Low-density ceramic proppant for uniform hydraulic fracturing distribution
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Solution Overview
Problem
Existing proppants used in hydraulic fracturing techniques are inefficient in enhancing oil and gas production due to their bulk density and distribution uniformity issues.
Innovation Solution
Development of low-density ceramic proppant granules formed from a light aggregate and ceramic binding material, where the light aggregate expands in volume upon burning, with a density of 2.65 g/cm3 or less, and pre-coated with organic or inorganic coatings, using materials like vermiculite, pearlite, and kaolins, combined with alumina and metallurgical-grade slags, to create proppant particles with improved molding and end-use properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional proppant granules are used in hydraulic fracturing, then the fracture walls are fixed and production is enhanced, but the distribution uniformity is poor and production efficiency is limited
Solution Approach 1:
The patent applies parameter changes by controlling the bulk density of proppant granules to be less than 1 g/cm³, which is significantly lower than conventional proppants. This density parameter change enables more uniform distribution of proppant throughout the fracture, directly improving the distribution uniformity while maintaining fracture openness and enhancing oil and gas production
Solution Approach 2:
The patent uses composite materials by combining inorganic materials (quartz and alumina in a ratio of 2.2:5) to create proppant granules with specific physical properties. This composite structure achieves both the required mechanical strength to hold fractures open and the low bulk density for uniform distribution, resolving the contradiction between structural integrity and distribution uniformity
2Manufacturing precision
If proppant density is reduced to improve distribution uniformity, then distribution improves, but the ability to maintain fracture openness may be compromised
Solution Approach 1:
The patent resolves this contradiction by using composite materials consisting of quartz and alumina in a specific ratio (2.2:5). This composite structure provides both low bulk density (less than 1 g/cm³) for uniform distribution and sufficient mechanical strength to maintain fracture openness. The combination of different materials with complementary properties allows simultaneous achievement of distribution uniformity and fracture holding capability
Solution Approach 2:
The patent applies local quality by optimizing the composition and structure of proppant granules at the material level. The specific ratio of quartz to alumina (2.2:5) creates local variations in material properties within the granule structure, providing both low overall density for uniform distribution and localized strength zones for effective fracture support
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 low-density ceramic proppant granules provide a more uniform distribution and increased oil and gas production by maintaining fracture openness, enhancing well production efficiency through optimized propping and carrier fluid integration.
Implementation Method 1
The light aggregate expands in volume when burnt so that the density of the aggregate is changed
Data Source
AI summary
A low-density ceramic proppant is formed from a light aggregate of a natural mineral and a ceramic binding material in the form of a proppant granule. The light aggregate expands in volume when burnt so that the density of the aggregate is changed. A method of preparing a proppant material is carried out by pre-crushing and pre-mixing of raw components. This is followed by their granulation into proppant granules, drying and screening of the granules to a selected size. The raw components include at least a ceramic binding material and a light aggregate of a natural mineral that, when burnt, expands in volume so that the specific volume of the aggregate is changed. The burning of the light aggregate may be accomplished before or after the aggregate is mixed with the binding material.