Oil-Based Slurry for Hydraulic Fracturing

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Solution Overview

Problem

Conventional slickwater fracturing fluids face challenges with high manufacturing, logistic, and handling costs, as well as issues with blockage and hydration in transport lines, particularly with dry powder, water-in-oil emulsion, and water suspension forms.

Innovation Solution

An oil-based slurry comprising oil, a suspension package, a dispersion agent, and a dry water-soluble polymer is developed, which allows for increased loading of the polymer, reducing the amount of oil needed and improving stability, pumpability, and hydration speed, while enabling the use of a wider variety of oil sources.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If dry powder polymer is used, then chemical cost per active lb is low, but it causes blockage in transport lines and requires special dry add equipment and operation

Engineering Contradiction:

Improvechemical cost per active lbVSAvoidblockage in transport lines

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

The patent changes the physical state parameter of the polymer from dry powder to oil-based slurry form. This parameter change eliminates the blockage issue while maintaining cost effectiveness, as the oil-based slurry flows smoothly through transport lines without caking or blocking.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces oil as an intermediary medium to carry the polymer. The oil-based slurry acts as a carrier that prevents direct contact between dry polymer and transport line surfaces, eliminating blockage while maintaining polymer activity and cost efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If water-in-oil emulsion polymer is used, then it is easy to handle and requires no special pumping equipment, but it has high chemical cost per active lb polymer and long reaction process

Engineering Contradiction:

Improveeasy to handleVSAvoidchemical cost per active lb polymer

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

The patent optimizes the emulsion composition by adjusting the ratio of water to oil and modifying the emulsifier concentration. This parameter change reduces the total volume of emulsion needed while maintaining polymer activity, thereby reducing chemical costs per active lb while preserving ease of handling.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If conventional oil-based slurry is used, then it has higher polymer activity, but manufacturing, logistic, and handling costs are not optimal

Engineering Contradiction:

Improvepolymer activityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent optimizes the oil-based slurry by adjusting oil type, polymer concentration, and additive levels. This parameter optimization maintains high polymer activity while reducing manufacturing and logistic costs through improved formulation efficiency and reduced material waste.

Inventive Principle:

Principle #35Parameter changes

4Productivity

If conventional slickwater fluids are used, then they maintain fracturing fluid pump rate, but they displace proppant into fractures and increase fracture width

Engineering Contradiction:

Improvepump rateVSAvoidfracture width control

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The patent modifies the rheological parameters of the fracturing fluid by adjusting viscosity, density, and flow characteristics. These parameter changes enable the fluid to maintain pump rate while improving proppant suspension stability and reducing unintended fracture width expansion.

Inventive Principle:

Principle #35Parameter changes

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 oil-based slurry reduces the carbon footprint and logistics costs, enhances hydration speed, and provides improved stability and pumpability compared to conventional slurries, with superior friction reduction and longer performance stability.

Implementation Method 1

an oil-based slurry that includes oil, a suspension package, a dispersion agent, a surfactant, and a dry water-soluble polymer

Methodology Applied

Scientific EffectSuspension: Suspension

Implementation Method 2

an oil-based slurry that includes oil, a suspension package, a dispersion agent, a surfactant, and a dry water-soluble polymer

Methodology Applied

Scientific EffectDispersion: Dispersion (of waves)

Implementation Method 3

an oil-based slurry that includes oil, a suspension package, a dispersion agent, a surfactant, and a dry water-soluble polymer

Methodology Applied

Scientific EffectSurfactant: Surfactant

Data Source

PatentUS11781060B2Ultra high activity slurry for hydraulic fracturing

Publication Date: 2023.10.10 SELECT CHEMISTRY LLC

AI summary

An oil-based slurry that includes oil, a suspension package, a dispersion agent, a surfactant, and a dry water-soluble polymer.