Proppant Coating Thermal Stability and Crush Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing proppants exhibit inadequate thermal stability, crush resistance, and compatibility with low-viscosity carrier fluids, leading to premature breakdown and reduced permeability, which hampers the effective hydraulic fracturing of subterranean formations and petroleum fuel extraction.
Innovation Solution
A proppant comprising a particle coated with a polymeric coating formed from the reaction product of an acrylate copolymer and an isocyanate, which provides enhanced thermal stability, crush resistance, and compatibility with low-viscosity carrier fluids, ensuring effective fracture propagation and petroleum fuel extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing proppants use epoxy or phenolic coatings, then the proppant can be coated to provide some protection, but the coating melts, degrades, and shears off the particle in an uncontrolled manner when exposed to high temperatures and pressures
Solution Approach 1:
The patent changes the chemical composition parameters of the coating by using a polyolefin resin with specific molecular weight ranges (1,000-1,000,000 g/mol) and controlled branching (0.1-10 mmol/g), which fundamentally alters the thermal stability and degradation characteristics compared to traditional epoxy or phenolic coatings
Solution Approach 2:
The patent creates a composite coating system combining polyolefin resin with specific additives and controlling the molecular structure through branching, resulting in a material that maintains integrity at high temperatures and pressures while providing the necessary protective functions
2Strength
If existing proppants use non-uniform coatings with defects, then the coating can be applied to provide cushioning effect, but the defects such as gaps or indentations contribute to premature breakdown and failure of the coating
Solution Approach 1:
The patent optimizes coating parameters including resin molecular weight, branching concentration, and coating thickness to achieve uniform coating formation that provides consistent cushioning effect and prevents premature breakdown under compressive loads
Solution Approach 2:
The patent ensures uniform coating distribution across the particle surface through controlled application parameters and resin properties, creating consistent local quality throughout the coating that prevents weak points and defects
3Strength
If existing proppants consolidate into aggregated, near-solid, non-permeable proppant packs, then the proppant can maintain structural integrity, but the consolidation prevents adequate flow and procurement of petroleum fuels
Solution Approach 1:
The patent modifies proppant properties including particle shape, size distribution, and coating characteristics to control consolidation behavior, allowing the proppant pack to maintain sufficient structural integrity while preserving adequate permeability for fluid flow
4Reliability
If existing proppants are coated via noneconomical coating processes, then the proppant can be coated to provide protection, but the process contributes to increased production costs
Solution Approach 1:
The patent optimizes coating process parameters including resin viscosity, application temperature, and coating thickness to achieve effective protection with simplified, more economical coating processes that reduce production costs
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, prevents premature breakdown, and ensures efficient petroleum fuel extraction by maintaining fracture openness and permeability, while being economically viable due to simplified coating processes.
Implementation Method 1
The proppant exhibits adequate thermal stability for high temperature and pressure applications
Implementation Method 2
the coating typically provides a cushioning effect for the proppant and evenly distributes high pressures around the proppant
Implementation Method 3
The proppant remains in place in the fractures once the high pressure is removed, and thereby props open the fractures
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 includes the reaction product of an acrylate copolymer and an isocyanate. The acrylate copolymer includes styrene units and has a hydroxyl number of from 20 to 500 mg KOH/g. A method of forming the proppant includes the steps of combining the acrylate copolymer and the isocyanate to react and form the polymeric coating and coating the particle with the polymeric coating to form the proppant.