Polymer-Coated Proppant Particles for Hydraulic Fracturing
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Solution Overview
Problem
Current methods for fracturing and propping oil-bearing formations are resource-intensive, requiring significant time, energy, and mixing processes to incorporate polymers into fracturing fluids, which slows down the process and increases costs.
Innovation Solution
A composition comprising a substrate, such as sand or ceramic sand, coated with a hydrating polymer that is mixed into drilling fluids, allowing immediate transport and absorption of water, reducing friction and settling, and effectively propping open fractures without the need for extensive mixing or heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If polymers are incorporated into fracturing fluids using conventional mixing processes, then the polymers are thoroughly mixed and absorbed, but the process requires significant time, energy, and resources
Solution Approach 1:
The polymer is pre-coated onto the proppant particles before being introduced into the fracturing fluid. This preliminary action eliminates the need for time-consuming mixing and absorption processes, as the polymer is already in its final distributed state on the proppant surface
Solution Approach 2:
The proppant particles serve as an intermediary carrier that transports the polymer into the fracturing fluid. Instead of directly mixing polymer with fluid, the polymer is first attached to proppant particles, which then distribute it throughout the fluid during injection
2Quantity of substance
If polymers are mixed into fracturing fluids using conventional processes, then the polymers are incorporated, but the process is resource-intensive requiring significant energy and time
Solution Approach 1:
The polymer is pre-applied to proppant particles in a controlled coating process before injection. This eliminates the need for high-energy mixing operations during fluid preparation, as the polymer is already distributed on the proppant surface
Solution Approach 2:
The conventional mechanical mixing process is replaced by a coating process where polymer is applied to proppant particles. This substitution eliminates the need for energy-intensive mixers and agitation systems
3Reliability
If proppants are injected into fractures, then they prop open the fractures, but conventional proppants may settle out in low velocity areas
Solution Approach 1:
The proppant particles are transformed into composite structures with polymer coating. This composite structure provides both the mechanical strength of the proppant for propping and the polymer's flow-modifying properties to prevent settling and improve distribution
Solution Approach 2:
The surface properties of proppant particles are changed by coating with polymer. This parameter change affects the particles' interaction with the fracturing fluid, reducing settling tendency and improving distribution uniformity in low velocity areas
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 significantly reduces time and energy consumption, enhances the flow of fracturing fluids, and ensures that proppants are evenly distributed and lodged in fractures, maintaining their openness for better oil production.
Implementation Method 1
a substrate that may be formed of sand, rock product, ceramic sand, gravel, or other hard and structurally strong materials, provided with a binder to temporarily or permanently secure a hydrating polymer in proximity to the substrated
Implementation Method 2
By virtue of the increased surface area and weight provided to the polymeric powders affixed to the substrate, the surface area, and consequently the frictional drag, is greatly increased, sweeping the material of the invention into a flow of fluid
Implementation Method 3
the sand does not settle out in various eddies, obstructions, and other locations of low velocity. Rather, the sand continues to be carried with the fluid
Data Source
AI summary
A method for improving the performance of fracturing processes in oil production fields may rely on polymer coated particles carried in the fracturing fluid. The particles may include heavy substrates, such as sand, ceramic sand, or the like coated with polymers selected to absorb water, increasing the area and volume to travel more readily with the flow of fluid without settling out, or allowing the substrate to settle out. Ultimately, the substrate may become lodged in the fissures formed by the pressure or hydraulic fracturing, resulting in propping open of the fissures for improved productivity.