Microproppant Coke Fracturing Fluid for Secondary Fracture Access
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Solution Overview
Problem
Existing proppants used in hydraulic fracturing operations, such as sand, suffer from high cost and limited hydrocarbon recovery rates, and currently available microproppants are cost-prohibitive for widespread use due to high costs and limited effectiveness in reaching secondary fractures.
Innovation Solution
The use of microproppant coke particles, derived from petroleum coke fines with sizes up to 105 μm, dispersed in a fracturing fluid at concentrations of 3-480 kg/m³, effectively transport and prop open both primary and secondary fractures, enhancing hydrocarbon recovery by increasing the stimulated reservoir volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional proppants like sand are used in hydraulic fracturing, then the fractures can be propped open, but the cost is high and hydrocarbon recovery rate is limited
Solution Approach 1:
The patent uses coke particles, a byproduct of petroleum refining, as a disposable proppant material. These particles are designed to be used once in the fracturing operation and then discarded, eliminating the need for expensive reusable or high-performance proppants while significantly reducing costs and improving hydrocarbon recovery rates.
Solution Approach 2:
The patent changes the physical parameters of the proppant material by using coke particles with specific size distributions (including fine particles that can reach secondary fractures) and chemical properties (oil-wet characteristics) that differ from traditional sand proppants, thereby improving fracture penetration and hydrocarbon recovery.
2Ease of operation
If microproppants are used to reach secondary fractures, then fracture penetration improves, but cost becomes prohibitive for widespread use
Solution Approach 1:
The patent employs coke particles as a low-cost alternative to expensive commercial microproppants. These particles achieve comparable or superior fracture penetration capabilities while being significantly cheaper, enabling widespread adoption in industrial hydraulic fracturing operations.
Solution Approach 2:
The patent utilizes coke particles, a waste byproduct from petroleum refining operations, as a self-service proppant material. This converts a waste stream into a valuable resource, eliminating the need to purchase expensive specialized microproppants while providing effective fracture penetration.
3Productivity
If higher proppant concentrations are used to improve recovery, then stimulated reservoir volume increases, but fluid loss increases
Solution Approach 1:
The patent changes the chemical parameters of the proppant material by using oil-wet coke particles that are compatible with oil-based fracturing fluids. This reduces interfacial tension and minimizes fluid loss while allowing higher proppant concentrations to be used effectively, thereby increasing stimulated reservoir volume without proportionally increasing fluid loss.
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
Microproppant coke particles enhance hydrocarbon recovery by maintaining fractures open, reducing fluid loss, and allowing for lower treatment pressures, thereby increasing the overall effectiveness and reducing costs compared to traditional proppants.
Implementation Method 1
pumping of large quantities of fracturing fluid into a subterranean formation (e.g., a low-permeability formation) under high hydraulic pressure to promote the formation of one or more fractures
Implementation Method 2
Once the fracturing fluid has been pumped into the subterranean formation, it is desired that such proppant particles could be transported into the fractures and settle therein
Data Source
AI summary
A fracturing fluid comprises a carrier fluid and coke particles. The coke particles include microproppant coke particles (e.g., petroleum coke fines) having particle sizes of at most 105 μm, where the microproppant coke particles have a total concentration of at least 3 wt % based on the total weight of the coke particles. The coke particles also have a total concentration in the fracturing fluid from 14 kilograms per cubic meter to 480 kilograms per cubic meter, based on the volume of the carrier fluid. A method includes introducing such fracturing fluid into a subterranean formation.