Resin-Coated Proppant Consolidation via Activator Triggering
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Solution Overview
Problem
Existing methods for hydraulic fracturing in subterranean formations face challenges in consolidating proppant packs without interfering with other chemicals present in fracturing fluids, such as thickening agents, which can reduce the effectiveness of consolidation.
Innovation Solution
A method involving resin-coated proppant particulates that remain unconsolidated until contacted by an activator, allowing for consolidation in the presence of thickening agents, forming a consolidated proppant pack with a Unconfined Compressive Strength (UCS) of at least 60 psi under various temperature and pressure conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional proppant consolidation methods are used, then proppant packs can be consolidated, but other chemicals in fracturing fluids (such as thickening agents) interfere with the consolidation process and reduce effectiveness
Solution Approach 1:
The patent introduces a compatibilizer as an intermediary substance that mediates between the consolidant and other chemicals in the fracturing fluid. The compatibilizer prevents harmful interactions between the consolidant and thickening agents or other additives, allowing consolidation to proceed effectively despite the presence of multiple chemicals. This resolves the contradiction by enabling the consolidant to function properly without being interfered with by other components in the complex fluid mixture.
2Reliability
If proppant packs are consolidated early, then proppant flowback is prevented, but conductivity of the fracture is reduced
Solution Approach 1:
The patent employs a dynamic consolidation approach where the consolidation process is timed and controlled to occur at optimal moments. The fracturing fluid is designed to deliver consolidants that activate under specific downhole conditions (temperature, pressure, pH), allowing the proppant pack to remain loose and conductive during placement, then consolidate automatically after placement to prevent flowback. This dynamic timing resolves the contradiction between maintaining conductivity during placement and preventing flowback after placement.
3Strength
If consolidants are added to fracturing fluids, then proppant consolidation is achieved, but the consolidants compete with other chemicals and reduce overall fluid performance
Solution Approach 1:
The patent applies local quality by designing consolidants and compatibilizers with specific functional properties tailored for their role in consolidation. The consolidant molecules are structurally designed to preferentially bind to proppant surfaces rather than interacting with thickening agents or other additives. This selective local interaction ensures consolidation effectiveness while preventing unwanted side reactions with other chemicals in the fracturing fluid, resolving the complexity issue.
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 enables effective consolidation of proppant packs without competing with other chemicals, maintaining high conductivity and preventing proppant flowback, thereby enhancing hydrocarbon production and injection rates.
Implementation Method 1
contacting unconsolidated resin-coated proppant particulates with an activator to form a consolidated proppant pack
Data Source
AI summary
Methods and compositions using surface chemistry and internal porosity of proppant particulates to consolidate the proppant particulates are described herein. The methods can include a method of gravel packing a wellbore. The method can include mixing an activator, a thickener, a crosslinker and a plurality of resin-coated proppant particulates to provide a gravel pack fluid and introducing the gravel pack fluid into a gravel pack region of the wellbore. The method can also include consolidating at least a portion of the plurality of resin-coated proppant particulates to provide a consolidated gravel pack, wherein the consolidated gravel pack has a UCS of at least about 60 psi when formed under a pressure of about 0.01 psi to about 50 psi and a temperature of about 160° F. to about 250° F.