Proppant Aggregates for High-Stress Fracture Conductivity
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Solution Overview
Problem
Traditional proppant particulates used in subterranean formation operations often fail to meet ISO 13503 standards, leading to subpar performance in fracturing operations, and there is a need for more cost-effective and readily available materials that can form effective proppant aggregates without compromising conductivity and strength.
Innovation Solution
The use of 'subpar' proppant particulates combined with a binding agent to form proppant aggregates, where the binding agent enhances grain-to-grain contact and mechanical strength, reducing porosity and increasing crush resistance, allowing for the creation of conductive pathways in fractures despite non-ideal particulate characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional proppant particulates are used, then cost and availability are improved, but conductivity and strength performance deteriorate
Solution Approach 1:
The patent applies composite materials by combining subpar proppant particulates with a binding agent to form proppant aggregates. The binding agent (polymer, resin, or cementitious material) creates a composite structure where the matrix binds the particulates together, transforming individually poor-performing materials into a composite with enhanced mechanical strength and conductivity that meets or exceeds ISO 13503 standards
Solution Approach 2:
The patent changes the physical and chemical parameters of the proppant system by controlling the binding agent content (0.1-10 wt%), curing conditions (temperature, pressure, time), and aggregate formation parameters. These parameter changes transform the properties of subpar particulates into functional proppant aggregates with desired strength, conductivity, and stability characteristics
2Reliability
If proppant particulates are formed into aggregates, then fracture conductivity is improved, but device complexity increases
Solution Approach 1:
The binding agent serves as an intermediary substance that mediates between the subpar proppant particulates and the desired performance characteristics. It binds the particulates together to form aggregates with improved conductivity while maintaining a relatively simple process that can be integrated into existing fracturing operations
Solution Approach 2:
The patent applies preliminary action by pre-forming the proppant aggregates with the binding agent before injection into the fracture. The aggregates are prepared in advance with controlled composition and structure, then introduced into the fracture where they immediately provide the desired conductivity and structural support
3Strength
If binding agent is added to enhance grain-to-grain contact, then crush resistance is improved, but porosity decreases
Solution Approach 1:
The patent optimizes the binding agent content parameter (0.1-10 wt%) to achieve the desired balance between crush resistance and porosity. By controlling this parameter, the aggregate gains sufficient mechanical strength to resist closure stresses while maintaining adequate porosity for fluid flow through the fracture
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 aggregates demonstrate improved conductivity, crush resistance, and stability, enabling effective fluid flow and fracture maintenance at high closure stresses and temperatures, even with proppant particulates that would otherwise perform poorly on their own.
Implementation Method 1
a binding agent that binds the proppant particulates together
Implementation Method 2
the binding agent enhances grain-to-grain contact and mechanical strength
Implementation Method 3
The proppant aggregates may be placed into the fracture(s) in a spaced apart fashion to maintain sufficient integrity to hold open the fracture once the hydraulic pressure is removed
Data Source
AI summary
Proppant aggregates comprising proppant particulates and a binding agent, wherein the proppant aggregate exhibits a conductivity of less than about 3000 millidarcy-feet when exposed to aggregate operational conditions, the aggregate operational conditions having a closure stress of at least about 100 pounds per square inch and a temperature of at least about 10° C.