Proppant Dust Control via Chemical Coating in Fracturing
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Solution Overview
Problem
Hydraulic fracturing operations generate significant dust from proppants, leading to health hazards and explosion risks due to dust accumulation and dispersal, which existing methods fail to adequately mitigate.
Innovation Solution
A method involving the application of a chemical coating to proppants using a combination of compounds such as surfactants, silicones, and resins to prevent dust formation, applied through a metering and mixing system integrated within a vehicle or container, which can be transported to the well site for efficient treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If proppants are handled during hydraulic fracturing operations, then the fracturing operation can proceed, but dust is generated causing health hazards and explosion risks
Solution Approach 1:
The proppant is coated with a dust control agent before being used in the hydraulic fracturing operation. This preliminary treatment prevents dust generation during subsequent handling, conveying, and storage operations, allowing the fracturing operation to proceed efficiently without dust-related hazards.
Solution Approach 2:
A dust control agent serves as an intermediary substance applied to the proppant surface. This coating layer acts as a mediator that reduces the interaction between proppant particles and air, preventing dust generation while maintaining proppant functionality in the fracturing operation.
2Ease of operation
If proppants are stored in open sand bins or surge pits, then easy access is provided for handling, but dust accumulates and can exit into the environment causing health hazards
Solution Approach 1:
The proppant receives a dust control coating treatment before being placed in storage bins or surge pits. This advance treatment ensures that even when stored in open containers for easy access, the proppant does not generate dust that could disperse into the environment or create health hazards.
3Productivity
If proppants are conveyed through pneumatic systems or handling equipment, then efficient transport is achieved, but dust is generated during movement and transfer
Solution Approach 1:
The proppant is coated with a dust control agent before being loaded into pneumatic conveying systems or handling equipment. This preliminary treatment prevents dust generation during the efficient transport and transfer operations, maintaining productivity without creating dust-related problems.
Solution Approach 2:
The dust control coating acts as an intermediary layer between the proppant particles and the conveying system environment. This coating prevents direct interaction that would cause dust generation during pneumatic transport and handling, while allowing the efficient transport process to continue.
4Object-affected harmful factors
If chemical coating is applied to proppants, then dust generation is reduced, but additional processing time and equipment complexity are required
Solution Approach 1:
A dust control agent serves as an intermediary substance that can be applied through relatively simple coating equipment. This agent effectively reduces dust generation without requiring complex processing systems, achieving dust control with minimal added equipment complexity.
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 chemical coating significantly reduces dust generation during proppant handling, enhancing safety by minimizing health hazards and explosion risks while also controlling flowback by ensuring the proppants adhere better to the formation.
Implementation Method 1
treating a proppant that has been transported to a well site with a chemical coating at level sufficient to prevent or at least mitigate the formation of dust during handling of the proppant
Data Source
AI summary
Dust produced by handling proppant during fracking or other mechanical operations can be a health and/or safety hazard. The dust can be eliminated or at least mitigated using a method of conducting a hydraulic fracturing or other mechanical operation on an oil or gas well including treating a proppant that has been transported to an end use site at a level sufficient to prevent the formation of dust during handling of the proppant.