Molding Proppants Using Cavity Block and Core Block
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Solution Overview
Problem
Existing methods for manufacturing proppants in the petroleum industry lack the ability to produce uniform, spherical particles with consistent properties such as size, weight, compressibility, specific gravity, and heat resistance, which are essential for effective fracturing and gravel packing of wells.
Innovation Solution
An apparatus and method for molding proppants using a cavity block with semi-spherical cavities and a core block with reciprocal semi-spherical cavities, combined with a system for injecting and ejecting plastic fluid to form uniform, linked spheres (star clusters) with precise control over size and properties, allowing for mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sand is used as a fracturing agent, then heat resistance and compressibility are improved, but uniformity of geometry deteriorates
Solution Approach 1:
The invention changes the physical and chemical parameters of the fracturing agent by using injection-molded plastic spheres instead of natural sand. This allows precise control over geometric parameters (uniform diameter, spherical shape) while maintaining or improving mechanical properties (compressibility, heat resistance) through material selection and molding process parameters.
Solution Approach 2:
The invention applies local quality by creating uniformly spherical particles with consistent surface properties throughout the entire batch. Each proppant particle has the same geometric characteristics (spherical shape, uniform diameter), ensuring consistent flow and packing behavior, which addresses the non-uniformity issue of natural sand while maintaining the desired mechanical properties.
2Ease of manufacture
If prior art injection techniques are used, then manufacturing process is simple, but production quantity and uniformity of proppants deteriorate
Solution Approach 1:
The invention segments the molding process into standardized injection cycles that can be repeated rapidly. The mold design with multiple cavities and the injection molding process allow simultaneous production of multiple proppant particles, dramatically increasing production quantity while maintaining uniformity through consistent process parameters.
Solution Approach 2:
The invention implements continuous production through automated injection molding cycles. The process eliminates interruptions between particle production, with continuous injection, molding, and ejection cycles. This maintains steady-state operation, ensuring both high productivity and consistent particle uniformity through uninterrupted manufacturing.
3Ease of manufacture
If prior art injection techniques are used, then manufacturing process is simple, but uniformity of proppant properties deteriorates
Solution Approach 1:
The invention uses injection molding to precisely control and standardize particle properties. By controlling injection parameters (pressure, temperature, rate) and mold design, the process produces particles with uniform size, shape, density, and surface characteristics. This level of parameter control achieves property uniformity that cannot be obtained through simpler methods.
Solution Approach 2:
The invention replaces simple mechanical mixing or aggregation methods with controlled injection molding. This substitution of the manufacturing mechanism allows precise control over particle formation, ensuring uniform properties through consistent injection parameters and mold geometry, while still maintaining ease of manufacture through the automated molding process.
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 solution enables the mass production of proppants with superior uniformity and physical properties, enhancing their effectiveness in fracturing subterranean reservoirs and controlling sand production, while ensuring consistent performance across all proppants.
Implementation Method 1
An apparatus for molding a proppant is disclosed. The apparatus comprises a first member comprising a manifold for channeling a plastic fluid to a cavity block
Implementation Method 2
a piston plate operatively attached to the ejector plate for advancing and contracting the ejector plate
Data Source
AI summary
An apparatus for molding a proppant is disclosed. The apparatus comprises a first member comprising a manifold for channeling a plastic fluid to a cavity block, with the cavity block containing a plurality of semi-spherical cavities. The apparatus further includes a second member that comprises a movable plate for engaging with the first member, with the movable plate having an opening therein, and a core block positioned within the opening, with the core block containing a plurality of reciprocal semi-spherical cavities configured to engage the semi-spherical cavities of the cavity block so that a plurality of spheres are formed, with the core block further containing a plurality of arm cavities that link the plurality of spheres so that a star cluster (which links the proppants) is formed. A method of manufacturing proppants and a method of using the proppants is also disclosed.