Modified Reactive Resin Coating for Proppant Fracture Resistance
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Solution Overview
Problem
Current proppant coatings used in hydraulic fracturing are brittle and prone to fracturing under high pressure, leading to reduced oil or gas production due to the release of fine particles that block cracks, and existing solutions are complex, costly, and difficult to control.
Innovation Solution
A modified reactive resin composition comprising 92%-99.5% of a reactive resin and 0.5%-8% of a silicone resin, specifically formulated to provide improved hardness, compressive strength, and elastic properties, reducing the tendency of the coating to fracture or flake off, while maintaining free-flowing properties for storage and partial curing during fracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional reactive resins are used for coating proppants, then the coating provides basic protection, but the coating becomes brittle and fractures under high pressure
Solution Approach 1:
The patent applies composite materials by combining reactive resin with flexible modifiers (such as polyols, polyesters, or polyacrylic acids) to create a coating that integrates the strength benefits of the resin with the flexibility benefits of the modifier. This composite approach allows the coating to maintain compressive strength while resisting fracture under high pressure conditions.
Solution Approach 2:
The patent modifies the chemical parameters of the reactive resin by adjusting the molecular weight, functionality, and composition of the resin and its modifiers. By controlling these parameters, the coating achieves optimal balance between hardness for compressive strength and flexibility for fracture resistance, preventing brittleness while maintaining protective properties.
2Reliability
If block copolymers and adhesion promoters are added to reduce brittleness, then impact resistance improves, but the process becomes more complex and costly
Solution Approach 1:
The patent extracts and eliminates the need for separate block copolymer additives and adhesion promoters by incorporating flexible modifying components directly into the reactive resin formulation. This extraction of unnecessary additives simplifies the manufacturing process while maintaining impact resistance through the inherent flexibility provided by the modified resin structure.
Solution Approach 2:
The flexible modifying components serve multiple functions simultaneously: they reduce brittleness, improve impact resistance, and act as adhesion promoters all within the single reactive resin formulation. This multi-functionality eliminates the need for separate additives, reducing process complexity while achieving the desired mechanical properties.
3Reliability
If multiple partial coats are applied interleafed together, then coating stability improves, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent merges multiple coating layers into a single applied layer that cures to form an integrated protective structure. By combining the application steps and using a formulation that cures to provide both adhesion and flexibility in one layer, the manufacturing process becomes simpler while maintaining the stability and protective properties previously requiring multiple layers.
4Reliability
If silicone resins are used in large amounts to improve elasticity, then fracture resistance improves, but the cost increases significantly
Solution Approach 1:
The patent applies partial action by using small amounts of flexible modifying components (less than 10% by weight) rather than large amounts of silicone resins. These partial additions of modifiers provide sufficient flexibility and fracture resistance without the need for excessive silicone content, thereby reducing cost while maintaining the desired mechanical properties.
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 coated proppants exhibit enhanced fracture resistance, toughness, and elasticity, maintaining stability and oil/gas flow rates by reducing the release of fines and extending the lifespan of wells, offering economic and environmental benefits.
Implementation Method 1
the modified reactive resin shows improved fracture toughness and impact resistance as a cured thermoset
Data Source
AI summary
Proppants coated with a cured reactive resin composition containing 92-99.5 wt. % of a reactive resin and 0.5 to 8 wt. % of a silicone resin containing at least 5 wt. % of alkoxy groups and at least 20 mol percent of T and/or Q units, in liquid form, exhibit high freedom from fines generation, and are free flowing.