Attrition-Resistant Proppant Composite Coating
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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 rather than preventing dust formation.
Innovation Solution
A surface-modified proppant with a non-petroleum-based, glycerin-based or propylene glycol-based chemical coating that reduces attrition and dust generation, applied through mechanical or spray methods, to create an attrition-resistant proppant with low dust/fines levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional proppants (quartz sand, resin coated sand, ceramics) are used for hydraulic fracturing, then oil and gas production is increased, but dust/fines are generated during shipping and handling
Solution Approach 1:
The proppant particles are pre-coated with a binder material before shipping and handling. This preliminary coating action prevents dust/fines generation during subsequent shipping, handling, and pneumatic unloading operations, while maintaining the proppant's effectiveness in hydraulic fracturing
Solution Approach 2:
A binder material serves as an intermediary coating layer between the proppant particles and the environment. This binder coating prevents direct contact and attrition between particles during handling, thereby reducing dust/fines generation without compromising the proppant's function in the wellbore
2Productivity
If pneumatic air unloading is used to transport proppant, then unloading efficiency is improved, but high levels of dust/fines are created
Solution Approach 1:
The proppant is pre-coated with binder material before pneumatic unloading. This preliminary coating prevents particle attrition and dust generation during the high-velocity pneumatic transport process, allowing efficient unloading without creating harmful dust/fines
3Strength
If resin coated proppant is used to increase crush strength, then attrition resistance is improved, but cost increases
Solution Approach 1:
The invention changes the binder material parameters by using alternative materials (such as colloidal silica, polymer emulsions, or other non-resin binders) that provide adequate attrition resistance at lower costs. This parameter substitution maintains the strength improvement while reducing manufacturing expenses
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 solution significantly reduces respirable dust levels and turbidity, enhancing worker safety, environmental protection, and oil/gas recovery by preventing proppant attrition and dust formation, while being cost-effective and compliant with regulatory standards.
Implementation Method 1
The chemical coating increases the attrition-resistance of the proppant and reduces the generation of dust/fines
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.