Proppant Drying System Using Pressurized Nitrogen
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Solution Overview
Problem
Current methods for hydraulic fracturing in hydrocarbon reservoirs face challenges in maintaining conductivity and increasing productivity due to near-wellbore permeability damage and the need for improved hydrocarbon recovery, especially in low-permeability formations, where proppant freezing issues arise when using low-temperature waterless hydraulic fracturing fluids.
Innovation Solution
A proppant drying system that dehydrates proppant to a bone-dry condition using pressurized gaseous nitrogen injection and exhaustion within a proppant silo, maintaining back pressure to prevent moisture and ensure proppant does not freeze during injection into a subsurface formation, combined with low-temperature waterless hydraulic fracturing fluids for thermal stress and secondary fracturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If low-temperature waterless hydraulic fracturing fluid is used to thermally stress and cause secondary fracturing, then productivity is improved, but proppant freezing occurs
Solution Approach 1:
The proppant is dehydrated to a bone-dry condition before injection into the subsurface formation. This preliminary dehydration action ensures that the proppant particles are completely free of moisture, preventing freezing when contacted with the low-temperature waterless hydraulic fracturing fluid (below 0°F), thereby maintaining reliability while enabling productivity improvement
2Manufacturing precision
If conventional proppant dehydration methods are used, then equipment complexity is reduced, but dehydration effectiveness is insufficient to achieve bone-dry condition
Solution Approach 1:
The patent replaces conventional mechanical dehydration systems with a gas-phase dehydration method using gaseous nitrogen. The nitrogen gas is injected into the proppant bed, absorbs moisture through adsorption, and is then exhausted from the silo. This substitution achieves bone-dry proppant (less than 0.01% moisture) without requiring complex mechanical dehydration equipment
3Manufacturing precision
If proppant is not dehydrated to bone-dry condition, then processing time is reduced, but fracture conductivity is compromised
Solution Approach 1:
The patent uses gaseous nitrogen to create an inert atmosphere within the proppant silo during dehydration. The nitrogen gas displaces moisture-laden air and provides a controlled environment for efficient moisture removal. This inert atmosphere method achieves bone-dry proppant faster than conventional air drying, preventing freeze-thaw cycles that would compromise fracture conductivity while minimizing processing time
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 system effectively enhances wellbore productivity by maintaining proppant conductivity and preventing freezing, resulting in improved fracture conductivity and increased hydrocarbon recovery, with reservoir simulation indicating a 20% improvement in wellbore productivity.
Implementation Method 1
injecting gaseous nitrogen into the proppant silo; and exhausting the gaseous nitrogen and moisture from the proppant silo to dehydrate the proppant
Implementation Method 2
pressurizing a proppant silo that is filled with proppant; maintaining a back pressure within the proppant silo
Implementation Method 3
low temperature waterless hydraulic fracturing fluid that is chilled to a low temperature to thermally stress and cause secondary fracturing to the subsurface formation
Data Source
AI summary
A method of dehydrating proppant is achieved by pressurizing a proppant silo that is filled with proppant and injecting gaseous nitrogen into the proppant silo. The gaseous nitrogen is used to exhaust moisture from the proppant silo until the proppant is in a bone-dry condition. The moisture is exhausted from the proppant silo while maintaining a back pressure within the proppant silo. The bone-dry proppant can be mixed with a stimulation fluid and injected into a hydrocarbon bearing reservoir.