Vibration-Induced Dripping for Uniform Ceramic Proppant Pellets
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Solution Overview
Problem
Existing methods for forming ceramic proppant particles in hydraulic fracturing produce a wide range of pellet sizes and pore distributions, leading to reduced strength and effectiveness due to random agitation and recycling requirements, as well as high porosity and surface roughness, which degrades their performance under stress.
Innovation Solution
The vibration-induced dripping method, known as drip casting, forms uniform-sized, spherical ceramic proppant pellets with reduced porosity by controlling the slurry viscosity, nozzle diameter, and vibration frequency, eliminating the need for recycling and producing pellets with enhanced strength and smooth surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional dry mixing or spray fluidized bed methods are used to form ceramic proppant pellets, then production volume can be achieved, but the pellets exhibit wide size distribution and high porosity leading to reduced strength
Solution Approach 1:
The patent applies mechanical vibration to a nozzle to generate monodisperse droplets from ceramic slurry. The vibration frequency and amplitude are controlled to produce droplets of uniform size, which then dry and sinter into pellets with narrow size distribution and reduced porosity, thereby improving both manufacturing precision and strength
Solution Approach 2:
The patent changes the physical parameters of droplet formation by using vibration-induced dripping instead of conventional spray or fluidized bed methods. By controlling vibration frequency, amplitude, and nozzle geometry, the process produces droplets with uniform diameter, leading to pellets with consistent size and improved strength after sintering
2Productivity
If conventional pellet formation methods with random agitation are used, then production can proceed, but extensive screening and recycling are required increasing process complexity
Solution Approach 1:
The vibration-induced droplet formation process inherently produces monodisperse droplets with very narrow size distribution. This eliminates the need for extensive screening and recycling operations required by conventional methods, simplifying the process while maintaining high productivity
Solution Approach 2:
The invention extracts the droplet formation step from conventional spray or fluidized bed processes and replaces it with vibration-induced dripping. This isolation of the droplet generation mechanism allows for precise control of droplet size without requiring subsequent screening and recycling operations
3Reliability
If ceramic proppant pellets with high porosity are produced, then material usage is efficient, but surface roughness increases degrading performance under stress
Solution Approach 1:
The vibration-induced droplet formation creates smooth spherical droplets that dry and sinter into pellets with smooth surfaces and controlled porosity. The uniform droplet formation avoids the surface roughness and irregular shapes produced by conventional spray or fluidized bed methods, improving performance under stress
Solution Approach 2:
The process produces spherical droplets through vibration-induced dripping, which maintain their spherical shape during drying and sintering. The spherical geometry with smooth surfaces improves stress distribution and performance under the confining pressures encountered in hydraulic fracturing applications
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 results in proppant pellets with superior strength and uniform size distribution, maintaining high permeability under stress, reducing the need for extensive screening and recycling, and enhancing the hydraulic fracturing process efficiency.
Implementation Method 1
vibration-induced dripping from a nozzle of a slurry
Implementation Method 2
vibration-induced dripping process forms uniform-sized, spherical ceramic proppant pellets
Implementation Method 3
sintered ceramic proppant particles formed from vibration-induced dripping
Data Source
AI summary
Proppant material for hydraulic fracturing is provided. The particles of the proppant are formed by drip casting. A slurry of finely divided ceramic particles is flowed through nozzles and formed into droplets under the influence of vibration. Uniform sized, smooth surface, spherical green particles are formed. The green particles are dried and sintered to form the proppant. The proppant is used in the process of hydraulic fracturing of wells.