Proppant Coating Reduces Pumping Power and Equipment Erosion

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Solution Overview

Problem

Conventional hydraulic fracturing operations in subterranean formations face challenges due to equipment erosion and high costs associated with large volumes of low viscosity fracturing fluids and proppant use, which can lead to inefficiencies and equipment damage.

Innovation Solution

The method involves partially coating proppant particulates with a hydratable polymer or dry friction reducer (DFR) before fracturing, reducing abrasiveness and friction, and enhancing suspension within the fracturing fluid, thereby mitigating equipment erosion and reducing pumping horsepower without significant additional cost or complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If large amounts of low viscosity fracturing fluid and proppant are pumped at high rates and pressures, then sufficient energy is provided to form fractures in low permeability formations, but equipment erosion and damage occur

Engineering Contradiction:

Improvepumping powerVSAvoidequipment erosion

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The proppant surface characteristics are modified by coating with friction reducer, changing the physical-chemical parameters of the proppant-fluid interface. This reduces the friction and abrasiveness of proppant particles, thereby decreasing equipment erosion while maintaining the high pumping rates and pressures needed to create fractures in low permeability formations

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

A friction reducer coating is applied to proppant particles, serving as an intermediary layer between the proppant and the equipment surfaces. This coating mediates the interaction by reducing direct contact and friction between proppant particles and equipment, thereby protecting equipment from erosion while allowing the proppant to maintain its propping function

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If small size proppant (e.g., 100-mesh) is used to create complex fracture networks, then fracture conductivity is improved, but equipment erosion increases

Engineering Contradiction:

Improvefracture conductivityVSAvoidequipment erosion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The surface properties of small size proppant particles are modified through friction reducer coating, changing their abrasiveness parameter. This allows the proppant to maintain small size for good fracture conductivity while the coating reduces the harmful abrasive effects on equipment

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The friction reducer coating is applied locally to the proppant surface, creating a differentiated structure where the core proppant particle maintains its small size and propping function, while the surface coating provides erosion protection. This local modification allows simultaneous achievement of good fracture conductivity and reduced equipment erosion

Inventive Principle:

Principle #3Local quality

3Productivity

If high injection rates are used to pump fracturing fluid, then fracture creation efficiency is improved, but equipment wear and tear increases

Engineering Contradiction:

Improvefracture creation efficiencyVSAvoidequipment wear and tear

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The friction characteristics of proppant particles are changed through coating with friction reducer, reducing the wear and tear they cause to equipment during high rate pumping. This allows maintenance of high injection rates for efficient fracture creation while minimizing equipment degradation

Inventive Principle:

Principle #35Parameter changes

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 effectively reduces equipment erosion and enhances proppant suspension, leading to more efficient fracturing operations with lower additive concentrations, while maintaining the conductivity of fractures for hydrocarbon production.

Implementation Method 1

contacting a plurality of proppant particulates with an aqueous liquid concentrate comprising a hydratable polymer to at least partially coat one or more of the plurality of proppant particulates with the hydratable polymer... reducing abrasiveness and friction

Methodology Applied

Scientific EffectFriction reduction: Friction

Implementation Method 2

Methodology Applied

Scientific EffectHydration and swelling: Absorption (physical)

Implementation Method 3

enhancing suspension within the fracturing fluid, thereby mitigating equipment erosion

Methodology Applied

Scientific EffectSuspension enhancement: Suspension

Data Source

PatentUS10988683B2Proppant treatments for mitigating erosion of equipment in subterranean fracturing operations

Publication Date: 2021.04.27 HALLIBURTON ENERGY SERVICES INC

AI summary

Systems and methods for treating proppant to mitigate erosion of equipment used in certain subterranean fracturing operations are provided. In some embodiments, the methods comprise: conveying a plurality of coated proppant particulates into a blender, wherein the coated proppant particulates comprise at least a partial coating of DFR and/or a hydratable polymer; blending the plurality of coated proppant particulates with an aqueous base fluid in the blender to form a treatment fluid; and introducing the treatment fluid from the blender into at least a portion of a subterranean formation.