Proppant Composite Coating for Dust Reduction
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Solution Overview
Problem
Hydraulic fracturing proppants generate dust/fines during shipping and handling, posing health and environmental risks and reducing oil and gas recovery efficiency, while existing coatings focus on increasing crush strength or agglomerating dust rather than preventing its formation.
Innovation Solution
A surface-modified proppant with a chemical coating comprising low molecular weight polyethylene glycol, glycerin, or their combinations, applied to the proppant to enhance attrition resistance and reduce dust generation, which is non-toxic and environmentally friendly, applied through various methods including spraying and mechanical mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional proppants (quartz sand, ceramics) are used to increase oil and gas production, then productivity is improved, but dust/fines are generated during shipping and handling, creating health and environmental hazards
Solution Approach 1:
The proppant particles are coated with a protective layer (resin, polymer, or chemical compound) before shipping and handling. This preliminary coating action prevents dust/fines generation during transport and handling operations, eliminating the harmful effect while maintaining the proppant's productivity function
Solution Approach 2:
A coating layer acts as an intermediary between the proppant particles and the environment. This intermediate layer prevents direct contact between proppant surfaces and air/handling equipment, thereby preventing dust/fines generation while allowing the proppant to maintain its integrity and functionality
2Productivity
If proppant particles are handled and transported through various operations (bin loading, belt transfer, pneumatic unloading), then productivity is maintained, but attrition and impingement increase, creating respirable dust
Solution Approach 1:
The proppant is pre-coated with a protective substance before entering the handling and transport system. This preliminary protection ensures that during subsequent attrition and impingement operations, the coating prevents particle breakdown and dust generation, maintaining both productivity and safety
Solution Approach 2:
The protective coating serves as a cushioning layer that absorbs the mechanical stress of handling operations. Before the proppant particles experience attrition and impingement during transport, the coating is already in place to mitigate these effects and prevent respirable dust creation
3Strength
If existing coatings are applied to proppant to increase crush strength, then strength is improved, but dust control is only secondary and does not prevent dust formation
Solution Approach 1:
The coating composition is designed to perform multiple functions simultaneously: it provides crush strength enhancement, prevents dust/fines generation, and controls particle size maintenance. This multi-functional approach eliminates the need for separate treatments and directly addresses the dust problem while maintaining strength
Solution Approach 2:
The coating formulation is optimized with specific physical and chemical parameters (molecular weight, composition ratios, application concentration) to achieve both strength enhancement and dust prevention. By carefully controlling these parameters, the coating simultaneously improves mechanical properties and prevents harmful dust generation
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 coating significantly reduces respirable dust levels, improves attrition resistance, and maintains proppant particle size, ensuring compliance with regulatory standards and enhancing well productivity by minimizing dust-related hazards and environmental impact.
Implementation Method 1
attrition and impingement among quartz particulates and between quartz particulates and the walls of the container occurs during shipping
Implementation Method 2
applied through various methods including spraying and mechanical mixing
Data Source
AI summary
A hydraulic fracturing and gravel packing proppant composite with protectant on the surface of the proppant and the composition matters of the protectant and proppant. The surface protectant reduces the generation of dust/fines from the proppant caused by abrasion and impingement during transportation and conveyance, particularly pneumatic transfer.