Mobile Coating Unit for On-Site Proppant Formulation
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Solution Overview
Problem
Current hydraulic fracturing processes face inefficiencies due to variability in well conditions, requiring extensive equipment and logistical challenges for mixing and transporting proppants, leading to delays, waste, and increased operational footprints.
Innovation Solution
A mobile coating unit that produces custom coated proppants on-site, using real-time data to adjust formulations and minimize equipment footprint, allowing for flexible use of wet or dry proppants and reducing chemical usage by integrating with existing well-site equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If proppants are coated off-site and transported to the well-site, then the coating process is completed in advance, but the logistical costs, transportation time, and inability to adapt to real-time down-hole conditions increase
Solution Approach 1:
The system prepares coating formulations and proppant coatings in advance through pre-programmed recipes stored in the control unit, allowing rapid deployment when needed while maintaining adaptability to real-time conditions through AI-driven adjustments during the fracturing operation
Solution Approach 2:
The mobile coating unit acts as an intermediary between the proppant supply and the fracturing operation, enabling on-site coating that bridges the gap between pre-prepared materials and real-time operational requirements, thus reducing transportation time while maintaining coating quality
2Adaptability or versatility
If extensive equipment is used for mixing and transporting proppants, then the proppant blending capability is enhanced, but the equipment footprint and logistical complexity increase
Solution Approach 1:
The mobile coating unit is designed as a multi-functional system that combines proppant coating, formulation mixing, and real-time adjustment capabilities in a single integrated platform, eliminating the need for separate mixing and transporting equipment while maintaining enhanced blending capability
Solution Approach 2:
The system merges the coating application mechanism with the proppant handling and formulation delivery systems into a unified mobile unit, reducing the number of separate equipment pieces and simplifying logistics while preserving versatile proppant blending capabilities
3Ease of manufacture
If fixed formulation proppants are used, then the manufacturing process is simplified, but the ability to adapt to varying well conditions and optimize performance is reduced
Solution Approach 1:
The system transitions from static fixed formulations to dynamic adjustable formulations by incorporating AI technology that continuously monitors down-hole conditions and automatically adjusts coating parameters in real-time, allowing the same manufacturing system to produce both simple and customized formulations as needed
Solution Approach 2:
The control unit enables modification of coating formulation parameters such as chemical composition, coating thickness, and application rate based on real-time well conditions, allowing the system to maintain ease of manufacture through standardized processes while achieving adaptability through parameter adjustment
4Reliability
If more chemicals are used for proppant coating, then the proppant performance is enhanced, but the chemical usage and environmental impact increase
Solution Approach 1:
The AI technology incorporates real-time feedback from down-hole condition monitoring to optimize chemical usage in coating formulations, ensuring that only the necessary amount of chemicals is applied to achieve the required proppant performance, thereby reducing excess chemical usage and environmental impact
Solution Approach 2:
The system adjusts chemical concentration and formulation parameters dynamically based on real-time well conditions, allowing optimal proppant performance to be achieved with minimized chemical usage by adapting the formulation to the specific operational requirements rather than using fixed high-chemical formulations
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 reduces logistical costs, minimizes waste, and enhances well completion efficiency by tailoring proppant compositions to real-time down-hole conditions, optimizing the use of materials and reducing the environmental impact of hydraulic fracturing operations.
Implementation Method 1
a coating mixer supported by the platform
Implementation Method 2
a liquid additive dispenser supported by the platform
Implementation Method 3
a volumetric powder dispenser supported by the platform
Data Source
AI summary
A method for improving the performance of hydraulic fracturing processes in oil production fields wherein modifiable coated proppants used in the fracturing fluid are produced on a well-site. Various types of coated proppants may be produced based on real-time, down-hole information obtained and utilized at the well-site.