Sequential Coke Proppant Fracturing for Extended Fracture Reach
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Solution Overview
Problem
Existing proppants such as sand, ceramics, and polymers used in hydraulic fracturing suffer from high costs and limited hydrocarbon recovery rates, necessitating the development of high-performance proppants and fracturing fluids.
Innovation Solution
A hydraulic fracturing process involving the sequential pumping of first and second fracturing fluids, where the first fluid contains coke proppant particles, and the second fluid contains non-coke proppant particles, with a weight ratio of coke proppant particles to total proppant particles greater than or equal to 1.2, enhancing the transport and placement of proppants within fractures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional proppants like sand, ceramics, and polymers are used in hydraulic fracturing, then the fractures can be propped open, but the cost increases and hydrocarbon recovery rates are limited
Solution Approach 1:
The patent changes the material composition parameter by using coke proppant particles with specific properties (hydrophobic surface, controlled density, appropriate size distribution) to improve hydrocarbon recovery while reducing costs compared to traditional proppants
Solution Approach 2:
The patent employs composite proppant systems combining coke particles with specific surface treatments and size distributions to achieve both cost-effectiveness and enhanced hydrocarbon recovery performance
2Manufacturing precision
If gelled fracturing fluids are used to transport proppant, then proppant placement is improved, but the complexity and cost of the operation increases
Solution Approach 1:
The patent uses simple, water-based fracturing fluids without complex gelling agents, relying instead on the optimized proppant particle characteristics to achieve effective placement, thereby reducing fluid complexity and operational costs
Solution Approach 2:
The proppant particles themselves provide the necessary transport and placement functions through their hydrophobic surface properties and size distribution, eliminating the need for complex gelled fluids to achieve precise placement
3Reliability
If wellbore cleanout operations are performed to remove damaged proppant, then well productivity is maintained, but the time and cost of the operation increases
Solution Approach 1:
The patent selects proppant materials and sizes that are resistant to damage and degradation under fracturing conditions, preventing proppant breakdown before it occurs and thereby eliminating the need for subsequent cleanout operations
Solution Approach 2:
The patent transforms the potential harm of proppant damage by selecting inherently durable coke proppant particles that resist crushing and degradation, converting what would be a problematic situation into a beneficial outcome where no cleanout is needed
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
This approach results in larger conductive fractures and significant production uplift by ensuring that coke proppant particles travel further and remain in place, reducing the need for costly gelled fluids and wellbore cleanouts, while increasing hydrocarbon recovery.
Implementation Method 1
pumping a first fracturing fluid comprising first coke proppant particles into a subterranean formation
Implementation Method 2
proppant particles could be transported into the fractures and settle therein
Data Source
AI summary
A hydraulic fracturing process comprises, during a time interval T1, pumping a first fracturing fluid comprising first coke proppant particles into a subterranean formation, such that a first weight of the first coke proppant particles, WCP1, is pumped into the subterranean formation. The process also comprises, during a time interval T2 that occurs before or after T1, pumping a second fracturing fluid differing from the first fracturing fluid and comprising non-coke proppant particles and optionally second coke proppant particles into the subterranean formation, such that a second weight of the second coke proppant particles, if any, WCP2, is pumped into the subterranean formation, where WCP1/WCP2≥1.2.