Polymeric Coated Proppant Thermal Stability
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Solution Overview
Problem
Existing proppants face challenges with inadequate thermal stability, crush resistance, compatibility with low-viscosity carrier fluids, and inefficient coating processes, leading to premature breakdown and reduced petroleum fuel procurement efficiency during hydraulic fracturing.
Innovation Solution
A proppant comprising a particle coated with a polymeric coating formed from a curable composition of isocyanate, acrylate, and optionally polyol, which provides enhanced thermal stability, crush resistance, and compatibility with low-viscosity carrier fluids, while optimizing coating processes for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing proppants use traditional coatings (epoxy or phenolic), then the coating provides basic protective function, but the coating melts, degrades, and shears off under high temperature and pressure conditions
Solution Approach 1:
The patent applies parameter changes by modifying the coating material's chemical composition and thermal properties. The new polymeric coating is formulated with specific polymers and curing agents that raise the glass transition temperature and decomposition temperature, allowing the coating to maintain structural integrity at temperatures where traditional epoxy and phenolic coatings fail.
Solution Approach 2:
The patent employs composite materials by creating a multi-component polymeric coating system that combines heat-resistant polymers with specialized curing agents. This composite approach integrates multiple material properties to achieve both thermal stability and mechanical adhesion, overcoming the limitations of single-material traditional coatings.
2Ease of manufacture
If existing proppants include non-uniform coatings with defects, then the coating can be applied, but the coating experiences premature breakdown and failure under high pressure
Solution Approach 1:
The patent utilizes pneumatic and hydraulic principles by employing fluidized bed coating technology. The proppant particles are fluidized with air or liquid, allowing the coating material to uniformly deposit on each particle surface. This method eliminates gaps and indentations by ensuring complete surface coverage through fluid dynamics, resulting in defect-free coatings with superior crush resistance.
Solution Approach 2:
The patent applies preliminary action by pre-treating the proppant particle surfaces before coating application. Surface preparation steps such as cleaning, roughening, or chemical etching are performed in advance to ensure optimal adhesion. This preliminary treatment prevents coating defects and ensures uniform distribution, eliminating the need for rework and improving overall coating integrity.
3Reliability
If existing proppants use multi-layer coating processes, then the coating provides enhanced protection, but the manufacturing process becomes time-consuming and expensive
Solution Approach 1:
The patent applies merging by consolidating multiple coating functions into a single-layer polymeric coating system. Instead of applying separate primer, intermediate, and topcoat layers, the invention integrates adhesion promotion, corrosion protection, and mechanical strength enhancement into one coating application step. This single-layer approach maintains comprehensive protection while dramatically reducing manufacturing time and cost.
Solution Approach 2:
The patent employs universality by designing a polymeric coating that performs multiple functions simultaneously. The coating provides adhesion to the proppant surface, resistance to thermal degradation, protection against chemical corrosion, and mechanical strength for crush resistance. This multi-functional coating eliminates the need for specialized layers for each function, streamlining the manufacturing process.
4Ease of manufacture
If existing proppants use coatings with inadequate adhesion, then the coating can be applied, but the coating shears off the particle in an uncontrolled manner under high pressure
Solution Approach 1:
The patent applies the intermediary principle by introducing adhesion promoters and coupling agents as intermediate layers between the proppant particle surface and the polymeric coating. These intermediaries chemically bond to both the substrate and the coating material, creating a strong interface that prevents uncontrolled shear-off. The adhesion promoter acts as a molecular bridge, ensuring reliable bonding under high-pressure conditions.
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 proppant maintains structural integrity under high temperature and pressure conditions, ensures effective fracture propping, and reduces impurities in petroleum fuels, while also being cost-effective due to streamlined coating processes.
Implementation Method 1
a polymeric coating formed from a curable composition of isocyanate, acrylate, and optionally polyol
Data Source
AI summary
A proppant includes a particle present in an amount of from 90 to 99.5 percent by weight and a polymeric coating disposed about the particle and present in an amount of from 0.5 to 10 percent by weight, based on the total weight of the proppant. The polymeric coating is formed from a curable composition comprising an isocyanate, an acrylate, and a polyol. A method of forming the proppant includes the steps of combining the isocyanate, the acrylate, and the polyol to form the curable composition, coating the particle with the curable composition, and curing the curable composition to form the polymeric coating.