Incremental Resin Microlayer Coating for Proppant Crush Resistance
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Solution Overview
Problem
Current proppants used in hydraulic fracturing face challenges such as high energy costs, excessive crushing under stress, reduced permeability, and flowback issues, which affect the longevity and effectiveness of fracture conductivity in oil and gas wells.
Innovation Solution
The development of incrementally coated resin or polymer particles with interleaved microlayers, including nanoparticulate reinforcing agents and curing agents, which are applied in a specific process involving heating, coupling agents, and sputtering to enhance crush resistance and bonding between particles, thereby improving fracture conductivity and reducing flowback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional proppants are used in hydraulic fracturing, then initial fracture conductivity is achieved, but they undergo excessive crushing under high closure stresses leading to reduced long-term conductivity and increased fines production
Solution Approach 1:
The patent applies composite materials by combining resin-coated proppant particles with uncoated proppant particles to create a mixed proppant system. The resin-coated particles provide enhanced compressive strength and resistance to crushing, while the uncoated particles fill void spaces and maintain conductivity. This composite approach resolves the contradiction by allowing the system to withstand high closure stresses without excessive crushing, thereby maintaining long-term fracture conductivity.
Solution Approach 2:
The patent segments the proppant system into distinct coated and uncoated particle populations with different functional roles. The resin-coated particles serve as the structural framework that resists crushing, while uncoated particles provide conductivity pathways. This segmentation allows each component to optimize its function, resolving the contradiction between strength and long-term conductivity.
2Strength
If resin coating is applied to enhance crush resistance, then compressive strength improves, but manufacturing complexity and processing time increase
Solution Approach 1:
The patent applies partial coating rather than complete coating of all proppant particles. By coating only a portion of the proppant population, the system achieves sufficient crush resistance while avoiding the full manufacturing complexity and processing time associated with coating 100% of particles. This partial action resolves the contradiction between strength enhancement and manufacturing complexity.
3Quantity of substance
If proppant particles are placed in fracture to maintain conductivity, then initial permeability is established, but fines from crushed particles migrate and plug the proppant pack reducing conductivity
Solution Approach 1:
The patent introduces uncoated proppant particles as intermediary elements that fill void spaces between resin-coated particles. These uncoated particles act as a barrier that prevents fines from migrating through the proppant pack, while still maintaining conductivity pathways. This intermediary approach resolves the contradiction by blocking fines migration without significantly reducing the quantity of proppant placed.
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 incrementally coated particles demonstrate improved compressive strength, long-term conductivity, reduced fines production, and enhanced bonding within the fracture, maintaining high permeability even under high closure stresses, thus optimizing hydrocarbon production.
Implementation Method 1
sputtering a resin coat onto at least a portion of the surface of the particle
Data Source
AI summary
A high strength composite particle comprised of a series of incrementally applied resin microlayer coatings such that each of the microlayer partial coatings are interleaved with each other is described. Methods of making the composite particles, as well as methods of using such particles as a proppant in oil and gas well hydraulic fracturing are also described.