Micromesh Ceramic Proppant for Crush-Resistant Deep-Well Fractures
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Solution Overview
Problem
Existing proppants, such as silica sand and ceramic materials, fail to maintain mechanical strength under high closure stress in deep wells, leading to crushing and reduced production efficiency.
Innovation Solution
Development of a micromesh proppant with angular sintered particles made from kaolin or bauxite, sized between 150 mesh to 500 mesh, and a crush strength of 1% to 20% at 7,500 psi, formed through a process involving slurry formation, droplet creation, drying, and sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If silica sand or ceramic materials are used as proppant, then the proppant can be pumped into fractures, but the proppant crushes under high closure stress in deep wells
Solution Approach 1:
The invention changes the particle size parameter to micromesh range (150-500 mesh) and controls the crush strength parameter to 1%-20% at 7,500 psi. This parameter optimization allows small particles to access microfractures while maintaining sufficient strength through controlled sintering, resolving the contradiction between particle size for fracture penetration and strength for stress resistance
Solution Approach 2:
The invention uses composite ceramic materials including alumina, silica, and other ceramic oxides in specific proportions. This composite formulation creates a material that combines the abrasive characteristics needed for microfracture penetration with the mechanical strength required to resist crushing under high closure stress, addressing both requirements simultaneously
2Length of moving object
If proppant particles are made smaller (100 mesh and smaller) to form microfractures, then the proppant can penetrate deeper fractures, but the proppant breaks easily and crushes at high closure stress
Solution Approach 1:
The invention optimizes the particle size parameter to the micromesh range (150-500 mesh) and controls the crush strength parameter to 1%-20% at 7,500 psi through controlled sintering. This parameter optimization allows small particles to access microfractures while maintaining sufficient strength, resolving the contradiction between particle size for fracture penetration and strength for stress resistance
Solution Approach 2:
The invention uses sintering as a phase transition process to transform green pellets into sintered pellets with enhanced mechanical properties. The sintering process creates strong interparticle bonds while maintaining the small particle size needed for microfracture penetration, effectively resolving the contradiction between small size and strength
3Strength
If conventional sintered proppant is used, then the proppant has high strength, but the proppant lacks abrasive characteristics for forming microfractures
Solution Approach 1:
The invention uses composite ceramic materials including alumina, silica, and other ceramic oxides in specific proportions. This composite formulation creates a material that combines the abrasive characteristics needed for microfracture penetration with the mechanical strength required to resist crushing under high closure stress, addressing both requirements simultaneously
Solution Approach 2:
The invention controls the crush strength parameter to a specific range (1%-20% at 7,500 psi) rather than maximizing it. This parameter optimization maintains sufficient strength while preserving the abrasive characteristics of the ceramic material, resolving the contradiction between strength and abrasiveness
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 micromesh proppant effectively props open fractures in deep wells, maintaining strength and preventing crushing, thereby enhancing hydrocarbon production rates.
Implementation Method 1
flowing the slurry through a nozzle to form droplets
Implementation Method 2
drying the droplets to form pellets
Implementation Method 3
sintering the pellets to form sintered pellets
Data Source
AI summary
The present disclosure relates to a micromesh proppant for use in hydraulic fracturing of oil and gas wells. In one embodiment, a process for forming proppant particles includes providing a slurry comprising a ceramic raw material containing alumina, atomizing the slurry into droplets, coating seeds comprising alumina with the droplets to form green pellets, sintering the green pellets to form sintered pellets, and breaking the sintered pellets to form proppant particles comprising a sintered ceramic material and having a size of from about 150 mesh to about 500 mesh and a crush strength at 7,500 psi of from about 1% to about 20%. In one embodiment, a proppant particle includes a sintered ceramic material and having a size of from about 150 mesh to about 500 mesh and a crush strength at 7,500 psi of from about 1% to about 20%.