Ultra-light Ultra-strong Proppants for Hydraulic Fracturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current proppant materials used in hydraulic fracturing are denser than the fracking fluid, leading to non-optimal distribution and degradation over time, resulting in reduced oil and natural gas permeability due to the production of 'fines' which settle and reduce fracture permeability.
Innovation Solution
Development of ultra-light and ultra-strong proppant materials with specific gravities close to water (1.0-3.0) and crush strengths above 10,000 psi, formed through heating oxide-rich waste stream materials in reactive atmospheres to create spherical particles, which maintain high strength and prevent fines formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional proppant materials (sand, ceramic, glass, sintered bauxite) are used, then high strength is achieved, but density becomes too high causing non-optimal distribution and degradation over time
Solution Approach 1:
The patent applies porous materials by creating proppant particles with controlled porosity through the gelcasting process. The porous structure reduces the specific gravity of the proppant particles while maintaining adequate crush strength, allowing them to distribute optimally in the fracking fluid without excessive weight that would cause settling and degradation over time.
Solution Approach 2:
The patent uses composite materials by combining alumina or silica gel precursors with organic binders and porogens to create multi-phase proppant particles. This composite structure enables the particles to achieve both low density and high strength simultaneously, resolving the contradiction between weight and strength requirements for effective hydraulic fracturing proppants.
2Weight of moving object
If proppant particles are made lighter to improve distribution, then optimal distribution is achieved, but strength decreases leading to fines production and permeability reduction
Solution Approach 1:
The patent applies parameter changes by systematically adjusting the gelcasting parameters including gel concentration, porogen content, drying temperature, and sintering conditions. These parameter modifications enable the production of proppant particles with optimized porosity and wall thickness, achieving low specific gravity while maintaining crush strength above 10,000 psi to prevent fines formation.
Solution Approach 2:
The patent implements local quality by creating a heterogeneous microstructure within the proppant particles, with denser alumina or silica gel walls providing strength and an optimized porous interior reducing overall density. This local differentiation of material properties allows the particle to simultaneously achieve light weight for good distribution and high strength to prevent degradation.
3Strength
If proppant particles are made denser to increase strength, then crush strength is improved, but distribution becomes non-optimal and degradation increases
Solution Approach 1:
The patent applies porous materials with controlled pore size distribution and connectivity to create proppant particles that maintain structural integrity while remaining lightweight. The porous structure is designed to prevent particle fragmentation under closure stress, ensuring long-term performance stability and preventing the generation of fines that would reduce fracture permeability over time.
4Weight of moving object
If complex processing methods are used to achieve low density and high strength, then proppant performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies self-service through the gelcasting process where the proppant particles self-assemble and self-structure during gel formation and drying. The organic binders and porogens automatically create the desired porous microstructure without requiring complex external molding or sintering equipment, simplifying manufacturing while achieving the target specific gravity and strength properties.
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 new proppant materials ensure optimal distribution and retention in hydraulic fractures, enhancing oil and natural gas well productivity by maintaining high permeability and preventing settlement of fines, thus improving hydrocarbon recovery.
Implementation Method 1
The reaction mixture is heated in a reactive atmosphere to a temperature above the melting point of the reaction mixture to form a melt
Implementation Method 2
The melt is allowed to solidify in a mold, the solidified melt being in the form of spherical particles
Implementation Method 3
The reaction mixture is heated in a reactive atmosphere to a temperature below the melting point of the reaction mixture to form a powder comprising one or more reaction products
Data Source
AI summary
The present invention provides a method of preparing a proppant material by heating a reaction mixture comprising a plurality of oxides in a reactive atmosphere to a temperature above the melting point of the reaction mixture to form a melt, and then allowing the melt to solidify in a mold in the form of spherical particles. The present invention also provides a method of preparing a proppant material by heating a reaction mixture comprising a plurality of oxides and one or more additives in a reactive atmosphere to a temperature below the melting point of the reaction mixture to form a powder including one or more reaction products, and then processing the powder to form spherical particles. The present invention also provides a proppant material including spherical particles characterized by a specific gravity of about 1.0 to 3.0 and a crush strength of at least about 10,000 psi.