Lightweight Proppant Variable Rate Fracturing
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Solution Overview
Problem
Conventional proppants tend to settle out during hydraulic fracturing, limiting the effective reach and depth of proppant distribution and hindering the broader adoption of variable rate fracturing techniques, which aim to maximize fracture numbers, sizes, and complexities.
Innovation Solution
The use of a lightweight proppant composed of granules made from polyolefins, petroleum coke, and polyaromatic hydrocarbon resins, with a characteristic dimension of 10 micrometers to 3 millimeters, is introduced to minimize settling within the near-wellbore region, allowing for better suspension and distribution during variable rate fracturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional proppants are used during hydraulic fracturing, then proppant can be pumped into the formation, but the proppant settles out within the near-wellbore region, limiting effective reach and depth of proppant distribution
Solution Approach 1:
The patent changes the density parameter of the proppant material from conventional high-density materials (sand, ceramic) to low-density materials (polyolefin, petroleum coke, polyaromatic hydrocarbon resin). This parameter change reduces the density difference between proppant and fracturing fluid, thereby minimizing settling velocity and extending proppant distribution reach and depth within the fractures
Solution Approach 2:
The patent employs composite material strategies by selecting proppant materials with specific combinations of low density, appropriate crush strength, and suitable particle size characteristics. The use of polyolefin, petroleum coke, and polyaromatic hydrocarbon resin creates a composite proppant system that optimizes suspension stability while maintaining propping effectiveness
2Productivity
If variable rate fracturing is implemented to maximize fracture numbers and sizes, then fracture complexity increases, but conventional proppant settling limits the ability to distribute proppant into remote reaches of fracture networks
Solution Approach 1:
The patent applies parameter changes by selecting proppant materials with optimized density and size characteristics that enable effective distribution throughout complex fracture networks created by variable rate fracturing. The low-density proppant materials can be transported further into remote fracture reaches while maintaining suspension during the variable pumping rate cycles
3Adaptability or versatility
If pumping rate is rapidly decreased during variable rate fracturing, then pressure and stress are applied to open previously unopened perforation clusters, but conventional proppant settles out, limiting effective transport
Solution Approach 1:
The patent changes the density parameter of the proppant to match more closely with the fracturing fluid density, reducing gravitational settling during variable rate pumping cycles. This enables effective proppant transport even when pumping rates are rapidly decreased to activate additional perforation clusters
Solution Approach 2:
The patent employs dynamic proppant materials that maintain suspension stability under varying flow conditions. The low-density proppant adapts to the changing pumping rates by maintaining adequate suspension without requiring constant high-velocity flow, enabling effective transport during both high and low rate phases of variable rate fracturing
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
This approach enhances the propping potential and extends the effective reach and depth of proppant deposition within fractures, increasing hydrocarbon production rates and reducing the need for wellbore cleanout operations.
Implementation Method 1
Conventional proppants tend to settle out during hydraulic fracturing, limiting the effective reach and depth of proppant distribution
Implementation Method 2
The use of a lightweight proppant composed of granules made from polyolefins, petroleum coke, and polyaromatic hydrocarbon resins, with a characteristic dimension of 10 micrometers to 3 millimeters, is introduced to minimize settling within the near-wellbore region, allowing for better suspension and distribution during variable rate fracturing
Data Source
AI summary
Methods for completing hydrocarbon wells using variable rate fracturing are provided herein. One method includes positioning a perforation device within a tubular conduit of a downhole tubular, where the downhole tubular extends within a wellbore, and where the wellbore extends within a subsurface region, as well as perforating the downhole tubular using the perforation device to define perforations within the downhole tubular. The method also includes pumping a slurry including fracturing fluid and a lightweight proppant into the tubular conduit according to a variable pumping rate schedule to fracture zones of the subsurface region that are proximate to the perforations, forming corresponding fractures within the subsurface region. The method further includes flowing the slurry into the fractures, via the perforations, to prop the fractures with the lightweight proppant, where the lightweight proppant includes granules formed from a polyolefin, petroleum coke, and/or a polyaromatic hydrocarbon resin.