Thermally Treated Coke Proppants for High-Stress Fracture Conductivity
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Solution Overview
Problem
Existing proppants used in hydraulic fracturing, such as sand, suffer from high cost and limited hydrocarbon recovery rates, necessitating the development of high-performance proppant particles and fracturing fluids.
Innovation Solution
The use of thermally post-treated fluid coke and flexicoke proppant particles, treated at temperatures between 400°C to 1200°C for durations ranging from 1 minute to 24 hours, which are then mixed with a carrier fluid and optionally other additives to enhance mechanical properties and improve fracture conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional sand proppant is used in hydraulic fracturing, then the fracturing operation can be performed, but the cost is high and hydrocarbon recovery rate is limited
Solution Approach 1:
The patent applies parameter changes by thermally treating coke particles at elevated temperatures (400-1200°C) to transform their physical and chemical properties. This thermal treatment modifies the coke's strength, conductivity, and surface characteristics, creating a superior proppant that overcomes the limitations of traditional sand while using a different material basis, thereby improving hydrocarbon recovery rates
Solution Approach 2:
The patent employs composite materials by combining coke particles with various coatings and treatments. The proppant consists of a coke base material enhanced with thermal treatment and optional coating layers, creating a composite structure that delivers both mechanical strength and chemical resistance, ultimately improving fracturing effectiveness and hydrocarbon recovery
2Strength
If thermally post-treated fluid coke and flexicoke proppant particles are used, then strength and conductivity are improved, but thermal treatment time and energy consumption increase
Solution Approach 1:
The patent optimizes the thermal treatment parameters by identifying specific temperature ranges (400-1200°C) and time durations that achieve the desired strength and conductivity improvements. By carefully controlling these parameters, the process achieves effective proppant enhancement while minimizing unnecessary energy consumption beyond the required treatment threshold
Solution Approach 2:
The patent applies preliminary action by pre-selecting and preparing coke particles with appropriate size distributions and chemical compositions before thermal treatment. This pre-preparation ensures that the subsequent thermal treatment is more efficient and requires less energy to achieve the desired proppant properties, as the starting material is already optimized for the treatment process
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 thermally treated proppant particles demonstrate improved strength and conductivity, enabling more effective propping of hydraulic fractures, thereby increasing hydrocarbon production efficiency and fracture conductivity under high stress conditions.
Implementation Method 1
The thermally post-treated fluid coke particles and/or thermally post-treated flexicoke proppant particles include fluid coke particles and/or flexicoke particles, respectively, that have been thermally post-treated to a temperature in a range from 400° C. to 1200° C. for a predetermined duration
Data Source
AI summary
A fracturing fluid comprises a carrier fluid and thermally post-treated fluid coke and/or flexicoke proppant particles, comprising fluid coke and/or flexicoke particles, respectively, that have been thermally post-treated to a temperature in a range from 400° C. to 1200° C. for a predetermined duration. A method of utilizing such fracturing fluid comprises introducing the fracturing fluid into a subterranean formation. A method of making such fracturing fluid comprises producing the thermally post-treated fluid coke and/or flexicoke proppant particles by thermally post-treating the fluid coke and/or flexicoke particles, respectively, to the temperature in the range from 400° C. to 1200° C. for the predetermined duration and mixing the thermally post-treated fluid coke and/or flexicoke proppant particles with the carrier fluid, optionally along with one or more other types of proppant particles and/or one or more additives.