Onsite Micro-Proppant Grinding for Deep Fracture Placement
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Solution Overview
Problem
The challenge in hydraulic fracturing is the difficulty in obtaining smaller, cost-effective micro-proppants that can be effectively transported and placed deeper into fractures in shale and tight reservoirs, especially with low-viscosity slickwater, and the high cost of ceramic micro-proppants.
Innovation Solution
A system and method for manufacturing micro-proppants onsite using a grinder to crush granular materials like silica sand or drilling cuttings into particles ranging from 3 to 88 microns, combined with conventional proppants, to create a slurry for hydraulic fracturing, utilizing either dry or wet grinding processes to minimize dust and enhance permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ceramic micro-proppant is used, then proppant placement depth and fracture conductivity are improved, but cost increases significantly
Solution Approach 1:
The patent replaces expensive ceramic micro-proppant with inexpensive natural sand that is ground into micro-sized particles onsite. This substitution uses a cheap, readily available material (sand) to achieve the same functional outcome (deep proppant placement) without the high cost of ceramic alternatives.
Solution Approach 2:
The patent changes the particle size parameter of natural sand by grinding it into micro-sized particles (3-88 microns) onsite. This parameter transformation allows natural sand to achieve the deep placement capability traditionally associated with ceramic micro-proppant, while maintaining cost effectiveness.
2Ease of manufacture
If slickwater is used for fracturing, then cost-effectiveness and fracture surface area are improved, but proppant transport capability deteriorates
Solution Approach 1:
The patent changes the particle size parameter of the proppant to micro-sized (3-88 microns), which enables effective transport through low-viscosity slickwater. The smaller particle size reduces gravitational settling and allows the proppant to remain suspended and transported deeper into fractures despite the low viscosity carrier fluid.
Solution Approach 2:
The patent segments the proppant material into much smaller particle sizes (micro-proppant) compared to conventional sand. This segmentation allows the proppant to be effectively carried by slickwater's low viscosity while still achieving deep fracture placement and maintaining transport capability.
3Ease of manufacture
If natural sand is used as proppant, then cost is reduced, but particle size is too large for deep fracture placement
Solution Approach 1:
The patent applies parameter change by transforming the particle size of natural sand from conventional sizes (105-841 microns) to micro-sizes (3-88 microns) through onsite grinding. This maintains the cost advantage of natural sand while achieving the small particle size needed for deep fracture placement.
Solution Approach 2:
The patent replaces the need to transport pre-manufactured ceramic micro-proppant with an onsite mechanical grinding system that processes natural sand into micro-proppant. This substitution eliminates the need to import expensive micro-proppant while achieving the same particle size requirements.
4Manufacturing precision
If micro-proppant is transported from external sources, then fracture conductivity is improved, but transportation cost and complexity increase
Solution Approach 1:
The patent enables self-service by equipping the wellsite with an onsite grinding system that produces micro-proppant from locally available sand. This eliminates the need for external transportation and supply chains for micro-proppant, making the operation self-sufficient and reducing logistical complexity.
Solution Approach 2:
The patent performs preliminary action by grinding the sand into micro-proppant sizes before the fracturing operation begins. This onsite preparation ensures the correct particle size is available when needed, eliminating the need for complex transportation and timing coordination of pre-manufactured micro-proppant delivery.
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 provides a cost-effective and efficient method to produce micro-proppants at the well lease site, improving proppant placement and fracture conductivity, reducing the need for transporting ceramic micro-proppants, and enhancing hydrocarbon production from shale and tight formations.
Implementation Method 1
The grinder may be located adjacent to a wellsite, wherein the grinder may crush a first granular material having a particle size of 105 microns to 841 microns to produce a micro-proppant having an average particle size of 3 microns to 88 microns.
Data Source
AI summary
The present disclosure provides methods and systems for hydraulic fracturing applications and optimization utilizing micro-proppant manufactured adjacent to the wellsite to facilitate its availability. The micro-proppant can be combined with conventional proppant in a slurry and the slurry can be injected into a well during hydraulic fracturing applications.