Methane-Pyrolysis Proppant Particles for Fracture Conductivity
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Solution Overview
Problem
Hydraulic fracturing operations face challenges with the deposition and distribution of proppant particulates in fractures, leading to clogging and reduced fluid conductivity due to settling and the formation of fine-grained particles, which decreases production rates and necessitates wellbore cleanout operations.
Innovation Solution
The use of pyrolysis coke particles with a core-and-shell structure, formed through hydrocarbon pyrolysis, offering a combination of high apparent density, controlled particle size distribution, and improved fracture conductivity, which enhances the distribution and retention of proppant particulates in fractures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional proppant particulates are used in hydraulic fracturing operations, then proppant particulates can be deposited in fractures, but settling occurs and fine-grained particles are formed, leading to clogging and reduced fluid conductivity
Solution Approach 1:
The patent changes the physical and chemical parameters of proppant particles by forming them through methane pyrolysis at controlled temperatures (700-1200°C). This process creates particles with specific density (1.8-2.2 g/cm³), size distribution (D50: 75-300 μm), and morphology that prevent fine particle formation and clogging while maintaining fracture conductivity
Solution Approach 2:
The patent produces composite proppant particles with a core-shell structure where the core consists of carbonaceous material and the shell consists of pyrolysis coke. This composite structure provides optimal mechanical strength, density, and surface properties that prevent particle breakdown and fine particle generation during fracturing operations
2Ease of operation
If proppant particulates are transported into fractures under hydraulic pressure, then fractures can be propped open, but denser proppant materials settle, making it difficult to distribute particulates into remote reaches of fracture networks
Solution Approach 1:
The patent optimizes the density parameter of proppant particles to a specific range (1.8-2.2 g/cm³) through controlled methane pyrolysis. This density is sufficiently high to provide propping support but not so high as to cause excessive settling, enabling better distribution into remote fracture regions while maintaining operational effectiveness
3Quantity of substance
If fine-grained particles are formed during proppant deposition, then proppant packs can be formed, but port throats become clogged, resulting in arrested fluid conductivity and decreased production rates
Solution Approach 1:
The patent controls the particle size distribution parameter by adjusting pyrolysis conditions to produce particles with D50 between 75-300 μm and minimal fine particle content. This size distribution ensures adequate proppant pack formation while preventing port throat clogging, thereby maintaining fluid conductivity and production rates
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 pyrolysis coke particles provide enhanced fracture conductivity and reduced settling, maintaining fracture openness and improving production rates by minimizing clogging and the need for cleanout operations.
Implementation Method 1
pyrolysis particles made from hydrocarbon pyrolysis, such as methane pyrolysis
Data Source
AI summary
Compositions for pyrolysis coke particles are provided. The pyrolysis coke particles can have at least an outer shell of pyrolysis coke. In some aspects, the pyrolysis coke particles can be based on a homogeneous seed, so that the entire particle corresponds to pyrolysis coke and/or the particle consists essentially of pyrolysis coke. In other aspects, the particle can be based on a heterogeneous seed, so that a different type of carbon-containing material serves as the core of a particle. Systems and methods for forming such particles are also provided.