffectPrecipitation: Precipitation

Data Source

PatentUS12618001B2Ultra-lightweight proppants

Publication Date: 2026.05.05 SAUDI ARABIAN OIL CO

AI summary

A system and method for making and using proppant particles includes an exemplary proppant particle which includes a composite of a precipitated polymer matrix and a plant-based material, wherein the precipitated polymer matrix includes a thermoplastic, and wherein the plant-based material includes microparticles.