U.S. patent application number 17/202774 was filed with the patent office on 2021-11-04 for hydraulic fracture composition and method.
The applicant listed for this patent is Aquasmart Enterprises, LLC. Invention is credited to Calder Hendrickson, Todd Naff, Tommy K. Thrash.
Application Number | 20210340434 17/202774 |
Document ID | / |
Family ID | 1000005708832 |
Filed Date | 2021-11-04 |
United States Patent
Application |
20210340434 |
Kind Code |
A1 |
Hendrickson; Calder ; et
al. |
November 4, 2021 |
HYDRAULIC FRACTURE COMPOSITION AND METHOD
Abstract
A method for improving the performance of fracturing processes
in oil production fields may rely on polymer coated particles
carried in the fracturing fluid. The particles may include heavy
substrates, such as sand, ceramic sand, or the like coated with
polymers selected to absorb water, increasing the area and volume
to travel more readily with the flow of fluid without settling out,
or allowing the substrate to settle out. Ultimately, the substrate
may become lodged in the fissures formed by the pressure or
hydraulic fracturing, resulting in propping open of the fissures
for improved productivity.
Inventors: |
Hendrickson; Calder;
(Lubbock, TX) ; Thrash; Tommy K.; (Lubbock,
TX) ; Naff; Todd; (Lubbock, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Aquasmart Enterprises, LLC |
Lubbock |
TX |
US |
|
|
Family ID: |
1000005708832 |
Appl. No.: |
17/202774 |
Filed: |
March 16, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16253934 |
Jan 22, 2019 |
10947447 |
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17202774 |
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15416950 |
Jan 26, 2017 |
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16253934 |
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15136352 |
Apr 22, 2016 |
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15416950 |
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15011111 |
Jan 29, 2016 |
9856415 |
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15136352 |
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14171920 |
Feb 4, 2014 |
10266757 |
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15011111 |
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13418227 |
Mar 12, 2012 |
9057014 |
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14171920 |
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13299288 |
Nov 17, 2011 |
8661729 |
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13418227 |
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12789177 |
May 27, 2010 |
8341881 |
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13299288 |
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12324608 |
Nov 26, 2008 |
7726070 |
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12789177 |
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61012912 |
Dec 11, 2007 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C09K 8/805 20130101 |
International
Class: |
C09K 8/80 20060101
C09K008/80 |
Claims
1. A method for producing a self-suspending proppant particle, the
method comprising: providing a substrate, constituted as discrete
particles; providing a binder; providing a first composition
containing a polymer, and formed as a first powder; coating the
substrate individually with the binder; forming granules by coating
the binder on the substrate individually with the first powder;
providing a second composition containing a flowing agent to
increase flowability of the resultant granules, and formed as a
second powder; and forming granules by coating the first powder on
the substrate individually with the second powder, wherein the
self-suspending proppant particles are configured to remain
suspended in a 1000 ppm CaCO3 aqueous solution for at least 30
minutes at a temperature of approximately 170.degree. F.
2. The method of claim 1, wherein the second composition is
selected from the group consisting of sodium aluminosilicate, fumed
silica, potassium aluminosilicate, calcium aluminosilicate, silicon
dioxide, calcium silicate, powdered cellulose, whey protein, and
DFC.
3. The method of claim 1, wherein the second composition is whey
protein.
4. The method of claim 1, wherein the first composition comprises a
plurality of polymers, distinct from one another.
5. The method of claim 3, where in the first composition comprises
a plurality of polymers, distinct from one another.
6. The method of claim 1, wherein the second composition comprises
at least two compounds selecting from the group consisting of
sodium aluminosilicate, fumed silica, potassium aluminosilicate,
calcium aluminosilicate, silicon dioxide, calcium silicate,
powdered cellulose, whey protein, and DFC.
7. The method of claim 1, wherein the second composition consists
of whey protein and fumed silica.
8. The method of claim 1, wherein the second composition consists
of whey protein and sodium aluminosilicate.
9. The method of claim 1, wherein the substrate has a first density
and the first powder has a second density, the first density being
greater than the second density.
10. The method of claim 9, wherein the first and second densities
are selected, and the size of the granules is selected to effect
sinking the polymer, by the substrate, into a fluid.
11. The method of claim 10, wherein the fluid is moving as a
carrier, characterized by a viscosity, and the polymer is selected
based on its effectiveness to increase in size by absorbing the
fluid.
12. A method for producing a proppant particle, the method
comprising: providing a substrate, constituted as discrete
particles; providing a water soluble material as a binder;
providing a first composition containing a polymer, and formed as a
first powder, wherein the substrate has a first density and the
first powder has a second density, the first density being greater
than the second density; coating the substrate individually with
the binder; forming granules by coating the binder on the substrate
individually with the first powder; providing a second composition
containing a flowing agent to increase flowability of the resultant
granules, and formed as a second powder, wherein the second
composition is selected from the group consisting of sodium
aluminosilicate, fumed silica, potassium aluminosilicate, calcium
aluminosilicate, silicon dioxide, calcium silicate, powdered
cellulose, whey protein, and DFC; and forming granules by coating
the first powder on the substrate individually with the second
powder, wherein the proppant particles are configured to remain
suspended in a 1000 ppm CaCO3 aqueous solution for at least 30
minutes at a temperature of approximately 170.degree. F.
13. The method of claim 12, wherein the second composition consists
of whey protein and fumed silica.
14. The method of claim 12, wherein the second composition consists
of whey protein and sodium aluminosilicate.
15. The method of claim 12, wherein the first and second densities
are selected, and the size of the granules is selected to effect
sinking the polymer, by the substrate, into a fluid.
16. The method of claim 15, wherein the fluid is moving as a
carrier, characterized by a viscosity, and the polymer is selected
based on its effectiveness to increase in size by absorbing the
fluid.
17. The method of claim 12, wherein the substrate is a proppant
selected from the group consisting of a sand, a ceramic, and a rock
product.
18. A method for producing a proppant particle, the method
comprising: providing a substrate comprising discrete particles;
providing a binder; providing a first composition containing a
plurality of polymers formed as powders and distinct from one
another; coating the substrate individually with the binder;
forming granules by coating the binder on the substrate
individually with the first composition; providing a second
composition containing a flowing agent to increase flowability of
the resultant granules, and formed as a second powder, wherein the
second composition is selected from the group consisting of sodium
aluminosilicate, fumed silica, potassium aluminosilicate, calcium
aluminosilicate, silicon dioxide, calcium silicate, powdered
cellulose, whey protein, and DFC; and forming granules by coating
the first powder on the substrate individually with the second
powder, wherein the proppant particles are configured to remain
suspended in a 1000 ppm CaCO3 aqueous solution for at least 30
minutes at a temperature of approximately 170.degree. F.
19. The method of claim 18, wherein the substrate is a proppant
selected from the group consisting of a sand, a ceramic, and a rock
product.
20. The method of claim 19, wherein the second composition
comprises a plurality of flowing agents, distinct from one another.
Description
RELATED APPLICATIONS
[0001] This application: is a continuation of U.S. patent
application Ser. No. 16/253,934, filed Jan. 22, 2019, scheduled to
issue as U.S. Pat. No. 10,947,447 on Mar. 16, 2021; which is a
continuation of U.S. patent application Ser. No. 15/416,950, filed
Jan. 26, 2017, now abandoned; which is a continuation-in-part of
U.S. patent application Ser. No. 15/136,352, filed Apr. 22, 2016,
now abandoned; which is a continuation-in-part of U.S. patent
application Ser. No. 15/011,111, filed Jan. 29, 2016, now U.S. Pat.
No. 9,856,415 issued Jan. 2, 2018; which is a continuation-in-part
of U.S. patent application Ser. No. 14/171,920, filed Feb. 4, 2014,
now U.S. Pat. No. 10,266,757 issued Apr. 23, 2019; which is a
continuation of U.S. patent application Ser. No. 13/418,227, filed
Mar. 12, 2012, now U.S. Pat. No. 9,057,014 issued Jun. 16, 2015;
which is a continuation-in-part of U.S. patent application Ser. No.
13/299,288, filed Nov. 17, 2011, now U.S. Pat. No. 8,661,729 issued
Mar. 4, 2014; which is a continuation-in-part of U.S. patent
application Ser. No. 12/789,177, filed May 27, 2010, now U.S. Pat.
No. 8,341,881 issued Jan. 1, 2013; which is a continuation of U.S.
patent application Ser. No. 12/324,608, filed on Nov. 26, 2008, now
U.S. Pat. No. 7,726,070, issued Jun. 1, 2010; which claims the
benefit of U.S. provisional patent application Ser. No. 61/012,912,
filed Dec. 11, 2007; all of which are hereby incorporated by this
reference in their entireties.
BACKGROUND
The Field of the Invention
[0002] This invention relates to oil field and oil well
development, and, more particularly, to novel systems and methods
for fracturing and propping fissures in oil-bearing formations to
increase productivity.
The Background Art
[0003] Oil well development has over one hundred years of extensive
engineering and chemical improvements. Various methods for
stimulating production of well bores associated with an oil
reservoir have been developed. For example, United States Patent
Application Publication US 2009/0065253 A1 by Suarez-Rivera et al.
and entitled "Method and System for Increasing Production of a
Reservoir" is incorporated herein by reference in its entirety and
provides a description of fracturing technology in order to
increase permeability of reservoirs. Moreover, various techniques
exist to further improve the fracture channels, such as by acid
etching as described in U.S. Pat. No. 3,943,060, issued Mar. 9,
1976 to Martin et al., which is likewise incorporated herein by
reference in its entirety.
[0004] In general, different types of processes require various
treatments. In general, well production can be improved by
fracturing formations. Fracturing is typically done by pumping a
formation full of a fluid, containing a large fraction of water,
and pressurizing that fluid in order to apply large surface forces
to parts of the formation. These large surface forces cause
stresses, and by virtue of the massive areas involved, can produce
extremely high forces and stresses in the rock formations.
[0005] Accordingly, the rock formations tend to shatter, increasing
porosity and providing space for the production oil to pass through
the formation toward the bore hole for extraction. However, as the
foregoing references describe, the chemistry is not simple, the
energy and time required for incorporation of various materials
into mixtures is time, money, energy, and other resource
intensive.
[0006] It would be an advance in the art if such properties as
viscosity, absorption, mixing, propping, and so forth could be
improved by an improved composition and method for
introduction.
[0007] Moreover, hydraulic fracturing has a rather sophisticated
process for adding various constituents to the fracking fluids. Not
only must proppants be added, but various other chemicals. In
certain fracturing processes, it has been found important or even
necessary to blend materials into the working fluid for fracturing.
Such blending requires substantial equipment, occupying a very
significant footprint on the overall well site.
[0008] Moreover, this equipment requires manpower, and maintenance
of numerous receiving and storage areas. These are needed for
various constituent products that will ultimately be added to the
working fluid. All of these processes for mixing auxiliary
materials into the fluid cause delays in time, since many of the
materials require substantial mixing.
[0009] Particularly with small particles, surface tension tends to
float such materials on the surface of liquids and require
substantial mixing and substantial associated time. Many solids
must be pre-mixed in oils, emulsions, and the like, increasing the
effect of any spill. Meanwhile, addition of chemicals to a
fracturing flow necessarily creates uneven distributions of
additives. For example, upon addition, into the flow, a constituent
is at a very high concentration near the well head. Meanwhile, none
of that newly added constituent exists elsewhere. Thus, the ability
to thoroughly distribute material, or to even get it distributed
well throughout the fluid being introduced, has proven
difficult.
[0010] Similarly, transportation of individual constituent
chemicals and materials to the well site requires multiple vehicles
specialized to different types of materials and phases. For
example, some materials are fluids, some are solids, some use a
water solvent, some use a petroleum-based solvent, and such
materials must be hauled, delivered, and handled in distinct ways
with their own suitable storage, handling, and transport
equipment.
[0011] Various complaints have been encountered with the amount of
hydrocarbons, such as various emulsions, chemical additives,
including such materials as diesel fuel and the like that are often
used. With such liquid chemicals on site, the risk of surface
contamination due to chemical spills of such materials is
increased. Even when contained in smaller containers, such
materials run the risk of spills, carrying about by water, wind,
and other weather, as well as the prospect of possible spilling
during delivery, handling, or the feeding and mixing processes.
[0012] Meanwhile, the operational footprint required for storage,
mixing systems, receiving, shipping, and the like increase the
overall operational footprint of a well site. Moreover, money,
labor, and time are substantial for the process of receiving,
preparation, storage, handling, and ultimately mixing materials
that will be added to a fracturing fluid.
[0013] Thus, it would be a substantial advance in the art to
provide a system and method, and particularly a material, that
would eliminate many of the handling, equipment, footprint,
transportation, and other problems that exist in prior art
materials and mixing systems to service fracture fluids.
BRIEF SUMMARY OF THE INVENTION
[0014] In view of the foregoing, in accordance with the invention
as embodied and broadly described herein, a method, apparatus, and
composition are disclosed in certain embodiments in accordance with
the present invention, as including a substrate that may be formed
of sand, rock product, ceramic sand, gravel, or other hard and
structurally strong materials, provided with a binder to
temporarily or permanently secure a hydrating polymer in proximity
to the substrate. When used herein any reference to sand or
proppant refers to any or all of these used in accordance with the
invention. In certain embodiments of a method in accordance with
the invention, a composition as described may be mixed directly
into drilling fluids, such as a fracturing fluid made up of water
and other additives.
[0015] By virtue of the increased surface area and weight provided
to the polymeric powders affixed to the substrate, the surface
area, and consequently the frictional drag, is greatly increased,
sweeping the material of the invention into a flow of fluid. This
greatly decreases the time required to absorb polymers into the
fluid.
[0016] In fact, rather than having to wait to have the polymers
thoroughly mixed, or absorb a full capacity of water, and thereby
flow properly with the drilling fluid or fracturing fluid, a
composition in accordance with the invention will sweep along with
the fluid immediately, with the weight of the substance submerging
the polymer. Meanwhile, the cross sectional area presented results
in hydrodynamic drag sweeps the composition along with the
flow.
[0017] Meanwhile, over time, the polymeric powder adhered to the
substrate will absorb water, without the necessity for the time,
energy, temperature, mixing, and so forth that might otherwise be
required by surface mixing. Thus, the composition in accordance
with the invention is immediately transportable and flows, relying
on the drilling or fracturing fluid as its carrier.
[0018] Moreover, as the polymer tends to pick up more water, the
density of the granule of substrate and polymer powder becomes
closer to the density of water. Accordingly, the size increase and
the density change tend to drive the particles of the composition
even more homogeneously with the flowing fluid. Thus, the sand does
not settle out in various eddies, obstructions, and other locations
of low velocity. Rather, the sand continues to be carried with the
fluid, providing a double benefit. That is, the sand weight and
area helps to initially mix and drive the particles (granules) with
the fluid. Thereafter, the hydration of the polymer tends to
increase the surface area and reduce the density of the granule or
particle, tending to make the particles flow even better and more
homogeneously with the surrounding fluid.
[0019] Ultimately, as the particles (granules) of the composition
flow into fracture locations, they provide very small proppants as
the substrates, such as sand, becomes trapped and lodged at various
choke points. Nevertheless, because of the small size, the sand or
other substrate acting as a proppant, simply needs to provide an
offset, keeping fractured surfaces from collapsing back against one
another. By providing the small, strong points of separation, the
substrate provides a well distributed proppant, carried to maximum
extent that the fluids will travel, and deposited in various traps,
choke points, and the like.
[0020] The net saving in time, money, energy for heating and
pumping, and the like is significant. Meanwhile, various
technologies for reducing friction in the flow of fluid pumped into
bore holes and other formation spaces is described in several
patents, including U.S. Pat. No. 3,868,328, issued Feb. 25, 1975 to
Boothe et al. and directed to friction reducing compounds, as well
as U.S. Pat. No. 3,768,565, issued Oct. 30, 1973 to Persinski et
al. and directed to friction reducing, U.S. Patent Application
Publication US 2001/0245114 A1 by Gupta et al. directed to well
servicing fluid, and U.S. Patent Application Publication US
2008/0064614 A1 by Ahrenst et al. and directed to friction
reduction fluids, all described various techniques, materials,
methods, and apparatus for developing, implementing, and
benefitting from various well fluids. All the foregoing patent
application publications and patents are hereby incorporated by
reference.
[0021] Similarly, the development of various chemicals has been
ubiquitous in oil field development. For example, U.S. Pat. No.
3,442,803, issued May 6, 1969 to Hoover et al. is directed to
thickened friction reducers, discusses various chemical
compositions, and is also incorporated herein by reference in its
entirety.
[0022] In one embodiment of an apparatus, composition and method in
accordance with the invention, a method may be used for formation
fracturing. The formation may be in rock and within or near an oil
reservoir underground. One may select an oil field region having a
formation to be fractured. Fracturing may be sought to increase
production. By providing a bore into the formation and a pump, a
carrier material, typically comprising a liquid, and sometimes
other materials dissolved or carried therein may be pumped into the
formation through the bore.
[0023] The carrier as a liquid, or slurry comprising a liquid, or
otherwise containing a liquid may be driven by the pump to be
pressurized into the formation. However, the carrier may be
provided an additive formed as granules. Each granule may include a
substrate, such as a grain of sand, ceramic sand, crushed rock,
other rock products, or the like having bonded thereto many
particles (e.g., powder) formed from a polymer.
[0024] The polymer may be selected to have various properties,
including lubricity, water absorption, water solubility, or the
like. This hydrophilic polymer may be bonded permanently,
temporarily, or the like to secure to the substrate. Various
binders may be used alone or in combination. These may range from a
solvent (e.g., organic or water) simply softening the polymer
itself to bond it, to glues, sugars, molasses, and various other
saccharides, as well as other products, including starches, other
polymers, and so forth.
[0025] Thus, with some bonds, the polymer powder may be less
permanent or attached to have a bond that is less robust. Over
time, the polymer powder so attached may wear off, pull away, or
otherwise remove from the substrate into the carrier fluid, and may
even act as a viscous agent, lubricant, or the like in the
carrier.
[0026] The method may include introducing the additive directly
into the carrier. The more dense substrate will immediately
submerge the granules in the carrier at ambient conditions. Thus
heating, extensive mixing, waiting, and the like may be dispensed
with, as the granules typically will not float or resist mixing
once initial surface tension is broken.
[0027] Pumping the carrier toward the formation is possible
immediately. The carrier fluid carries the granules by the liquid
dragging against the substrate, with the particles of polymer
attached. The substrate's cross sectional area engages immediately
the surrounding liquid, dragging it into the carrier to flow
substantially immediately therewith.
[0028] Meanwhile, weighting, by the substrate of the polymer,
permits the granules to flow into and with the carrier
independently from absorption of any of the liquid into the
polymer. Nevertheless, over time, absorbing by the polymer a
portion of the liquid results in the polymer expanding and
providing by the polymer, lubricity to the carrier with respect to
the formation.
[0029] Creating fractures may be accomplished by pressurizing the
carrier in the formation. This creates fissures or fractures. Thus,
flowing of the carrier and particles throughout the fractures or
fissures in the formation results in lodging, by the particles,
within those fractures or fissures. Unable to re-align, adjacent
surfaces of rock, now fracture cannot close back together due to
propping open the fractures by the substrate granules lodging in
the fractures.
[0030] The substrate is best if selected from an inorganic
material, such as sand, ceramic sand, or other hard, strong, rock
product. The polymer may be selected from natural or synthetically
formulated polymers. For example polymers of at acrylic acid,
acrylate, and various amides are available. Polyacrylamide has been
demonstrated suitable for all properties discussed above.
[0031] In fracturing a rock formation, the method may include
providing an additive comprising a substrate formed as granules,
each having an exterior surface, particles formed of a hydrophilic
material, the particles being comminuted to a size smaller than the
size of the granules and having first and second sides comprising
surfaces. The granules may each be coated with the particles, the
particles being dry and bonded to the exterior surface by any
suitable binder, including the polymer softened with a solvent. The
particles are each secured by the first side to the granules, the
second side extending radially outward therefrom.
[0032] Upon identifying a reservoir, typically far underground from
thousands of feet to miles, perhaps, and extending in a formation
of rock, one needs to provide a bore into the formation. Providing
a carrier, comprising a liquid, and possibly other materials known
in the art, is for the purpose of fracturing the formation.
Introducing the additive directly into the liquid at ambient
conditions is possible, because the substrate weighs the granules
down, and there is no need for long mixing, heating or the like as
in addition of polymers directly to the carrier.
[0033] Thus, pumping may continue or begin immediately to move the
carrier and additive down the bore and toward the formation. This
results in exposing the second sides of the polymer powder
particles directly to the liquid during transit of the carrier and
additive toward and into the formation. The polymer particles thus
begin absorbing, a portion of the liquid, typically principally
water. Swelling of the polymer increases the size, effective
diameter, and cross-sectional area, thus increasing the fluid drag
on the granules.
[0034] Fracturing, typically by hydraulic pressure in the carrier
creates fissures in the formation by fracturing the rock pieces in
bending, or by layer separation, with tensile stresses breaking the
rock. The resulting fissures allow carrying, by the carrier, of the
granules into the fissures. However, fissures vary in size and
path, resulting in lodging of granules, within the fissures. The
granules do not settle out from the carrier, and thus may travel
far into the formation and every fissure. However, each time a
grain or granule is lodged like a chock stone, it obstructs the
ability of the adjacent rock surfaces to close back with one
another.
[0035] Thus, rather than the proppant (substrate) settling out
ineffectually, failing to prop open the fissures, the granules are
swept forcefully with the flow of the carrier wherever the carrier
can flow, until lodged. Meanwhile, the lubricity of the polymer
aids the granules, and thus the substrate from being slowed,
trapped, or settled out by the slow flowing boundary layer at the
solid wall bounding the flow.
[0036] In summary, weighting, by the substrate, sinks the polymer
into the carrier readily and independently from absorption of the
liquid into the polymer. Mixing, dissolving, and so forth are
unnecessary, as the substrate drags the polymer into the carrier,
and the carrier drags the granule along with it in its flow path.
Lubrication is provided by the polymer between the substrate of
each granule and adjacent solid walls of the bore, passages
previously existing in the formation, and the fissures formed by
fracturing. Any separating, by some of the powdered polymer
particles from the substrate, still reduces friction drag on
passage of the carrier and particles within the formation.
[0037] A composition for fracturing and propping a formation of
rock may include a fluid operating as a carrier to be pumped into a
rock formation, a substrate comprising granules of an inorganic
material, each granule having an outer surface and a size
characterized by a maximum dimension thereacross, and all the
granules together having an average maximum dimension corresponding
thereto. A polymer comprising a hydrophilic material selected to
absorb water in an amount greater than the weight thereof may be
bound to the substrate. The polymer is comminuted to particles,
each particle having a size characterized by a maximum dimension
thereacross.
[0038] All the polymer particles may be characterized by an average
maximum dimension, and an effective (e.g., hydraulic diameter). The
average maximum dimension of the particles is best if smaller,
preferably much smaller, than the average maximum dimension of the
granules.
[0039] The particles of the polymer, bound to the substrate, will
travel with it in the fluid. Particles of the polymer are thus
further directly exposed to water in the fluid during travel with
the fluid. The granules, flowing in the fluid, are carried by the
hydrodynamic drag of the fluid against the cross-sectional area of
the granules coated with the particles of the polymer. The polymer,
selected to expand by absorbing water directly from the fluid,
increases the area and drag, assisting distribution in the
formation by the carrier fluid. The polymer meanwhile operates as a
lubricant lubricating the motion of the substrate against the
formation during flow of the granules against solid surfaces in the
formation, bore, and fracture fissures.
[0040] The inorganic material, such as sand, ceramic sand, or the
like is typically sized to lodge in fissures formed in the
formation and has mechanical properties rendering it a proppant
capable of holding open fissures formed in the formation.
[0041] In certain embodiments, a water soluble binder is used, then
a substrate may release additives into the fracturing fluid quickly
or slowly after insertion in the working fluid. A substrate may
perform as a proppant, and may be constituted of sand, ceramic,
another rock or mineral product, a resin coated, or other material
used to prop open fractures. Such a substrate may be provided with
a binder securing powdered components of suitable additives to be
introduced into a fracturing fluid.
[0042] For example, a friction reducer, bioside, oxygen scavenger,
clay stabilizer, scale inhibitor, gelling agent, or the like may be
included in a mix, or as an element to be adhered to a substrate
proppant. The substrate thereby forms particles that will easily be
drawn into a flow of fracturing fluid, thus introducing all the
necessary constituents into the flow. This occurs rapidly, without
having to wait for mixing to occur topside on the site before
introduction into the bore. Rather, mixing can take place and
hydration or distribution in the flow may take place on the fly as
the flow of fluid courses through the bore toward the formation.
Thus, the preparation and introduction time on the surface at the
well site is minimized.
[0043] In certain embodiments, the composition may be mixed
directly into the fluid to form a complete and suitable fracturing
fluid with all the necessary additives desired. By adhering
chemicals to the proppant as the operable substrate, in the correct
ratios, elaborate mixing ratios and elaborate mixing processes, and
control thereof, as well as their related equipment, personnel,
time, storage, and handling are greatly reduced, and optimally
eliminated. Thus, the operational footprint of a service company on
the well site is reduced, as well as the time, cost, labor, and so
forth required to measure, add, mix, and otherwise introduce
desired chemical constituents into the fracturing fluid.
[0044] By coating a proppant or substrate with the suitable
materials (e.g., chemicals, etc.) an even mix of chemicals is
maintained within the fracturing fluid much more easily. Moreover,
distribution thereof within the flow is straightforward. In fact,
all those additives may thereby all be present in exactly the
proper ratios at all times at the time they are introduced. Thus,
adding them one at a time, working with them to try to get them all
introduced at about the same time, and so forth, as encountered in
the prior art is no longer a problem.
[0045] Because many or all desired constituents may be coated onto
a single substrate, or each granule of a single substrate, then
numerous constituents, including previously dissolved liquids or
solids that have been rendered liquid by introduction into
solvents, in order to ensure more rapid mixing, may be reduced or
eliminated. Thus the full array of constituent chemicals to be used
as additives in the fluid may be provided with proppants in the
delivery of a single material, granular in nature, solid in phase,
and simple to be stored, transported, handled, and the like. Thus,
emissions, spills, other environmental risks, may be reduced or
eliminated. By using powdered base chemicals, the carriers or
solvents that were previously needed, often hydrocarbon based
emulsions and the like, may be eliminated. Thus, the risk of
surface spills and consequent contamination may be reduced or
eliminated.
[0046] In one embodiment, a method for making self-suspending
proppant particles is provided. The method includes mixing a volume
of substrate particles with a liquid binder so that at least a
portion of the volume of substrate particles are at least partly
covered with the liquid binder on an outer surface, thereby forming
binder-coated substrate particles. The method also includes using a
water-in-oil emulsion to apply a first water-absorbing polymer to
at least a portion of the binder-coated substrate particles so that
the at least a portion of the binder-coated substrate particles are
at least partly coated with the first water-absorbing polymer,
thereby forming intermediate polymer-coated substrate particles.
The method further includes coating at least a portion of the
intermediate polymer-coated substrate particles with a second
water-absorbing polymer to thereby form polymer coated substrate
particles; and drying the polymer coated substrate particles to
remove at least a portion of the water-in-oil emulsion to thereby
form self-suspending proppant particles. Each of the
self-suspending proppant particles are at least partly coated with
the second water-absorbing polymer.
[0047] In another embodiment, a method for making self-suspending
proppant particles is provided. The method includes adding a volume
of substrate particles to a mixing vessel, the substrate particles
including sand particles. The method also includes applying a first
water-absorbing polymer suspended in a liquid to at least a portion
of the substrate particles in the mixing vessel, so that the at
least a portion of the substrate particles are at least partly
coated with the first water-absorbing polymer, thereby forming
intermediate polymer-coated substrate particles. The first
water-absorbing polymer includes an anionic polyacrylamide. The
method further includes coating at least a portion of the
intermediate polymer-coated substrate particles with a second
water-absorbing polymer in powdered form to thereby form
polymer-coated substrate particles; and drying at least a portion
of the polymer coated substrate particles to remove at least a
portion of the liquid thereby forming self-suspending proppant
particles.
[0048] In yet another embodiment, self-suspending proppant
particles are provided. The self-suspending proppant particles
including substrate particles, the substrate particles including
sand. The self-suspending proppant particles further including an
outer polymeric coating positioned on an outer surface of each of
the substrate particles, the outer polymeric coating including at
least one water-absorbing polymer in powdered form, where at least
a portion of the outer polymeric coating is applied to each of the
substrate particles using a water-in-oil emulsion.
[0049] In another embodiment, a method for making self-suspending
proppant particles is provided. The method includes mixing
substrate particles with a liquid binder so that at least a portion
of the substrate particles are at least partly coated with the
liquid binder. The method also includes applying one or more
water-absorbing polymers to the at least a portion of the substrate
particles that are at least partly coated with liquid binder to
form polymer-coated substrate particles. The applying one or more
water-absorbing polymers includes applying a first water-absorbing
polymer in a first form, and applying a second water-absorbing
polymer in a second form that is different from the first form,
where the first and second forms are selected from a powder and an
emulsion. Each of the first and second water-absorbing polymers is
about 20 mol. % anionic to about 50 mol. % anionic. The method
further includes exposing the polymer-coated substrate particles to
heat sufficient to cause crosslinking in at least a portion of the
one or more water-absorbing polymers present on the polymer coated
substrate particles, thereby forming self-suspending proppant
particles.
[0050] In yet another embodiment, a method for making
self-suspending proppant particles is provided. The method includes
adding a volume of substrate particles to a mixing vessel, the
substrate particles comprising sand. The method also includes
coating at least a portion of the substrate particles with glycerol
in the mixing vessel to form binder-coated substrate particles.
Further, the method includes mixing a first water-absorbing polymer
with the binder-coated substrate particles in the mixing vessel.
The first water-absorbing polymer includes a co-polymer of
acrylamide monomers and acrylate monomers, where the first
water-absorbing polymer is about 20 mol. % anionic to about 50 mol.
% anionic, and where the first water-absorbing polymer is in
powdered form. The method also includes, subsequent to mixing the
first water-absorbing polymer with the binder-coated substrate
particles, mixing a second water-absorbing polymer with first
water-absorbing polymer and the binder-coated substrate particles
to form polymer-coated substrate particles. The second
water-absorbing polymer including a co-polymer of acrylamide
monomers and acrylate monomers, where the second water-absorbing
polymer is about 20 mol. % anionic to about 50 mol. % anionic. The
second water-absorbing polymer is present in a water-in-oil
emulsion, and each of the polymer-coated substrate particles
includes a polymeric coating that includes the first
water-absorbing polymer and the second water-absorbing polymer. The
method further includes exposing the polymer-coated substrate
particles to heat sufficient to cause crosslinking in the polymeric
coating present on the polymer-coated substrate particles, thereby
forming self-suspending proppant particles.
[0051] In yet another embodiment, self-suspending proppant
particles are provided. The self-suspending proppant particles
include substrate particles, the substrate particles including
sand. The self-suspending proppant particles further include an
outer polymeric coating positioned on an outer surface of each of
the substrate particles, the outer polymeric coating including
first and second water-absorbing polymers that are at least partly
covalently cross-linked. Each of the first and second
water-absorbing polymers include a co-polymer of acrylate monomers
and acrylamide monomers, where a molecular weight of the first
water-absorbing polymer is at least about 1 Million Daltons (g/mol)
greater than a molecular weight of the second water-absorbing
polymer. Each of the first and second water-absorbing polymers is
about 20 mol. % to about 50 mol. % anionic, where the first
water-absorbing polymer was applied to the substrate particles in
the form of an emulsion, and wherein the second water-absorbing
polymer was applied to the substrate particles in powdered form.
The self-suspending proppant particles remain suspended in a 1000
ppm CaCO3 aqueous solution for at least 30 minutes at a temperature
of 170.degree. F.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] The foregoing features of the present invention will become
more fully apparent from the following description and appended
claims, taken in conjunction with the accompanying drawings.
Understanding that these drawings depict only typical embodiments
of the invention and are, therefore, not to be considered limiting
of its scope, the invention will be described with additional
specificity and detail through use of the accompanying drawings in
which:
[0053] FIG. 1 is a schematic cross-sectional view of a material
including a substrate provided with a binder securing a hydrating
polymer thereto in accordance with the invention;
[0054] FIG. 2 is a schematic block diagram of one embodiment of a
process for formulating and producing fluid additive particles in
accordance with the invention;
[0055] FIG. 3 is a schematic diagram of the fluid-particle
interaction in an apparatus, composition, and method in accordance
with the invention;
[0056] FIG. 4 is a chart illustrating qualitatively the
relationship between volumetric increase over time at various
temperatures, illustrating the improved activation with minimum
mixing and temperature increase of particles in accordance with the
invention;
[0057] FIG. 5 is a schematic diagram illustrating one embodiment of
friction reducing by polymers used in compositions in accordance
with the invention;
[0058] FIG. 6A is a schematic diagram of the fracturing and
proppant action of particles in accordance with a method and
composition according to the invention;
[0059] FIG. 6B is a schematic diagram illustrating a collection of
proppant particles positioning rock fragments in a formation away
from one another in order to maintain open passages in the
formation;
[0060] FIG. 7 is a schematic block diagram of a fracturing and
propping process using compositions and methods in accordance with
the invention;
[0061] FIG. 8 is a schematic diagram of processes illustrating
alternative options for coating, in which particles being adhered
to the binder layer may be added sequentially or simultaneously by
species or constituent particles;
[0062] FIG. 9 is a schematic diagram of an alternative coating
process in which multiple binding layers are added over previous
binding layers and layers of particles;
[0063] FIG. 10 is a schematic block diagram of some alternative
coating processes, including direct coating, sequentially adding
particular constituents, and sequentially adding binder and
particulate constituents to the particles;
[0064] FIG. 11 is an image of various self-suspending proppants in
the presence of various flowing agents after being exposed to heat
and humidity as described in Example 3;
[0065] FIG. 12 is an image of the various self-suspending proppants
with various flowing agents of FIG. 12 after being exposed to
additional heat and humidity as described in Example 3;
[0066] FIG. 13A depicts various self-suspending proppants with
various flowing agents after being centrifuged and inverted for an
initial attempt to remove the proppants from a centrifuge tube as
described in Example 3; and
[0067] FIG. 13B depicts the self-suspending proppants of FIG. 13A
after being removed from the centrifuge tube.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0068] It will be readily understood that the components of the
present invention, as generally described and illustrated in the
drawings herein, could be arranged and designed in a wide variety
of different configurations. Thus, the following more detailed
description of the embodiments of the system and method of the
present invention, as represented in the drawings, is not intended
to limit the scope of the invention, as claimed, but is merely
representative of various embodiments of the invention. The
illustrated embodiments of the invention will be best understood by
reference to the drawings, wherein like parts are designated by
like numerals throughout.
[0069] Referring to FIG. 1, a material 10 in accordance with the
invention may include a substrate 12 formed of a suitable material
for placement in the vicinity of a fracture region. For example, a
substrate may be a particle of sand, ceramic sand, volcanic grit,
or other hard material. In some embodiments, a substrate may be
formed of organic or inorganic material. Nevertheless, it has been
found effective to use sand as a substrate 12 inasmuch as it is
submersible in water and will not float as many organic materials
will when dry. Likewise, the sand as substrate 12 is comminuted to
such a small size that interstices between individual grains of the
sand substrate 12 provide ample space and minimum distance for
water to surround each of the substrate 12 particles.
[0070] In the illustrated embodiment, a binder 14 may be
distributed as a comparatively thin layer on the surface of the
substrate 12. Typical materials for binders may include both
temporary and permanent binders 14. Permanent binders include many
polymers, natural and synthetic. Temporary binders may be
sugar-based or other water soluble materials. For example, corn
syrup, molasses, and the like may form temporary binders. In the
presence of water, such material may ultimately dissolve.
Nevertheless, so long as the substrate 12 is not turned, mixed, or
otherwise disturbed significantly, any other materials supported by
the binder 14 would not be expected to dislocate.
[0071] Otherwise, certain naturally or synthetically occurring
polymers may also be used as a binder 14. Lignicite may be used as
a binder 14. Lignicite is a byproduct of wood, and provides
material having good adhesive properties, and substantial
permanence as a binder 14 on a substrate 12. Any suitable insoluble
polymer may be used for more permanent binding.
[0072] Other polymers may be used to form a binder 14. For example,
various materials used as glues, including mucilage, gelatin, other
water soluble polymers including, for example, ELMER'S.TM. glue,
and the like may also operate as binders 14 to bind materials to a
substrate 12.
[0073] In certain embodiments, the substrate 12 may be used in oil
fields as a substrate 12 for polymer additives to fracture fluids.
In other situations, the substrate 12 may be implemented as a
proppant.
[0074] Pigment 16 may be implemented in any of several manners. For
example, the substrate 12 may have pigment 16 applied prior to the
application of the binder 14. In alternative embodiments, the
pigment 16 may actually be included in the binder 14, which becomes
a pigmented coating on the substrate 12. In yet other embodiments,
the pigments 16 may be added to a hydration particle 18 either as a
pigment 16 mixed therein, or as a pigment 16 applied as a coating
thereto. Thus the location of the pigment 16 in the Figures is
schematic and may take alternative location or application
method.
[0075] Particles 18 of a hydrophilic polymer material may be bonded
to the substrate 12 by the binder 14. Particles may be sized to
substantially coat or periodically coat the substrate 12.
[0076] In certain embodiments, the hydrophilic material 18 may be a
powdered polymeric material 18 such as polyacrylamide or any of the
materials in the patent documents incorporated by reference. In
other embodiments, the particles 18 may actually be organic
material having capillary action to readily absorb and hold water.
In one presently contemplated embodiment of an apparatus in
accordance with the invention, the particles 18 may be powdered
polymeric material in a dehydrated state, and having a capacity to
absorb water, typically many times the weight (e.g., five to forty
times) of a particular particle 18.
[0077] The substrate 12, in certain embodiments, may be some form
of sand or granular material. The sand will typically be cleaned
and washed to remove dust and organic material that may inhibit the
binder 14 from being effective. Likewise, the substrate 12 may be
sized of any suitable size. For example, sand particles may range
from much less than a millimeter in effective diameter or distance
thereacross to approximately two millimeters across. Very coarse
sands or ceramic sands may have even larger effective diameters.
Hydraulic diameter is effective diameter (four times the area
divided by the wetted perimeter). However, in one presently
contemplated embodiment, washed and dried sand such as is used in
construction, such as in concrete, has been found to be suitable.
Fine sands such as masonry sands tend to be smaller, and also can
function suitably in accordance with the invention.
[0078] Accordingly, the distance across each powder particle 18 may
be selected to provide an effective coating of powdered particles
18 on the substrate 12. In one presently contemplated embodiment,
the effective diameter of the particles 18 may be from about a 30
mesh size to about a 100 mesh size. For example, a sieve system for
classifying particles has various mesh sizes. A size of about 30
mesh, able to pass through a 30 mesh sieve, (i.e., about 0.6 mm)
has been found suitable. Likewise, powdering the particles 18 to a
size sufficiently small to pass through a 100 mesh (i.e., about
0.015 mm) sieve is also satisfactory. A mesh size of from about 50
mesh to about 75 mesh is an appropriate material to obtain
excellent adhesion of particles 18 in the binder 14, with a
suitable size of the particles 18 to absorb significant liquid at
the surface of the substrate 12.
[0079] As a practical matter, about half the volume of a container
containing a substrate 12 as particulate matter will be space,
interstices between the granules of the substrate 12. One advantage
of using materials such as sand as the substrate 12 is that a
coating of the particle 18 may provide a substantial volume of
water once the particles 18 are fully saturated. By contrast, where
the size of the particles 18 is too many orders of magnitude
smaller than the effective diameter or size of the substrate
particles 12, less of the space between the substrate particles 12
is effectively used for storing water. Thus, sand as a substrate 12
coated by particles 18 of a hydrophilic material such as a polymer
will provide substantial space between the substrate particles 12
to hold water-laden particles 18.
[0080] The diameter of the particles 18, or the effective diameter
thereof, is typically with about an order of magnitude (e.g.,
10.times.) smaller than the effective diameter of the particles of
the substrate 12. This order of magnitude may be changed. For
example, the order of magnitude difference less than about 1 order
of magnitude (i.e., 10.times.) may still be effective. Similarly,
an order of magnitude difference of 2 (i.e., 100.times.) may also
function.
[0081] However, with particles 18 too much smaller than an order of
magnitude smaller than the effective diameter of the substrate 12,
the interstitial space may not be as effectively used. Likewise,
with an effective diameter of particles 18 near or larger than
about 1 order of magnitude smaller than the size of the particles
of the substrate 12, binding may be less effective and the
particles 18 may interfere more with the substrate itself as well
as the flow of water through the interstitial spaces needed in
order to properly hydrate a material 10.
[0082] Referring to FIG. 2, an embodiment of a process for
formulating the material 10 may involve cleaning 22 the material of
the substrate 12. Likewise, the material of the substrate 12 may be
dried 24 to make it more effective in receiving a binder 14. The
material of the substrate 12 may then be blended 26.
[0083] One embodiment, a ribbon blender provides an effective
mechanism to perform continuous blending as the binder 14 is added
28. Other types of mixers, such as rotary mixers, and the like may
be used. However, a ribbon blender provides a blending 26 that is
effective to distribute binder 14 as it is added 28.
[0084] For example, if an individual particle of the substrate 12
receives too much binder 14, and thus begins to agglomerate with
other particles of the substrate 12, a ribbon binder will tend to
separate the particles as a natural consequences of its shearing
and drawing action during blending 26.
[0085] As the binder 14 is added 28 to the mixture being blended
26, the individual particles of the substrate 12 will be
substantially evenly coated. At this stage, the binder 14 may also
be heated in order to reduce its viscosity and improve blending.
Likewise, the material of the substrate 12 or the environment of
the blending 26 may be heated in order to improve the evenness of
the distribution of the binder 14 on the surfaces of the substrate
12 materials or particles 12.
[0086] Blending 26 of the binder 14 into the material of the
substrate 12 is complete when coating is substantially even, and
the texture of the material 10 has an ability to clump, yet is
easily crumbled and broken into individual particles. At that
point, addition 30 of the hydrophilic particles 18 may be
accomplished.
[0087] For example, adding 30 the particles 18 as a powder into the
blending 26 is a naturally stable process. Typically the particles
18 attach to the binder 14 of the substrate 12 particles, thus
removing from activity that location. Accordingly, other particles
18 rather than agglomerating with their own type of material will
continue to tumble in the blending 26 until exposed to a suitable
location of binder 14 of the substrate 12. Thus, the adding 30 of
the particles 18 or powder 18 of hydrophilic material will tend to
be a naturally stable process providing a substantially even
coating on all the particles of the substrate 12.
[0088] Just as marshmallows are dusted with corn starch, rendering
them no longer tacky with respect to one another, the material 10
formulated by the process 20 are dusted with particles 18 and will
pour freely. Accordingly, distribution 32 may be conducted in a
variety of ways and may include one or several processes. For
example, distribution may include marketing distribution from
packaging after completion of blending 26, shipping to distributers
and retailers, and purchase and application by users.
[0089] An important part of distribution 32 is the deployment of
the material 10. In one embodiment of an apparatus and method in
accordance with the invention, the material 10 may be poured, as if
it were simply sand 12 or other substrate 12 alone. Since the
powder 18 or particles 18 have substantially occupied the binder
14, the material 10 will not bind to itself, but will readily pour
as the initial substrate material 12 will.
[0090] The material 10 may typically include from about 1 percent
to about 20 percent of a hydrophilic material 18 or particles 18.
The particles 18 may be formed of a naturally occurring material,
such as a cellulose, gelatin, organic material, or the like.
[0091] In one embodiment, a synthetic gel, such as polyacrylamide
may be used for the particles 18, in a ratio of from about 1 to
about 20 percent particles 18 compared to the weight of the
substrate 12. In experiments, a range of from about 5 to about 10
percent has been found to be the most effective for the amount
particles 18.
[0092] Size of particles 18 may range from about 20 mesh to smaller
than 100 mesh. Particles 18 of from about 50 to about 75 mesh have
been found most effective.
[0093] The binder 14 may typically be in the range of from about in
1/4 percent to about 3 percent of the weight of the substrate 12. A
range of from about 3/4 percent to about 11/2 percent has been
found to work best. That is, with a binder such as lignicite, 1/4
of 1 percent has been found not to provide as reliable binding of
particles 18 to the substrate 12. Meanwhile, a ratio of higher than
about 3 percent by weight of binder 14 to the amount of a substrate
12, such as sand, when using lignicite as the binder 14, tends to
provide too much agglomeration. The pouring ability of the material
10 is inhibited as well as the blending 26, due to agglomeration.
Other binders also operate, including several smaller molecules
that are water soluble. For example, glues, gelatins, sugars,
molasses, and the like may be used as a binder 14. Insoluble
binders are also useful and more permanent.
[0094] One substantial advantage for the material 10 in accordance
with the present invention is that the material remains flowable as
a sand-like material 10 into the fluids to be used in oil field
fracturing. Thus, handling and application is simple, and the
ability of granular material 10 to flow under and around small
interstices of fractures provides for a very effective
application.
[0095] Referring to FIG. 3, a formation 80 such as a reservoir area
of an oil may increase large and small flows 82 in passages 84
formed in the rock 86 of the formation 80. Typically, the flow 82
represented by arrows 82 indicating the development of flow at a
faster speed in center of a passage 84, and the lower velocity near
the wall 88 of the passage 84, illustrates the flow 82 of fluid in
the passage 84.
[0096] In the illustrated embodiment, the granules 10 or large
composite particles 10 or the materials 10 formed as a granulated
material 10, having the substrate 12 in the center column with the
polymer 18 adhered by a binder 12 on the outside thereof. This
material 10 may be added to a flow 82 being pumped into a formation
80. Initially, a particle 10 will have an effective diameter 90a.
In this condition, the particle 10 of material 10 is largely
dependent on the density of the substrate 12, which constitutes the
majority of its volume. Eventually, over time, with exposure to the
liquid 82 or flow 82 and the water of that flow 82, the polymer 18
will absorb water, increasing in its effective diameter 90b.
Ultimately, the polymer 18 or the polymer powder 18 will eventually
become fully hydrated, increasing many times its size, and
beginning to dominate the effective diameter 90c or hydraulic
diameter 90c of the particle 10.
[0097] Initially, the diameter 90a reflects the comparatively
smaller size and larger density of the particle 10 dominated by the
weight of the substrate 12, such as sand, ceramic sand, or some
other hard and strong material. Ultimately, the diameter 90a or
effective diameter 90a is sufficient to provide fluid drag
according to fluid dynamic equations, drawing the particle 10 into
the flow 82.
[0098] Meanwhile, the increase in diameter 90b and the ultimate
effective diameter 90c result in reduction of the density of the
particle 10 as the polymer 18 absorbs more water, bringing the net
density of the particle 10 closer to the density of water.
Accordingly, the particles 10 flow with the water exactly in sync,
so to speak, rather than settling out as a bare substrate 12 would
do.
[0099] For example, in areas where eddies in the flow occur, such
as corners, crevices, walls, and the like, heavy materials having
higher density, such as sand and the like, normally will tend to
drift out of the flow, toward a wall 88, and ultimately will settle
out. Instead, by virtue of the large "sail" presented by the larger
diameter 90c of a fully hydrated polymer 18, each particle 10 stays
with the flow 82 in passage 84, providing much more effective
transport.
[0100] Referring to FIG. 4, a chart 92 illustrates a volume axis 94
representing the volume of a particle 10 or material 10 in
accordance with the invention. The volume axis 94 is displayed
orthogonally with respect to a time axis 96, representing the
passage of time of the particle 10 submerged in a carrier 82 or
flow 82 of fluid 82. Typically, at different temperatures,
illustrated by curves 98a-98e, with the temperature associated with
curve 98a being the coldest and the temperature associated with the
curve 98e being the hottest, one can visualize how heat added to a
fluid flow 82 tends to increase the chemical activity and thus the
rate of absorption of water into a polymer 18.
[0101] In an apparatus and method in accordance with the invention,
the particles 10 may be added directly to a flow 82, without
waiting for any significant time to absorb water into the polymer
18. Instead, the normal flow 82 will draw the particles 10 along in
a passage 84 while exposing each individual particle 10 to
surrounding fluid 82, thus promoting maximum rates of exposure and
increased rates of absorption. Accordingly, the volume 94
increases, representing an increase in the absorption of water into
the polymer 18.
[0102] In an apparatus and method in accordance with the invention,
the curve 98a is suitable because the entire travel within the well
bore, and with the formation 80 by the fluid 82 bearing the
particles 10 is permissible and available as absorption time. By
contrast, prior art systems rely on the increased temperature of
curve 98e in order to provide the time, temperature, and mixing to
work polymers into a flow 82 or liquid carrier 82.
[0103] Referring to FIG. 5, in one embodiment of an apparatus,
composition, and method in accordance with the invention, some of
the polymer 18 may eventually be scraped, sheared, or otherwise
removed from the particles 10. If bonded only by itself with a
water solvent, such a separation may be easier than if bonded by a
more durable polymer. Such a release may even be engineered, timed,
controlled by a solvent, or the like.
[0104] Thus, a certain amount of the polymer 18 may be released
from the granule 10 into the carrier fluid 82 to flow with the
fluid 82 and operate as a general friction reducer or provide its
other inherent properties to the carrier fluid 82. By an engineered
process of bonding and un-bonding, the polymer powder may be less
permanent or attached to have a bond that is less robust. Over
time, the polymer powder so attached may release, tear, wear off,
pull away, or otherwise remove from the substrate into the carrier
fluid to act as a viscosity agent, surfactant, lubricant, or the
like in the carrier, according to its known properties available
for modifying the carrier 82.
[0105] For example, a polymer 100 or polymer chain 100 may be
captured on a corner 102 defining a passage 84 into which a flow 82
will proceed. Accordingly, the corner 102 renders less of an
orifice on the passage 84 against entry of the flow 82 by virtue of
the friction reduction of the polymer 100 in the fluid, deposited
temporarily or permanently about a corner 102. Thus, other
particles 10 passing the corner 100 may shear off a portion of the
polymer 18 carried thereby or may rely on the presence of the
polymer 18 as a direct friction reducing agent on the particle 10
(granule) itself, permitting the particles 10 to pass more easily
with the flow 82 into the passage 84.
[0106] Referring to FIGS. 6A and 6B, various fracture processes are
described in various literature, including U.S. Patent Application
publication US 2009/0065253 by Suarez-Rivera et al. incorporated
herein by reference. In a fracturing process, the pressure 110 or
force 110 applied to a formation 80 tends to force apart large
expanses of rock. As a result of that expansion of passages 84 in a
rock formation 80, the rock is stressed. Pressure pumped into the
fluid 82 flowing in the passages 84 within the formation 80 results
in bending stresses, tensile stresses, and so forth in the
formation 80.
[0107] In FIG. 6A, the forces 110 illustrated the effect of a large
pressure applied over a large area. Since pressure multiplied by
area equals force, applying an elevated hydraulic pressure to a
large surface of a rock 86 or rock segment 86 within a formation 80
results in tensile forces. Compressive forces will not tend to
break rock. However, a tensile force, which may be induced by
bending, expansion, or the like, results in fracture of the rock.
The fracture of the rock 86 thus results in condition shown in the
lower view, in which the passages 84 are mere fissures within the
rock 86.
[0108] The inset of FIG. 6A magnifies the fissures 84 or passages
84 formed in the rock 86 and immediately entered by the working
fluid 82 being used for the fracture. Having the particles 10
formed around substrates 12, the fluid 82 extends into each of the
fissures formed. Fissures 84 are simply passages 84. Some may be
large, others small.
[0109] Referring to FIG. 6B, proppants 10 trapped in a small
location still displace a large amount of fractured rock 86. Thus,
a small displacement at one location may still maintain opened
another opening much larger elsewhere near the rock 86. The
particles 10, even if as small as sand, may also collect and fill
larger dead ends, slow flowing, and eddying spaces, eliminating the
ability for rocks 86 to return to former positions.
[0110] After fracturing rock 86 to form all of the fissures 84, the
fluid 82 will pass through the fissures, carrying particles 10,
which eventually collect in cavities or reach choke points. In the
absence of the particles 10, fissures 84 could close back up after
the fracturing water leaves. However, by containing additives 18,
and then losing them, the individual substrates 12 are themselves
rock in the form of sand, ceramic sand, or the like. Thus, a
particle 10 or many particles 10 need only obstruct the ability of
the fissure 84 to close, and may "prop" open the fissures 84
precluding the rock 86 or the pieces of rock 86 from settling back
into alignment with one another.
[0111] Thus, the particles 10 both alone and in collected piles act
as proppants left behind by the fluid flow 82, by virtue of the
particles 10b captured. As a practical matter, it is the substrate
12 that acts as a proppant. The polymers 18 may eventually be worn
off, or released by a water-soluble binder, but can easily be
compressed, distorted, or cut. Regardless, as the fissures 84 open,
they are back filled and close in at choke points and settling
points collecting the substrate 12.
[0112] Continuing to refer to FIG. 6B, while referring generally to
FIGS. 1-10, a formation 80 when fractured into individual pieces of
stone 86, may form various passages 84 or fissures 84 therein. To
the extent that proppant materials 10 lose the adhered particles 18
or powders 18, once hydrated or mixed into the fluid 82, the
substrate 12 is then in a position to be deposited by eddies,
slower flows, turning corners, and the like. Thus, when the other
materials 18 that have acted sails, drifting the substrate 12 with
the fluid 82, have been removed, then the substrate 12 can more
easily settle out. Accordingly, near corners, in small crevices, in
dead corners, and the like, the particles 10, largely stripped of
their added constituent powders 18 (in whatever phase at that
point) may then drop out of the fluid 82 in a slow flow.
[0113] Once two portions of rock 86 separate from one another,
forming a passage 84 of some size, a supply of proppant 10b may
then prevent that rock portion 86 from moving back into its exact
position, necessarily forming passages 84 on virtually every side.
Where a single particle 10 of substrate 12 may drop out of the
fluid 82 and collect, many more may likewise collect. Accordingly,
the various particles 10b illustrated in FIG. 6B may collect,
forming substantial support for various edges, corners, and the
like of various rock 86. The result is that a small material, in
comparatively small quantities, supporting an edge, or a particular
region of a rock 86 in the formation 80 may nevertheless maintain a
large network of passages 84 as a direct result.
[0114] In stone formations having stronger tensile strength,
fractures may produce less debris to act as natural proppants.
Nevertheless, in addition to the particles 10 constituting
primarily substrate material 12 at this point, the passages 84 may
be maintained open as is the objective with fracturing.
[0115] Referring to FIG. 7, a process 111 may include preparing 112
a fluid 82. Processing 114 other additives other than the particles
10 may be done according to any suitable methods, including prior
art processes. Adding 116 directly to the fluid 82, the particles
10 as described hereinabove, may be done in such a manner that the
operators need not wait for absorption or any other processes to
take place. Additional energy for elevating temperature is not
required, neither mixing or the like, other than adding 116
directly particles 10 into the flow 82. The flow 82 will
immediately grab the particles 10 according to the principles of
fluid dynamics in which fluid drag is dependent upon a shape factor
of the particle 10, the density of the fluid 82, the square of
velocity of the fluid, and so forth, as defined in engineering
fluid mechanics.
[0116] The fluid 82 now bearing the particles 10 would be
immediately pumped 118 into the formation 80 that is the reservoir
80 of an oil field. Eventually, pressurizing 120 the reservoir by
pressurizing the fluid 82 results in creating 122 fractures 84 or
fissures 84 within the formation 80 by breaking up the rock 86 of
the formation 80. A fracture 84 with enough displacement may make a
site for material 10 to stagnate and collect.
[0117] Creating 122 fracture lines throughout the formation 80 is
followed by penetrating 124, by the particles 10 borne in the fluid
82 into the passages 84 or fissures 84 in the rock 86 of the
formation 80. Whenever the flow 82 of fluid 82 carries a particle
10 to a choke point 108 in a passage 84, as illustrated in FIG. 6,
a particle 10 will be lodged as illustrated in the insert of FIG.
6, a particle 10 with its polymer 18 still secured and intact may
be lodged. Similarly, the substrate 12 may be lodged 126 and the
polymer 18 may be stripped therefrom by the consequent or
subsequent flowing of material in the flow 82. Likewise, piles of
stagnant particles 10 may backfill spaces, precluding rock 86
settling back in.
[0118] After the lodging 126 or propping 126 of the fissures 84 by
the substrate 12, in the particles 10, the passages 84 will remain
open. These fissures 84 may then be used to later withdraw 128 the
fluid 82 from the formation 80. Thereafter, returning 130 the
formation 80 to production may occur in any manner suitable. For
example, heat may be added to the formation, liquid may be run
through the formation as a driver to push petroleum out, or the
like.
[0119] Referring to FIGS. 8-10, while continuing to refer generally
to FIGS. 1-10, in various alternative embodiments, multiple
constituents may be used as the particles 18 or powder 18 held by
the binder 14 to the substrate 12. For example, in various
alternative embodiments, one or more other constituents may be
added in addition to friction reducers. In the embodiments
described hereinabove, the polymeric powders 18 added to the
substrate 12 by the tacky or otherwise adhering binder material 14
operated partly as a friction reducer but also as a sill
encouraging drifting of the particles 10 with the flow of the fluid
82 or flow 82 in the fracture fluid 82. Thus, hydrophilic powder 18
served multiple purposes.
[0120] Meanwhile, as described hereinabove, such polymers may be
bonded to the outer surface of the binder 14, thus rendering
themselves more susceptible to absorbing water and being stripped
off by friction against the walls 88 of various passages 84 in the
formation 80. Accordingly, such materials may typically be used in
combination with others in various fractures. It has been found
effective to include a friction reducing material at a fraction of
about 0 to about 10 percent of the total coating granules 18 or
powder 18 adhered to the binder 14.
[0121] Similarly, biological organisms can change the pH in the
water 82 or fluid 82 used for the fracture process. Accordingly,
biocides or bacteriacides may eliminate the bacteria or reduce its
population in order to avoid changes in the mechanical properties
of the fluid 82 as well as changing the pH and thereby the
corrosiveness of the fluid 82.
[0122] In the contemplated embodiment, such materials such as
sodium hypochlorite as a powder or crystal form may be used as one
of the constituents for the powder 18 to be bound by the binder 14.
Likewise, chlorine dioxide may also be applied by a powder formed
of a crystal and form thereof. Other biocides that may be included
may be glutaraldehyde as a liquid, or as the constituents thereof
in solid form. Similarly, quaternary ammonium chloride may be
provided as a solid and therefore as a powder, or as a liquid.
[0123] Liquids may be included in the binder 14. Alternatively, the
liquid constituents may instead by separated from (or not dissolved
in) their solvents in order to provide powders 18 for adhering to
the particles 10. Thus, the foregoing liquids as well as tetrakis
hydroxhydroxymethyl-phosphonium sulfate may be similarly
treated.
[0124] As one or even as the only constituent, a particular
material may be used as powder 18 adhered to the substrate 12 as
part of a particle 10. Any one or more may be combined
appropriately. Biocides, typically appear to be suitable in the
range of from about 0 to about 3 percent of the particles 18 or
powder 18 secured to the substrate 12.
[0125] Oxygen scavengers also assist in changing pH as well as
preventing corrosion, by removing available oxygen from the fluid
82. Removal of oxygen prevents oxidation, commonly known as rust or
corrosion. Thus, the liners, drilling equipment, and other tubular
materials may increase their life and reliability and overall
integrity of the well by reducing oxygen in the fluid 82.
Accordingly, from about 0 to about 3 percent of an oxygen scavenger
may be included as part of the coating 18 or the powder 18 adhered
to each substrate 12.
[0126] Similarly, a clay stabilizer may be included in a proportion
of from about 0 to about 3 percent of the coating 18. Thus, clay
stabilizers that are used in the fluid 82 may be modified or
restricted from swelling or shifting. For example, choline chloride
as well as tetramethyl ammonium chloride as well as sodium chloride
(salt) may all be provided as powders 18 to be bonded to the
substrate 12 by a binder 14.
[0127] Likewise, scaling inhibitors may be included at a rate of
from about 0 to about 3 percent of the powder 18 adhered to the
substrate 12 or of the total weight of the product. Scaling
involves the deposition on various conduits and walls, typically in
pipes of various minerals, such as carbonates. Changes in pH,
changes in temperature, changes in various concentrations of other
materials including that of the scaling material may cause scale to
accumulate. Accordingly, scale inhibitors may be added as particles
18 in an overall mix, or as part of another coating process.
[0128] For example, various copolymers of acrylamides as well as
sodium acrylate are scale inhibitors that may be secured to the
substrate 12 by the binder 14. Similarly, sodium polycarboxylate
and phosphonic acid salt may all be provided in a solid form. All
may be comminuted to a powder 18, and sieved to a common size
corresponding to that of other materials. Accordingly, mixed in a
proper ratio, the powders 18 may actually be compositions of
numerous constituents in suitable proportions.
[0129] Likewise, a gelling agent may be added in a proportion of
from about 0 to about 10 percent as a powder 18 secured to the
substrate 12 of particle 10. A function of gelling agents is to
alter viscosity. This improves suspension of proppants, such as the
substrate 12, sand, or the like, in water. Typically, the speed or
velocity with which gravity or other effects may drift a heavy
substrate 12 or particle 10 out of solution to leave it elsewhere,
is controlled to a large extent by the relative viscosity of the
liquid fluid 82 through which the particles 10 are passing.
Accordingly, increasing the viscosity tends to keep the particles
10 entrained and more evenly distributed within the fluid 82.
[0130] Accordingly, various gelling agents, or a single gelling
agent selection may be used as a constituent forming the powder 18
adhered to a substrate 12. Typical processes describe hereinabove
and hereinafter illustrate that solid particles may be inducted
into the flow 82 or the fluid 82 almost instantly when introduced
as the particulates 10. Thus, rather than floating on top during
extensive mixing, such materials may be drawn quickly as part of
the particles 10 discharged into the fluid 82 at the well head.
[0131] Various experiments have shown the utility and ability to
add many of these materials. Generally, anything that can be
maintained stable for a suitable period of time may be added as
powder 18 to a suitable binder 14 holding it to a substrate 12.
Thus, various hydrophilic polymers, including polyacrylamides and
polyacrylates may be added. Guar gum, various guar derivatives,
polysaccharide blends all have the mechanical properties to be
suitable as constituents of the powder 18 of particles 10.
[0132] Referring to FIG. 8, in one embodiment of a process in
accordance with the invention, a substrate 12 may have added to it
a layer of binder 14. To the binder 14 may be added a particular
powder 18a or additive 18a in solid form to be bound to the
substrate 12 by the binder 14. In this particular embodiment, the
powder 18a is added first, in a particular fraction. Thereafter,
various other constituents may be added in series as the powders
18b, 18c, 18d, illustrated by differing shapes of particles. For
example, the particles or powder 18a is illustrated by an irregular
shape, the powder 18b by a rectangular shape, 18 c by a diamond
shape, and 18d by a circular shape. These shapes are merely
schematic in order to show the addition of various materials.
[0133] Continuing to refer to FIG. 8, the process may also operate
by a method of first mixing each of the different powders 18,
including up to about 10 or more. Typically, additives in the range
of from about 5 to about 9 different constituents may be comminuted
and sieved (sorted) in order to maintain all at approximately the
same range of sizes.
[0134] In this way, by grinding to powder (comminuting) and then
sorting with a sieve, the various constituent materials may then be
treated mechanically as generic materials, mechanically equivalent.
Thus, all may be mixed together.
[0135] An important feature here is to avoid disparate sizes, and
particularly the inclusions of too many fines. Ultra fine particles
tend to provide less included volume in each powder particle, and
thus occupy more surface of the available binder 14 and the surface
area of the substrate 12, thus inhibiting even coating and the
addition of other constituents. Thus, in such an embodiment, the
powder particles 18a, 18b, 18c, 18d, and so forth may all be mixed
in the exact proportion desired, usually as a fraction or
percentage of the total weight of particles 10, and each may then
be included in a mixed supply (e.g., bin, etc.) having the
proportions desired, of each and every constituent. Thus, the
process described with respect to FIGS. 1 and 2 hereinabove may be
used directly, with the powder 18 simply being a mix of other
individual constituent chemicals as powders. Thus, all constituents
may be added "in parallel," simultaneously.
[0136] Referring to FIG. 9, in an alternative embodiment, the
substrate 12 may have added to it a binder 14, after which a layer
of particles 18 may be added to the binder. Following this, an
additional layer of binder 14 may be added to which additional
particles 18 may be adhered.
[0137] In this embodiment, the additional layers of binder 14 and
particles 18 may provide sequential de-layering of the various
powders 18 during the process of flowing through the bore and into
the formation 80. Nevertheless, it has been found that adhering a
supply of particles 18 or powder 18 to a single layer of binder 14,
provides adequate surface area, adequate binding, and sufficient
area to hold a wide variety of constituent chemicals all adhered in
a single coating process.
[0138] Referring to FIG. 10, while continuing to refer generally to
FIGS. 1-10, one embodiment of a process 20 may be illustrated with
the cleaning 22, drying 24, and blending 26 as described
hereinabove. Meanwhile, a decision 132 determines the mode of
coating. For example, if the decision is to coat directly, then
preparing 134 sieved constituents may include comminuting and
sorting constituents, each sieved or otherwise sorted in order to
provide a consistent size range for each.
[0139] Following the preparation 134 of the constituents, mixing
136 is needed for the constituents in the suitable ratios or
percentages. This provides a single mixture of powdered particles
18 suitable for bonding to a substrate 12. Applying 138 a binder is
followed by applying 140 the powder 18 to the binder 14 in coating
the substrate 12 as described hereinabove.
[0140] Following preparation of the granular particulates 10,
postprocessing may include bagging, may include additional drying,
or may include protection against elements to which the material 10
will be exposed.
[0141] Post processing 142 may be followed by distribution 144 to
various destinations. Distribution 144 may include, or may be
followed up by stocking the distributed 144 product 10 at various
sites for use. Ultimately, injecting 148 the granular material 10
into the fluid 82 for fracturing may complete the preparation and
use of the product 10 in accordance with the invention. Thereafter,
the processes described with respect to FIGS. 3-6B occur as a
consequence of the configuration of the granular material 10.
[0142] In certain alternative embodiments, as illustrated in FIGS.
8 and 9, the mode decision 132 may involve adding powder 18 in
series. For example, adding 150 a binder may be followed by adding
152 a powder species. Thereafter, a decision 154 may determine
whether to add another species. If the decision is affirmative,
then additional species may be added 152 until the coating is
completed. Thereafter, when no other additions are to be made,
according to the decision step 154, then postprocessing 142
continues, and the process 20 continues to ejection 148.
[0143] Similarly, the process of FIG. 9 illustrates the process in
which adding 160 a binder 14 is followed by adding 162 a powder
constituent, after which a decision 164 results in adding 160 more
binder before adding 162 more of a powder constituent. Thus, adding
152 powder only, compared to adding 168 binder 14 and adding 162
additional powdered constituents 18, reflect certain of the
embodiments such as FIG. 9. Nevertheless, the embodiment of
preparing 134 sieved constituents, through the applying 140 the
powder 18 as a mixture, is also illustrated in FIG. 8, or
represented thereby, as described hereinabove.
[0144] As discussed above, the material 10 may be utilized as
self-suspending proppants in hydraulic fracturing. As used herein,
the material 10 may also be referred to as self-suspending
proppants.
[0145] Methods for Forming Self-Suspending Proppant Particles
[0146] In various embodiments, as discussed above, the
self-suspending proppants described herein may include a substrate,
e.g., sand, having an outer polymeric coating that is
water-absorbing. In such embodiments, a water-absorbing outer
polymeric coating comprises one or more water-absorbing polymers,
such as the water-absorbing polymers discussed below. In addition,
in various embodiments, as discussed above, the self-suspending
proppants may include a binder, which may aid in securing at least
a portion of the water-absorbing polymeric coating to the
substrate.
[0147] In certain embodiments, the substrate can include frac sand.
In one or more embodiments, the frac sand can be graded as a 12-20
mesh frac sand, a 16-30 mesh frac sand, a 20-40 mesh frac sand, a
30-50 mesh frac sand, a 30-70 mesh frac sand, a 40-70 mesh frac
sand, or a 100+ mesh frac sand. In certain embodiments, a
combination of various grades of frac sand can be used, such as a
combination of the grades listed above. Such frac sands and grades
are commercially available.
Methods for Forming Self-Suspending Proppant Particles:
Binder-Coated Substrate Particles
[0148] In embodiments, as discussed above, the self-suspending
proppant can be made by first mixing a substrate with a binder to
form binder-coated substrate particles. In certain embodiments, the
binder may be a liquid binder, such as glycerol. Other liquid
binders are described above.
[0149] In one or more embodiments, when mixing a binder with a
substrate, one may add at least about 0.05 wt. % binder, at least
about 0.1 wt. % binder, at least about 0.15 wt. % binder, or at
least about 0.2 wt. % binder; and/or less than about 3 wt. %
binder, less than about 2 wt. % binder, less than about 1 wt. %
binder, or less than about 0.5 wt. % binder. In the same or
alternative embodiments, when mixing a binder with a substrate, one
may add about 0.25 wt. % binder. As used herein, "wt. % binder"
refers to the ratio of the weight of the binder to the weight of
the substrate, multiplies by 100.
[0150] In embodiments, the binder and substrate can be mixed using
any commercially available mixing device or mixing vessel and a
particular one can be chosen by one skilled in the art for a
specific purpose. In certain embodiments, a ribbon mixer or paddle
mixer may be utilized when mixing the binder and substrate.
[0151] In certain embodiments, the binder and substrate may be
mixed for a time sufficient to substantially evenly apply the
binder to the substrate particles. In one or more embodiments, the
binder may be mixed with the substrate for at least about 1-2
minutes. In certain embodiments, upon mixing the binder and
substrate under the conditions described herein, a substantial
portion, or substantially all of, the binder may be coated onto the
outer surface of the substrate particles so that there is little to
no excess free binder.
[0152] Methods for Forming Self-Suspending Proppant Particles:
Intermediate Polymer-Coated Substrate Particles
[0153] In embodiments, at least a portion of the binder-coated
substrate particles, or substrate particles without binder, may be
coated with one or more polymeric materials, such as
water-absorbing polymers to form intermediate polymer-coated
substrate particles. In one or more embodiments, the
water-absorbing polymers utilized to form the intermediate
polymer-coated substrate particles can include polyacrylamide,
polyacrylates, or a combination thereof. In certain embodiments,
the water absorbing polymers can include a co-polymer of acrylamide
monomers and acrylate monomers. In such embodiments, the co-polymer
of acrylamide monomers and acrylate monomers may be a random
co-polymer of acrylate monomers and acrylamide monomers such that
the acrylate monomers and the acrylamide monomers are randomly
positioned within the co-polymer.
[0154] In embodiments, any of the water-absorbing polymers
disclosed herein may be linear or cross-linked. As used herein, a
polymer that is linear refers to a polymer that is not cross-linked
with itself or another polymer by covalent bonds and/or ionic
bonds. In certain embodiments, a polymer that is linear, while not
being cross-linked, can include simple linear polymers and branched
linear polymers. A simple linear polymer refers to a polymer having
a single long chain, while a branched linear polymer refers to a
polymer having a long chain with one or more shorter chains
branched off from the long chain.
[0155] In certain embodiments, the water-absorbing polymer can
include an anionic polymer, such as polyacrylamide or a co-polymer
of acrylate monomers and acrylamide monomers. As discussed above,
the polyacrylamide can include a linear polyacrylamide. In various
embodiments, the anionic polyacrylamide or other anionic polymer,
such as an anionic co-polymer of acrylamide monomers and acrylate
monomers, can have an anionic charge in an amount of about 10 mol
%, about 20 mol %, about 30 mol %, about 40 mol % or about 50 mol
%. In embodiments, the anionic polymer or co-polymer can be about
10 mol % to about 50 mol % anionic, about 20 mol % to about 50 mol
% anionic, or about 30 mol % to about 40 mol % anionic. In certain
embodiments, within an anionic co-polymer of acrylate monomers and
acrylamide monomers, the anionic content may substantially
correlate to the content of the acrylate monomers in the
co-polymer. For instance, in such embodiments, a co-polymer of
acrylate monomers and acrylamide monomers that is about 20 mol % to
50 mol % anionic, can include about 20 mol % to about 50 mol %
acrylate monomers.
[0156] In various embodiments, a co-polymer of acrylate monomers
and acrylamide monomers may include neutral or non-ionic acrylamide
monomers and anionic acrylate monomers. In such embodiments, the
acrylamide monomers can be present in the co-polymer in an amount
of at least about 50 mol %, at least about 60 mol %, at least about
70 mol %, or at least about 90 mol %; or from about 40 mol % to
about 90 mol %, or from about 50 mol % to about 90 mol %, or from
about 50 mol % to about 80 mol %. In the same or alternative
embodiments, the water-absorbing polymer can include a non-ionic
polymer, cationic polymer, anionic polymer, or a combination
thereof. It is appreciated that one skilled in the art is aware
that such types of water-absorbing polymers can be commercially
obtained. Representative commercial vendors includes SNF and
Evonik.
[0157] In certain embodiments, utilizing water-absorbing polymers
having the anionic content ranges described above can provide some
advantageous functional properties to the self-suspending
proppants. For example, in certain embodiments, utilizing
water-absorbing polymers having the anionic content ranges
described above can result in the effective suspension of the
self-suspending proppants in an aqueous fluid, including brackish
water. Further, in certain embodiments, the anionic content of a
water-absorbing polymer described herein may affect the molecular
weight or size of the polymer, which may affect the ability of the
polymer to form a polymer coating on the substrate particle. In
such an embodiment, utilizing water-absorbing polymers having the
anionic content ranges described above allows for the appropriate
molecular weight of the water-absorbing polymer so that such a
polymer can form an effective polymer coating on the substrate
particles. These and other properties are discussed further
below.
[0158] In embodiments, the water-absorbing polymer can have a
molecular weight of at least about 1 million Daltons (g/mol), at
least about 5 million Daltons (g/mol), at least about 15 million
Daltons (g/mol), or at least about 20 million Daltons (g/mol). In
the same or alternative embodiments, the water-absorbing polymer
can have a molecular weight of about 40 million Daltons (g/mol) or
less, or about 30 million Daltons (g/mol) or less.
[0159] In certain embodiments, coating the binder-coated substrate
particles with one or more polymeric materials to form intermediate
polymer-coated substrate particles can include applying one or more
polymeric materials to a mixing vessel or device containing
binder-coated substrate particles, such as the mixing devices
discussed above.
[0160] In certain embodiments, the water-absorbing polymers may be
suspending in liquid prior to being added to a mixing vessel
containing the substrate particles or binder-coated substrate
particles. In one or more embodiments, the water-absorbing polymer
may be present in a water-in-oil emulsion (i.e., an invert
emulsion). In such embodiments, the water-in-oil emulsion may
include the water-absorbing polymer in the water or aqueous phase,
which is emulsified in the larger oil phase, such as a mineral oil
or other distillates of petroleum. In addition, in such
embodiments, the water-absorbing polymer may be present in the
water-in-oil emulsion in an amount of about 15 wt. %, about 20 wt.
%, about 25 wt. %, about 30 wt. %, about 40 wt. %, or about 50 wt.
%. It is appreciated that one skilled in the art understands that
water-in-oil emulsions comprising water-absorbing polymers can be
commercially obtained. One such commercial vendor is SNF.
[0161] In one or more embodiments, when a water-in-oil emulsion is
utilized, the emulsion can be added to the binder-coated substrate,
or plain substrate, in an amount of at least about 0.1 wt. %
emulsion relative to the weight of the substrate, at least about
0.2 wt. %, at least about 0.3 wt. %, at least about 0.4 wt. %, at
least about 0.5 wt. %, at least about 1 wt. %, at least about 2 wt.
%, at least about 2.5 wt. %, at least about 3 wt. %, at least about
4 wt. %, at least about 5 wt. %, or at least about 7.5 wt. %. In
the same or alternative embodiments, the emulsion can be added to
the binder-coated substrate, or plain substrate, in an amount of
less than about 20 wt. % emulsion relative to the weight of the
substrate, less than about 15 wt. %, or less than about 10 wt. %.
As used herein, "wt. % emulsion relative to the weight of the
substrate" refers to the ratio of the weight of the emulsion to the
weight of the substrate, multiplied by 100.
[0162] In certain embodiments, the water-absorbing polymer may be
mixed with the binder-coated substrate particles, or substrate
particles, for a time sufficient to substantially evenly apply the
water-absorbing polymer, or the liquid or emulsion containing the
water-absorbing polymer, to the substrate particles to form the
intermediate polymer-coated substrate particles. In one or more
embodiments, the intermediate polymer-coated substrate particles
can be fully coated with water-absorbing polymer and/or the liquid
or emulsion containing the water-absorbing polymer. In one or more
embodiments, the water absorbing polymer may be mixed with the
substrate for about 1-0 minutes, or about 2-3 minutes.
[0163] Without being bound by any particular theories, in certain
embodiments, it is believed that the humectant properties of the
binder, such as the humectant properties of glycerol, may attract
the aqueous dispersion of water-absorbing polymer from the
water-in-oil emulsion to the surface of the substrate particles
resulting in the coating of the water-absorbing polymer onto the
surface of the substrate particle. In such embodiments, the binder
can include other humectants or hygroscopic compounds known to one
skilled in the art.
[0164] In alternative embodiments, the water-absorbing polymers may
be in dried powdered form prior to being added to a mixing vessel
containing the substrate particles or binder-coated substrate
particles. The dried powdered form of the water-absorbing polymers
can include any or all of the features of the dried powdered form
of water-absorbing polymers discussed below. For instance, the
water-absorbing polymer in dried powdered form can include powder
particles of less than about 300 microns, less than about 200
microns, or less than about 100 microns. In one or more
embodiments, the water-absorbing polymer in dried powdered form can
include powder particles with a maximum dimension of less than
about 300 microns, less than about 200 microns, or less than about
100 microns. In the same or alternative embodiments, a
water-absorbing polymer in powdered form refers to a dry powdered
polymer having a dry content of: at least about 50%, at least about
75%, at least about 85%, at least about 95%, or at least about 99%;
or a dry content of from about 75%-100% or about 88%-100%.
[0165] In embodiments when the dried powdered form of the
water-absorbing polymer is added to a mixing vessel containing the
substrate particles or binder-coated substrate particles to form
intermediate-coated substrate particles, the water-absorbing
polymer can be added in an amount of 0.01 wt. % water-absorbing
polymer relative to the weight of the substrate, at least about 0.1
wt. %, at least about 0.25 wt. %, at least about 0.5 wt. %, at
least about 1 wt. %, at least about 1.5 wt. %, or at least about 2
wt. %, and/or less than about 10 wt. %, less than about 7.5 wt. %,
less than about 5 wt. %, or less than about 3 wt. %.
Methods for Forming Self-Suspending Proppant Particles:
Polymer-Coated Substrate Particles
[0166] In various embodiments, the intermediate polymer-coated
substrate particles can be coated with a second water-absorbing
polymer to form polymer-coated substrate particles. In certain
embodiments, the second water absorbing polymer can have any or all
of the parameters and properties of the water-absorbing polymers
described above. In various embodiments, the water-absorbing
polymer applied to the intermediate polymer-coated substrate
particles can include an acrylamide and acrylate co-polymer that is
cross-linked. In various other embodiments, the water-absorbing
polymer applied to the intermediate polymer-coated substrate can
include a linear co-polymer of acrylate monomers and acrylamide
monomers. In the same or alternative embodiments, the
water-absorbing polymer applied to the intermediate polymer-coated
substrate particles can include a linear polyacrylamide. In such
embodiments, the linear polyacrylamide applied at this step may
have an increased molecular weight relative to the water-absorbing
polymer applied in forming the intermediate polymer-coated
substrate particles.
[0167] In certain embodiments, a water-absorbing polymer utilized
in an emulsion can have a greater molecular weight than a
water-absorbing polymer utilized in powdered form. In such
embodiments, the molecular weight of the water-absorbing polymer
present in an emulsion can be at least about 1 million Daltons
(g/mol), at least about 2 million Daltons (g/mol), or at least
about 3 million Daltons (g/mol) greater than the molecular weight
of the water-absorbing polymer present in powdered form.
[0168] In one or more embodiments, the polymer coated substrate
particles can be formed by applying the second water-absorbing
polymer to the intermediate polymer-coated substrate particles in a
mixing vessel, such as the mixing vessels discussed above.
[0169] In certain embodiments, the second water-absorbing polymer
may be present in powdered form when applying to the intermediate
polymer-coated substrate particles. In certain embodiments, a
water-absorbing polymer in powdered form refers to a dry powdered
polymer with powder particles of less than about 300 microns, less
than about 200 microns, or less than about 100 microns. In the same
or alternative embodiments, a water-absorbing polymer in powdered
form refers to a dry powdered polymer having a dry content of: at
least 50%, at least about 75%, at least about 85%, at least about
95%, or at least about 99%; or a dry content of from about 75%-100%
or about 88%-100%. In embodiments, the processes described above
for forming the intermediate polymer-coated substrate particles may
result in the intermediate polymer-coated substrate particles
having an outer wet surface, due to the application of the binder
and/or the application of a water absorbing polymer in a liquid,
such as an emulsion described above. In such embodiments, a dry
powdered second water-absorbing polymer may adhere to the wet outer
surface of the intermediate polymer-coated substrate particles.
[0170] In one or more embodiments, the second water-absorbing
polymer may be applied in an amount so as to not completely, or
discontinuously, cover or coat the outer surface of the
intermediate polymer-coated substrate particles. In alternative
embodiments, the second water-absorbing polymer may be applied in
an amount so as to substantially coat or cover the outer surface of
the intermediate polymer-coated substrate.
[0171] In certain embodiments, the second water-absorbing polymer
may be applied in an amount of at least about 0.01 wt. %
water-absorbing polymer relative to the weight of the substrate, at
least about 0.1 wt. %, at least about 0.25 wt. %, at least about
0.5 wt. %, at least about 1 wt. %, at least about 1.5 wt. %, or at
least about 2 wt. %; and/or less than about 10 wt. %, less than
about 7.5 wt. %, less than about 5 wt. %, or less than about 3 wt.
%. As used herein, "wt. % water-absorbing polymer relative to the
weight of the substrate" refers to the ratio of the weight of the
second water-absorbing polymer to the weight of the substrate,
multiplied by 100.
[0172] In embodiments, the second water-absorbing polymer may be
mixed with the intermediate polymer-coated substrate particles to
form polymer-coated substrate particles for a time sufficient to
evenly distribute the second water-absorbing polymer amongst the
volume of intermediate polymer-coated substrate particles. In
certain embodiments, the second water-absorbing polymer may be
mixed with the intermediate polymer-coated substrate particles for
less than about 5 minutes, less than about 4 minutes, less than
about 3 minutes, less than about 2 minutes, or less than about 1
minute.
[0173] In certain embodiments, the second water-absorbing polymer
applied to the binder-coated substrate particles to form
intermediate-coated substrate particles in this step can be present
in a liquid, such as an emulsion. In such embodiments, this
water-absorbing polymer applied in a liquid can include any or all
of the properties of the water-in-oil emulsions discussed above.
Further, in such embodiments, the water-absorbing polymer in liquid
form can be applied to the binder-coated substrate particles to
form intermediate-coated substrate particles in this step in the
amount of at least about 0.1 wt. % emulsion relative to the weight
of the substrate, at least about 0.2 wt. %, at least about 0.3 wt.
%, at least about 0.4 wt. %, at least about 0.5 wt. %, at least
about 1 wt. %, at least about 2 wt. %, at least about 2.5 wt. %, at
least about 3 wt. %, at least about 4 wt. %, at least about 5 wt.
%, or at least about 7.5 wt. %.
[0174] As discussed above, the methods described herein can include
two separate, distinct applications of a water-absorbing polymer in
different forms from one another, such as powdered form and in the
form of an emulsion. In certain aspects, it may be desirable to add
the water-absorbing polymer in powdered form prior to applying the
water-absorbing polymer in the form of an emulsion, since this
particular order of application can prevent or reduce the
water-absorbing polymer in powdered form from clumping.
Methods for Forming Self-Suspending Proppant Particles: Optional
Third Application of Water-Absorbing Polymer
[0175] In one or more embodiments, a third application of
water-absorbing polymer may be optionally applied to the
polymer-coated substrate particles. In such embodiments, this
optional application of the water-absorbing polymer can include any
or all of the properties and parameters discussed above in applying
the water-absorbing polymer to the binder-coated substrate
particles to form the intermediate polymer-coated substrate
particles. For example, in various embodiments, this third
application of water-absorbing polymer can include mixing a
water-in-oil emulsion comprising a water-soluble polymer with the
polymer-coated substrates in a mixing vessel for 2-3 minutes.
Methods for Forming Self-Suspending Proppant Particles: Drying the
Polymer-Coated Substrate
[0176] In embodiments, the polymer-coated substrate, with or
without the third application of water-absorbing polymer, can be
dried in order to form self-suspending proppant particles. In such
embodiments, this drying step can remove at least a portion of the
liquid with which the water-absorbing polymer was suspended during
application of the water-absorbing polymer to the substrate, such
as that described above with reference to the formation of
intermediate polymer-coated substrate particles or the
polymer-coated substrate particles.
[0177] In certain embodiments, the polymer-coated substrate can be
exposed to mild heat, such as a temperature of at least about
100.degree. F., or at least about 150.degree. F.; and/or less than
about 300.degree. F., less than about 250.degree. F., or less than
about 225.degree. F. In embodiments, the drying temperature can be
about 200.degree. F. or less than about 230.degree. F. Any type of
oven or drying system, e.g., fluid bed dryer, can be used to dry
the polymer-coated substrate, and a particular system can be chosen
by one skilled in the art for a specific purpose. The
polymer-coated substrate can be exposed to mild heat for at least
about 10 minutes, at least about 20 minutes, or at least about 30
minutes.
[0178] In certain embodiments, exposing the polymer-coated
substrate particles to the temperature ranges described above can
be sufficient to cause cross-linking in at least a portion of the
one or more water-absorbing polymers present on the substrate
surface. In such embodiments, this method of cross-linking is
referred to as thermal cross-linking. Without being bound by any
particular theories, it is believed that, when the water-absorbing
polymer includes a co-polymer or acrylate monomers and acrylamide
monomers, the cross-linking can comprise a covalent cross-link that
includes the carboxylate anion on the acrylate monomers covalently
bonding to another portion of a water-absorbing polymer, such as an
acrylamide monomer. Further, without being bound by any particular
theories, it is believed that this thermal cross-linking
facilitates the securing of the polymer coating around the
substrate particle. In certain embodiments, prior to this thermal
cross-linking, one or more of the water-absorbing polymers in the
polymer-coated substrate particles is linear.
[0179] In certain embodiments, the amount of cross-linking of the
water-absorbing polymers can be controlled by the temperature and
time of heat exposure. In such embodiments, the polymer-coated
substrate particles can be exposed to a temperature of at least
about 100.degree. F. (38.degree. C.), or at least about 150.degree.
F. (66.degree. C.); and/or less than about 250.degree. F.
(121.degree. C.), or less than about 230.degree. F. (110.degree.
C.); or a temperature of about 180.degree. F. (82.degree. C.) for a
time period of at least about 10 minutes, at least about 20
minutes, or at least about 30 minutes.
[0180] In various embodiments, the amount of cross-linking of the
water-absorbing polymers can be controlled by the anionic content
of the water-absorbing polymers present on the polymer-coated
substrate particles. In such embodiments, one or more of the
water-absorbing polymers can be about 10 mol % to about 50 mol %
anionic, or about 20 mol % to about 50 mol % anionic. In certain
embodiments, the water-absorbing polymers present in the
self-suspending proppants produced according to the methods
described herein may be partially cross-linked (e.g., not full
cross-linked). In such embodiments, this partial cross-linking may
provide sufficient water swellability and suspension of the
proppant while still allowing for the ability to settle out when
exposed to a conventional breaker.
[0181] In certain embodiments, by controlling the heating
temperature, exposure time to the heat, and anionic content of the
water-absorbing polymers on the outer polymeric coating,
self-suspending proppants are formed that exhibit the desirable
suspension properties disclosed herein, including the ability to
remain suspending in brackish or salt water conditions, while also
being able to settle out when exposed to a conventional breaker, as
discussed further below.
[0182] In certain embodiments, two distinct applications of a
water-absorbing polymer in powdered form and in the form of an
emulsion can provide different coating properties to the
self-suspending proppant, which can result in advantageous
performance of the self-suspending proppants. For example, applying
a water-absorbing polymer in an emulsion or other liquid can
provide a substantially continuous or continuous coating of the
water-absorbing polymer to the surface of the substrate particle,
as the emulsion or liquid can evenly coat the substrate particle.
Further, in certain embodiments, this substantially continuous
coating, when subsequently cross-linked, can form a cross-linked
coating on the surface of the substrate particle, effectively
locking the substrate particle inside this cross-linked polymeric
coating. Additionally, in certain embodiments, the application of
the water-absorbing polymer in dried powdered form can increase the
water-absorbing polymer content in the self-suspending proppant's
polymer coating (relative to a single application of the
water-absorbing polymer in an emulsion), which may aid in the
suspension ability, including in salt water, while still allowing
for polymer coating removal from the substrate using conventional
breakers.
[0183] In certain embodiments, due to the size of the powdered
particles of the powdered form of the water-absorbing polymer
relative to the size of the substrate, such as various grades of
frac sand, and due to the amount of powdered polymer added in the
methods described herein, individual substrates may not be fully
coated with powdered polymer particles. Even though the substrates
may not be fully coated with the powdered polymer particles in
certain embodiments, the self-suspending proppant can also include
a coating of a water-absorbing polymer that was applied in an
emulsion, which may substantially or entirely coat the outer
surface of the substrate particle.
[0184] Further, in certain embodiments, utilizing two distinct
applications of the water-absorbing polymer where each application
includes applying the water-absorbing polymer in a different form
(e.g., one application with the water-absorbing polymer in powdered
form and another application in an emulsion), allows for the
modulation of the amount of the water-absorbing polymer present on
the substrate particle in a production efficient manner. For
instance, in such embodiments, an application of the
water-absorbing polymer in an emulsion form can provide a high
localized concentration of water-absorbing polymer to the surface
of the substrate particles; however, the amount of water-absorbing
polymer that may be applied to the surface of the substrate
particles may be limited, as only so much of the emulsion can
physically coat onto the substrate particles without falling off.
Thus in such embodiments, an application of the water-absorbing
polymer in powdered form, in addition to the application of a
water-absorbing polymer in an emulsion, can increase the
water-absorbing polymer content on the substrate surface (relative
to a single application of the water-absorbing polymer in emulsion
form), which can result in advantageous self-suspending proppant
performance, such as an enhanced salt water tolerance, and/or an
enhanced suspension ability. Further, this increase in the
water-absorbing polymer content on the substrate surface (relative
to a single application of the water-absorbing polymer in emulsion
form) can be achieved in a production efficient manner, e.g.,
utilizing a single vessel and a single drying and/or crosslinking
step (e.g., via heat exposure).
Methods for Forming Self-Suspending Proppant Particles: Addition of
a Flowing Agent
[0185] In various embodiments, once the polymer-coated substrate
particles are dried thereby forming the self-suspending proppant
particles, a flowing agent may be added to the self-suspending
proppant particles to aid in handling and distribution of the
self-suspending proppant particles in humid environments. In
embodiments, the flowing agent can include fumed silica, sodium
aluminosilicate, potassium aluminosilicate, calcium
aluminosilicate, synthetic zeolites, natural zeolites, or a
combination thereof. In one embodiment, the flowing agent can
include a synthetic sodium aluminosilicate zeolite. In certain
embodiments, other commercially available flowing agents can be
used. A non-limiting list of other commercially available flowing
agents includes potassium aluminum silicate, silicon dioxide,
calcium silicate, and powdered cellulose.
[0186] In embodiments, at least about 0.05 wt. % flowing agent
relative to the weight of self-suspending proppant particles can be
mixed with or added to the self-suspending proppant particles, at
least about 0.1 wt. %, at least about 0.25 wt. %, at least about
0.5 wt. %, at least about 0.75 wt. %, or at least about 1 wt. %,
and/or less than about 5 wt. %, less than about 4 wt. %, less than
about 3 wt. %, or less than about 2 wt. %. In certain embodiments,
about 0.1 wt. % flowing agent relative to the weight of
self-suspending proppant particles can be added, about 0.25 wt. %,
about 0.5 wt. %, about 0.75 wt. %, about 1 wt. %, about 2 wt. %,
about 3 wt. %, about 4 wt. %, or about 5 wt. %.
Self-Suspending Proppant Particles
[0187] As discussed above, the self-suspending proppant particles
described herein can include a substrate, e.g., sand particle,
having an outer polymeric coating. In embodiments, the outer
polymeric coating can be discontinuous. As used herein a
discontinuous out polymeric coating refers to a polymeric coating
on an outer surface of a substrate (that is or is not coated in
binder) that covers less than about 80% of the surface, less than
about 70%, less than about 60%, less than about 50%, or less than
about 25%. In an alternative embodiment, the outer polymeric
coating can be a continuous outer coating that covers at least
about 50% of the outer surface of the substrate, at least about
60%, at least about 70%, at least about 80%, at least about 90%, at
least about 95%, or at least about 99%.
[0188] In embodiments, the self-suspending proppant particles made
according to the methods described above can include more than one
application of a water-absorbing polymer to form the outer
polymeric coating. In certain embodiments, as discussed above, the
self-suspending proppant particles can include a first
water-absorbing polymer that may be applied to a substrate
particle, or binder-coated substrate particle, and a second
water-absorbing polymer that may be applied to the intermediate
polymer-coated substrate particles.
[0189] In certain embodiments, the combined amount of the first
water-absorbing polymer applied to the binder-coated substrate
particles and the second water-absorbing polymer applied to the
intermediate polymer-coated substrate particles can provide an
outer polymeric coating weight (or coat weight) to the
self-suspending proppant particles of at least about 0.5 wt. % coat
weight, at least about 1.0 wt. %, at least about 1.5 wt. %, at
least about 2.0 wt. %, at least about 2.5 wt. %, or at least about
3.0 wt. %, and/or less than about 7.5 wt. %, less than about 5.0
wt. %, or less than about 4.0 wt. %. As used herein, wt. % coat
weight refers to the ratio of the total weight of the
water-absorbing polymer applied to substrate, to the weight of the
substrate, multiplied by 100.
[0190] In certain embodiments, depending on the application of a
binder and one or more water-absorbing polymers, the outer
polymeric coating of the self-suspending proppant particles can
include glycerol, mineral oil, one or more water-absorbing
polymers, or a mixture thereof. In such embodiments, the
water-absorbing polymers can comprise, consist essentially of, or
consist of one or more linear polyacrylamides. In certain
embodiments, the one or more linear polyacrylamides can include two
linear polyacrylamides having different molecular weights and/or
different mol. % anionic charges.
[0191] In one or more embodiments, depending on the application of
a binder and one or more water-absorbing polymers, the outer
polymeric coating of the self-suspending proppant particles can
include glycerol, mineral oil, one or more water-absorbing
polymers, or a mixture thereof. In such embodiments, the
water-absorbing polymers can comprise, consist essentially of, or
consist of one or more of polyacrylamides, polyacrylates, or
co-polymers of acrylate monomers and acrylamide monomers.
[0192] In various embodiments, the first and second water absorbing
polymers can be different from one another. For example, in one
embodiment, the first and second water absorbing polymers can be
different polyacrylamide polymers of different molecular weights.
In such an embodiment, the second water-absorbing polymer, e.g.,
polyacrylamide polymer, may have a higher molecular weight than
that of the first water-absorbing polymer, e.g., a polyacrylamide
polymer.
[0193] In certain embodiments, the first and second water-absorbing
polymers can be different types of polymers, or similar types of
polymers with different properties. For example, the first and
second water-absorbing polymers can be the same types of polymers,
e.g., polyacrylamides, but one may be a linear, non-cross-linked
polymer, and the other polymer may be cross-linked. In another
example, the first and second water-absorbing polymers can be
different types of polymers, such as one being a polyacrylamide and
the other being a polyacrylate or co-polymer of acrylate and
acrylamide.
[0194] In embodiments, the ability to vary the types or properties
of the water-absorbing polymers applied to the substrate can impart
various beneficial properties to the self-suspending proppant
particles. For example, in certain embodiments, by using a
cross-linked water-absorbing polymer for at least one of the
water-absorbing polymers in the outer polymeric coating one can
increase the ability for such a self-suspending proppant particle
to remain suspending in brackish water conditions that may be found
in various wells.
[0195] In one embodiment, a self-suspending proppant having a first
water-absorbing polymer comprising linear polyacrylamide (which may
be applied via a water-in-oil emulsion) and a second
water-absorbing polymer comprising a crosslinked polymer, such as
crosslinked polyacrylate or a crosslinked co-polymer of acrylamide
and acrylate (which may be applied by to the substrate in powdered
form) can greatly increase the suspension of the proppant in
various types of salt or brackish water.
[0196] In another embodiment, a self-suspending proppant having a
first water-absorbing polymer comprising a first linear
polyacrylamide and a second water-absorbing polymer comprising a
second linear polyacrylamide that is different from the first
linear polyacrylamide, or is applied to the substrate differently
than the first linear polyacrylamide, can greatly increase the
suspension of the proppant in various types of salt or brackish
water.
[0197] In one or more embodiments, the self-suspending proppants
made as described herein may remain suspended in a 1000 ppm CaCO3
aqueous solution for at least 30 minutes, at least 60 minutes, at
least 90 minutes, or at least 120 minutes, at room temperature or,
alternatively at a temperature of 170.degree. F., after adding the
self-suspending proppant particles to the salt solution and shaking
to incorporate.
[0198] In certain embodiments, a breaker, such as ammonium
persulfate or sodium chlorite, may be present at varying levels in
a suspension test, such as that described above. The addition of a
breaker may be utilized to determine if the proppant will become
suspended, or if already suspended, to determine if the suspended
proppant can be "broken" (and settle out). In embodiments, the
breaker may be present in an amount of from 1-100 pounds per
thousand gallons.
[0199] In certain embodiments, by varying the types and/or
properties of the first and second water-absorbing polymers
utilized in forming the self-suspending proppant particles one may
be able to tailor a particular type of self-suspending proppant
particle for a particular type of water, such as water containing
cations, chlorine, iron, or other ionic components.
[0200] The concepts discussed herein will be further described in
the following examples, which do not limit the scope of various
embodiments described in the claims.
EXAMPLES
Example 1: Effect of Various Brackish Well Waters on Specific
Self-Suspending Proppants
[0201] In this Example, various self-suspending proppants were made
and analyzed for their ability to remain suspending in various
brackish water samples from fracking wells. Each of the proppants
tested in this method have been made according to the methods
described above. For example, frac sand (40-70 mesh frac sand,
unless otherwise noted below) was added to a mixing device, e.g., a
kitchen mixer, and 0.20 wt. % glycerol was added and allowed to mix
for two to three minutes. Then a water-in-oil emulsion containing a
linear polyacrylamide was added and allowed to mix for two to three
minutes, followed by the addition of another linear polyacrylamide
in powder form, which was mixed in for a period of two to three
minutes. The amounts of water-in-oil emulsion and powdered linear
polyacrylamide that were added in the various samples are provided
below in Table 1. The proppants were then dried at about
230.degree. F. for 15-20 minutes in an electric frying pan.
TABLE-US-00001 TABLE 1 Water-absorbing polymers components in
self-suspending proppant samples Amount of Water- Powdered
absorbing polyacrylamide polymer Amount of (Hyperfloc .RTM. AF coat
weight emulsion 308 product) Sample (wt. %)* Emulsion (wt. %) (wt.
%) A 1.5 Hyperfloc .RTM. 3.33 0.5 AE 873H B 2.0 Hyperfloc .RTM.
3.33 1.0 AE 853H C 2.5 Hyperfloc .RTM. 3.33 1.5 (30-50 mesh AE 853H
frac sand) D 2.0 Hyperfloc .RTM. 3.33 1.16 AE 852H E 1.5 Hyperfloc
.RTM. 2.0 0.5 AE 859H F 1.5 Hyperfloc .RTM. 3.33 0.66 AE 872H *wt.
% of coat weight refers to the ratio of the weight of the water
absorbing polymer added (from both the emulsion and the powdered
polyacrylamide) to the weight of the frac sand, multiplied by 100.
The weight of water absorbing polymer from the emulsion was
determined based on the weight percent of polyacrylamide in the
emulsion. The emulsion and powdered polyacrylamide were obtained
from SNF.
[0202] 11.88 grams of each of the self-suspending proppants were
added to 45 mL of various test waters in a 50 mL tube (2.2 ppg),
capped, and then shaken by hand vigorously for thirty seconds. The
shaken tubes were observed over time the settling of the
self-suspending proppants. The results appear below in Tables
2-4.
TABLE-US-00002 TABLE 2 Suspension results in brackish well water
sample #1 Well water sample #1: 11.73 mS conductivity and pH of
8.34 First Second Third Fourth Fifth reading: reading: reading:
reading: reading: Time and Time and Time and Time and Time and
Suspension Suspension Suspension Suspension Suspension Sample
Level* Level* Level* Level* Level* A 0 min. - 100% 5 min. - 18 min.
- 60 min. - 120 min. - (6 mL) 37 mL 42 mL 43 mL 44 mL B 0 min. -
100% 5 min. - 10 min. - 47 min. - 107 min. - (6 mL) 22 mL 25 mL 27
mL 28 mL C 0 min. - 100% 58 min. - n/a n/a n/a (6 mL) 28 mL D 0
min. - 100% 5 min. - 10 min. - 42 min. - 102 min. - (6 mL) 20 mL 25
mL 28 mL 33.5 mL E 0 min. - 100% 5 min. - 37 min. - 97 min. - n/a
(6 mL) 31 mL 34 mL 35 mL F 0 min. - 100% 32 min. - 92 min. - n/a
n/a (6 mL) 45 mL 46 mL *Suspension level was visually determined
based on the position of the top of the suspended proppants in the
brackish well water sample #1. For example, 100% suspended refers
to seeing no settled proppant and the position of the top of the
suspended proppants is approximately at the 6 mL level, as
determined based on the graduations on the tube. 28 mL is
determined to be 50% suspended.
TABLE-US-00003 TABLE 3 Suspension results in brackish well water
sample #2 Well water sample #2: 1024 .mu.S conductivity and pH of
7.83 First Second Third Fourth reading: reading: reading: reading:
Time and Time and Time and Time and Suspension Suspension
Suspension Suspension Sample Level* Level* Level* Level* A 0 min. -
100% 44 min. - 18 min. - 60 min. - (6 mL) 10 mL 42 mL 43 mL B 0
min. - 100% 5 min. - 49 min. - n/a (6 mL) 6 mL 7 mL C 0 min. - 100%
7 min. - 63 min. - n/a (6 mL) 1 mL 15 mL D 0 min. - 100% 5 min. -
53 min. - n/a (6 mL) 6 mL 7 mL E 0 min. - 100% 5 min. - 12 min. -
60 min. - (6 mL) 8 mL 11 mL 28 mL F 0 min. - 100% 4 min. - 11 min.
- 64 min. - (6 mL) 30 mL 33 mL 41 mL *Suspension level was visually
determined based on the position of the top of the suspended
proppants in the brackish well water sample #2. For example, 100%
suspended refers to seeing no settled proppant and the position of
the top of the suspended proppants is approximately at the 6 mL
level, as determined based on the graduations on the tube. 28 mL is
determined to be 50% suspended.
TABLE-US-00004 TABLE 4 Suspension results in brackish well water
sample #3 Well water sample #2: 3.62 mS conductivity and pH of 8.27
First Second Third Fourth reading: reading: reading: reading: Time
and Time and Time and Time and Suspension Suspension Suspension
Suspension Sample Level* Level* Level* Level* C 0 min. - 100% 3
min. - 24 min. - 92 min. - (6 mL) 21 mL 21 mL 26 mL *Suspension
level was visually determined based on the position of the top of
the suspended proppants in the brackish well water sample #3. For
example, 100% suspended refers to seeing no settled proppant and
the position of the top of the suspended proppants is approximately
at the 6 mL level, as determined based on the graduations on the
tube. 28 mL is determined to be 50% suspended.
TABLE-US-00005 TABLE 5 Suspension results in fresh water sample
Fresh water sample: 2.43 mS conductivity and pH of 8.05 First
reading: Second reading: Third reading: Time and Time and Time and
Suspension Suspension Suspension Sample Level* Level* Level* C 0
min. - 100% 21 min. - 90 min. - (6 mL) 16 mL 24 mL *Suspension
level was visually determined based on the position of the top of
the suspended proppants in the fresh water sample. For example,
100% suspended refers to seeing no settled proppant and the
position of the top of the suspended proppants is approximately at
the 6 mL level, as determined based on the graduations on the tube.
28 mL is determined to be 50% suspended.
[0203] As can be seen in the above results, Samples B and C, which
included the same water-absorbing polymers, just with varying coat
weight, unexpectedly appeared suspended longer than the other
samples (aside from Sample D). For example in brackish water
samples #1 and #2, at least 50% of Sample B and C were suspended
after about one hour subsequent to shaking. Further, Sample C
performed equally as well in brackish water sample #3 and the fresh
water sample. In any of the four water samples tested, Sample C was
not observed to be less than 50% suspended within the observed
timeframe. Although Sample D stayed almost 100% suspended in
brackish water sample #2 about 60 minutes after shaking, the same
sample was observed to be less than 50% suspended in brackish water
sample #1 after about 102 minutes.
Example 2: Self-Suspending Proppants in 1000 ppm CaCO.sub.3
[0204] In this Example, the suspension of various self-suspending
proppants were analyzed in 1000 ppm CaCO.sub.3. In this Example two
main samples were utilized, a self-suspending proppant having a
cross-linked water-absorbing polymer and another self-suspending
proppant with only linear water-absorbing polymers. The
self-suspending proppant having only linear water-absorbing
polymers was made as described in Example 1 with reference to
Sample B.
[0205] For the self-suspending proppant having a cross-linked
water-absorbing polymer, frac sand (40-70 mesh) was added to a
mixing device, a kitchen mixer, and 0.26 wt. % glycerol was added
and allowed to mix for less than two minutes. Then 0.45 wt. % SNF
Hyperfloc.RTM. AE 873H linear polyacrylamide emulsion was added and
allowed to mix for two to three minutes, followed by the addition
of 2 wt. % of an acrylamide and potassium acrylate co-polymer,
cross-linked (Evonik Industries Stockosorb.RTM. S 18G) in powder
form, which was mixed in over a period of about five minutes. Next
an additional 0.45 wt. % SNF Hyperfloc.RTM. AE 873H linear
polyacrylamide emulsion was added and allowed to mix for two to
three minutes. The proppants were then dried at 200.degree. F. for
30 minutes in a conventional oven and 0.5 wt. % fumed silica was
added.
[0206] Approximately the same amount of proppants were added to
separate vials containing a 1000 ppm CaCO.sub.3 solution and shaken
vigorously for thirty seconds and allowed to sit in an oven at a
temperature of 170.degree. F. for 75 minutes. An additional vial
contained the linear polyacrylamide self-suspending proppant and
the same 1000 ppm CaCO.sub.3 solution along with a breaker and was
treated similarly. After 75 minutes at 170.degree. F., both
self-suspending proppants remained suspended in the brackish
conditions. In addition, the vial containing the linear
polyacrylamide self-suspending proppant and the breaker settled
out, suggesting that such an outer polymeric coating can be
"broken" with a breaker to settle out the proppant. The
cross-linked self-suspending proppant was not exposed to the
breaker.
Example 3: Effects of Various Flowing Agents on Self-Suspending
Proppants in Humid Conditions
[0207] In this Example, various flowing agents were tested with a
self-suspending proppant in humid conditions to test for
flowability and water absorption. Table 6 below lists the various
self-suspending proppant samples and the various flow
treatments.
TABLE-US-00006 TABLE 6 Flowability Test Proppant Samples Base Sand
Coating Flow Agent Mix sand Sample (mesh) Mixture Drying Profile
Flow Agent (wt. %) (wt. %) A 30/50 A-1.5% 220.degree. F.-15 min
None -- 40/70-10% B 30/50 A-1.5% 220.degree. F.-15 min E-554 0.50%
-- C 40/70 A-1.5% 220.degree. F.-15 min DFC 0.17% -- D 40/70 A-1.5%
None E-554 0.50% -- E 40/70 A-1.5% 220.degree. F.-15 min Whey 1.00%
-- F 30/50 A-1.5% 220.degree. F.-15 min WPC 34 1.00% -- G 30/50
A-1.5% None Whey 1.00% -- H 40/70 A-1.5% None WPC 34 1.00% -- I
40/70 A-1.5% None E-554 1.00% -- J 40/70 A-1.5% None E-554 2.00% --
K 30/50 A-1.5% 220.degree. F.-15 min None -- -- L 30/50 A-1.5%
220.degree. F.-15 min E-554 1.00% -- M 40/70 A-1.5% 220.degree.
F.-15 min DFC 0.12% -- N 40/70 A-1.5% 220.degree. F.-15 min Whey
1.50% -- O 40/70 A-1.5% 220.degree. F.-15 min WPC 34 1.50% -- P
40/70 A-1.5% 220.degree. F.-15 min F 0.10% -- Q 40/70 A-1.5%
220.degree. F.-15 min F 0.15% -- R 40/70 A-1.5% None None -- --
[0208] The proppant samples listed in Table 6 were prepared as
described above with respect to sample A of Table 1 in Example 1 to
give a coated sand with a 1.5% by weight outer polymeric coating.
The same polyacrylamides utilized in sample A of Table 1 in Example
1 were utilized. However, the drying protocol differed as described
in Table 6, for example some of the samples were dried with a
standard temperature profile, while some were not heat treated.
Some of the samples were treated with a flow agent product, as
listed in Table 6. Some of the samples were mixed with uncoated
sand. The "E-554 (Zeolex 23A)" flow agent is Aerosil R202 fumed
silica purchased from Evonik Corporation. The "WPC 34" is a whey
protein concentrate at 34% that is commercially available. The
"whey" is commercially available. DFC is a proprietary coating
utilized to provide a dust-free frac sand.
[0209] First, the various proppant samples were exposed to a
humidity chamber. Specifically, the samples prepared as in Table 6
were added to an open vial and weighed. Then, the vials were
exposed to 85% relative humidity at 90.degree. F. for 15 minutes
and weighed thereafter. The temperature and humidity were verified
by sensor recordings. The results are listed in Table 7 below.
TABLE-US-00007 TABLE 7 Humidity Testing in vials Weight when
Pre-Trial Post-Trial Trial Weight Sample prepared (g) Weight (g)
Weight (g) Gain (g) A 41.23 41.23 41.24 0.01 B 42.94 42.93 42.95
0.02 C 39.52 39.52 39.53 0.01 D 35.82 35.81 35.81 0 E 41.95 41.94
41.95 0.01 F 42.3 42.29 42.31 0.02 G 31.91 31.92 31.92 0 H 30.56
30.57 30.56 -0.01 I 36.74 36.74 36.74 0 J 39.63 39.62 39.63 0.01 K
40.65 40.65 40.65 0 L 41.05 41.04 41.06 0.02 M 43.13 43.11 43.11 0
N 41.61 41.6 41.62 0.02 O 39.02 39.02 39.04 0.02 P 38.01 38.02
38.02 0 Q 37.88 37.88 37.9 0.02 R 29.95 29.9 29.9 0
[0210] Next, the samples exposed to the humidity chamber as above
were tested for their ability to flow out of a vial. Specifically,
each sample vial was emptied into the Petri dish. The number of
shakes/taps of the upside-down vial required to empty the sand from
the vial to the Petri dish were recorded. Each time further
agitation is required to break up vial sand clumps add 25
shakes/taps to the count. If the equivalent of 100 or more shakes
are required, record 100 shakes/taps and empty the remaining
contents into the Petri Dish by any means. If a surface clump was
formed on the top exposed surface of the vial, record the relative
size of the surface clump. The level of bulk clumping visible in
each sample, and whether the sand of the sample is uniformly
sticking together was recorded. The results appear in Table 8 below
and FIG. 12 shows the images of the petri dishes.
TABLE-US-00008 TABLE 8 Flow testing from vials Shake/Tap Surface
Sample Scale Clump Bulk Sticky A 5 Medium B 5 Medium C 10 Medium
Small D 1 Small E 5 Medium F 2 G 100 Bulk Large Yes H 75 Bulk Large
Yes I 0 J 0 K 3 Small Small L 1 M 0 Small N 2 Large O 8 Large Small
P 1 Small Q 1 Small R 100 Bulk Large Yes
[0211] Next the petri dishes from FIG. 12 containing the samples
A-R, were subjected to the humidity chamber again, this time for 60
minutes at 90.degree. F. with 85% relative humidity. The
temperature and humidity were verified by sensor recordings. The
petri dishes were weighed before and after this humidity chamber
exposure. The results are listed in Table 9 below.
TABLE-US-00009 TABLE 9 Humidity testing in petri dish Pre-Trial
Post-Trial Trial Weight Sample Weight (g) Weight (g) Gain (g) A
40.62 40.88 0.26 B 42.29 42.55 0.26 C 38.87 39.1 0.23 D 35.12 35.17
0.05 E 41.36 41.65 0.29 F 41.64 41.93 0.29 G 31.18 31.22 0.04 H
29.91 29.92 0.01 I 36.04 36.1 0.06 J 38.93 38.99 0.06 K 39.97 40.16
0.19 L 40.23 40.51 0.28 M 42.22 42.49 0.27 N 40.84 41.13 0.29 O
38.4 38.66 0.26 P 37.28 37.52 0.24 Q 37.07 37.31 0.24 R 28.55 28.52
-0.03
[0212] The samples in the petri dish were dumped over onto white
pieces of paper and are shown in FIG. 13.
[0213] Next the samples on the white pieces of paper were evaluated
for flowability by being transferred back to their original vials
using a plastic funnel. Specifically, an empty funnel was placed
into the sample's original sample vial and the sand sample was slid
off the paper into the sample funnel. The funnel was shaken
vertically 15 times to break up the sand sample in an attempt to
have the sand gravity flow into the sample vial. If the humidified
sand sample formed a Petri dished shaped clump when slid into the
funnel, it was noted how easily the clump breaks up when during the
shaking. Further, it was noted how easily the sample sand flowed
into the vial from the funnel once the initial clump was broken up
(if present). The approximate fill volume of sample sand that was
returned to each of the original sample vials was recorded. The
overall flow and transfer of humid sand was scored according to the
following Table 10 and the results are listed in Table 11.
TABLE-US-00010 TABLE 10 Scoring for the flow transfer return to
vials Points Scored Clump Breakage Funnel Flow Vial Fill 20 No
Clump 15 Very Easy Very Easy 90-110% 10 Easy Easy 75-90% 5 Slightly
Difficult Slightly Difficult 50-75% 2 Difficult Difficult 25-50% 1
Very Difficult Very Difficult <25% 0 No Breakage No Flow 0%
TABLE-US-00011 TABLE 11 Flow transfer return from vials Funnel
Loading Sample Clump Breakage Flow Vial Fill Score I No Clump Very
easy 90-110% 50 J No Clump Very easy 90-110% 50 D No Clump Easy
90-110% 45 B Very Easy Easy 90-110% 40 L Very Easy Easy 90-110% 40
P Very Easy Easy 90-110% 40 Q Very Easy Easy 90-110% 40 K Easy
Difficult 50-75%.sup. 17 O Slightly Difficult Difficult 50-75%.sup.
12 A Difficult Difficult <25% 5 E Difficult Difficult <25% 5
F Difficult Difficult <25% 5 M Difficult Difficult <25% 5 N
Difficult Difficult <25% 5 C Very Difficult Very Difficult
<25% 3 G Very Difficult Very Difficult <25% 3 H Very
Difficult Very Difficult <25% 3 R Very Difficult Very Difficult
<25% 3
[0214] Based on the above results from Tables 7-11 a humidity and
flow correlation analysis was performed, which is shown in Table
12.
TABLE-US-00012 TABLE 12 Mixture variation performance analysis
Drying Profile 220.degree. F.-15 min None Flow Weight Tap Flow
Weight Tap Score Gain Scale Score Gain Scale Flow Agents AVG AVG
AVG AVG AVG AVG E-554 40.0 0.79% 3 48.3 0.19% 0 Sample B 40.0 0.74%
5 Sample D 45.0 0.18% 1 Sample I 50.0 0.21% 0 Sample J 50.0 0.19% 0
Sample L 40.0 0.84% 1 F 40.0 0.80% 1 Sample P 40.0 0.79% 1 Sample Q
40.0 0.80% 1 None 11.0 0.67% 4 3.0 -0.14% 100 Sample A 5.0 0.77% 5
Sample K 17.0 0.58% 3 Sample R 3.0 -0.14% 100 WPC 34 8.5 0.83% 5
3.0 0.04% 75 Sample F 5.0 0.84% 2 Sample H 3.0 0.04% 75 Sample O
12.0 0.83% 8 Whey 5.0 0.85% 4 3.0 0.17% 100 Sample E 5.0 0.84% 5
Sample G 3.0 0.17% 100 Sample N 5.0 0.86% 2 DFC 4.0 0.74% 5 Sample
C 3.0 0.72% 10 Sample M 5.0 0.77% 0 Grand Total 18.1 0.78% 4 25.7
0.11% 46
[0215] Next various samples were subjected to centrifugal settling.
The proppant samples are listed below in Table 13. The samples were
made as discussed above with respect to the samples in Table 6.
TABLE-US-00013 TABLE 13 Proppant samples for centrifugal
compression Flow Agent Added (% by weight) Sample ID Base
Preparation E-554 - sodium aluminosilicate W 40/70, A-1.5% coat
0.5% weight, Undried X 40/70, A-1.5% coat 1.0% weight, Undried V
40/70, A-1.5% coat 2.0% weight, Undried
[0216] For each of the above samples, a 2.1 g standard method
sample was prepared of 40/70 mesh dried sand coated with the
standard polymer mixture, dried using the standard temperature
profile, and 0.1% weight percent of Product F (fumed silica)
added.
[0217] 2.1 g of each of samples W, X, and V (and the standard
samples) was hydrated, by placing it in 8 ml of water inside its
own 15 ml centrifuge tube. Each tube was then shaken vigorously to
mix the proppant and water mixture and then centrifuged at a low
speed for 2-5 minutes. A speed a 13% was used for this testing. The
centrifuge was an IEC International Centrifuge Model HT. This
centrifuge did not have working instrumentation to show its
rotational speed. According to associated literature, the model
centrifuge should have a maximum speed of 17,000 RPM and generate a
relative centrifugal force of 34375. After spinning at 20% speed
the rotor RPM was tested with a separate instrument which gave a
value of 3300 RPM. This is consistent with a maximum 100% speed of
17,000 RPM. After centrifuging, the samples were removed and the
settling of the materials was compared.
[0218] No difference in settling was noted in the samples spun for
5 minutes. The Sample X spun for 3 minutes showed slightly less
settling than the standard method sample. The undried samples with
the sodium aluminosilicate had more opaque gel layer than that of
the standard samples.
[0219] Finally, another centrifugal compression test was performed.
The samples for this test were prepared according to the below
Table 14.
TABLE-US-00014 TABLE 14 Centrifuge compression samples Flow Base
Sand Coating Drying Flow Agent Taps to Sample (mesh) Mixture
Profile Agent Amount Mix Sand Remove B 30/50 A-1.5% 220.degree.
F.-15 min E-554 0.50% 1 I 40/70 A-1.5% None E-554 1.00% 9 K 30/50
A-1.5% 220.degree. F.-15 min None 40/70-20% 0 Q 40/70 A-1.5%
220.degree. F.-15 min F 0.15% 3
[0220] The samples were prepared as indicated in the Table 14 and
according to the procedures set out with respect to Table 6. In
this test, 5 ml of each sample proppant was placed into a 15 ml
centrifuge tube and centrifuged at a medium or high speed for about
5 minutes (for centrifuge force see the above description with
respect to Table 13). The samples were removed and the compaction
of the materials was compared. The samples were removed by slowly
inverting the centrifuge tube above a white paper. If some
compressed sand was stuck in the centrifuge tube, the tube was
lightly tapped on the table until the sand was removed. Any
required taps are recorded in the above Table 14. FIGS. 13A and 13B
show the results of the initial dump (FIG. 13A) and the sand fully
removed after tapping (FIG. 13B).
[0221] In view of these results of Example 3, the flowing agent
that worked the best to promote flowability of the coated sand when
exposed to high humidity environments is the sodium aluminosilicate
(E-554). Unlike the fumed silica samples, the sodium
aluminosilicate-containing samples showed unexpectedly beneficial
properties, such as having coated sand product flowability even
when added to product that was not heat treated with a drying
process.
[0222] The amount of water vapor absorbed by the coated sand
mixtures was not changed significantly by the flowing agents added.
If the coated sand was not heat treated by drying after coating, it
didn't absorb as much moisture in the humid environment. When
exposed to an environment of 90.degree. F. and 85% relative
humidity for 60 minutes the undried samples increased weight an
average of 0.1% compared to an average weight increase of 0.8% for
the dried samples.
[0223] The present invention may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative, and not restrictive. The scope
of the invention is, therefore, indicated by the appended claims,
rather than by the foregoing description. All changes which come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
* * * * *