UV/EB Cured Precured Proppant Particles for Fracture Conductivity
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Solution Overview
Problem
Current proppant technologies face challenges with the high cost and inefficiency of ceramic proppants due to high production costs and low flow capacities, while precured resin-coated proppants lack significant particle-to-particle bond strength, limiting their effectiveness in maintaining fracture conductivity in subterranean formations.
Innovation Solution
The development of precured coated particles with a single layer of curable resin coating, cured using ultraviolet light or electron beam in the absence of added heat, applied to particulate substrates like sand or ceramic particles, resulting in a coating that enhances crush strength and flow capacity without significant particle bonding, allowing for efficient fracture conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ceramic particles are used as proppants, then fracture support capability is improved, but production cost increases and flow capacity decreases
Solution Approach 1:
The patent applies composite materials by coating ceramic or sand particles with a resin layer, creating a hybrid structure that combines the high strength of ceramics/sand with the cost-effectiveness and flow properties of resin-coated particles. This composite approach allows achieving fracture support capability comparable to ceramic proppants while reducing production costs and improving flow capacity through optimized coating formulations and UV/EB curing processes
2Ease of manufacture
If precured resin coating is applied to proppant particles, then production cost is reduced, but particle-to-particle bond strength decreases
Solution Approach 1:
The patent employs parameter changes by utilizing UV/EB radiation curing parameters to control the degree of resin curing. By adjusting radiation dose, exposure time, and intensity, the process achieves a partially cured state that maintains adequate particle-to-particle bond strength while preserving flow capacity and reducing production costs compared to full ceramic proppants. The resin coating parameters (composition, thickness, crosslink density) are optimized to balance bond strength and flow properties
3Strength
If high crosslinking resin formulation is used, then coating strength is improved, but flow capacity decreases
Solution Approach 1:
The patent applies local quality by creating a resin coating with spatially varying properties - the coating provides localized strength enhancement at particle surfaces through controlled crosslinking, while maintaining overall particle流动性 (flowability) by optimizing coating thickness and crosslink density. The UV/EB curing process enables precise control of local resin properties, ensuring sufficient coating strength for fracture support while preserving the flow capacity needed for efficient fracture conductivity and proppant transport
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 method produces proppants with improved crush strength and flow capacity, reducing production costs and environmental impact, while maintaining fracture conductivity, thus enhancing oil and gas production efficiency.
Implementation Method 1
curing the resin with ultraviolet (UV) light or electron beam (EB) in the absence of added heat
Implementation Method 2
curing the resin with ultraviolet (UV) light or electron beam (EB)
Data Source
AI summary
Disclosed herein are methods of making free flowing coated particles and low temperature including a step of curing the coating with UV light or electron beam. Each particle has a precured coating disposed upon a substrate. Methods of using the particles are also disclosed.