Efficient placement technology of proppants based on structural stabilizers

Fiber is highly escapable in conventional slickwater,making it difficult to form fiber-proppant agglomerate with proppant and exhibit limited effectiveness.To solve these problems,a novel structure stabilizer(SS)is developed.Through microscopic structural observations and performance evaluations in indoor experiments,the mechanism of proppant placement under the action of the SS and the effects of the SS on proppant placement dimensions and fracture conductivity were elucidated.The SS facilitates the formation of robust fiber-proppant agglomerates by polymer,fiber,and quartz sand.Compared to bare proppants,these agglomerates exhibit reduced density,increased volume,and enlarged contact area with the fluid during settlement,leading to heightened buoyancy and drag forces,ultimately resulting in slower settling velocities and enhanced transportability into deeper regions of the fracture.Co-injecting the fiber and the SS alongside the proppant into the reservoir effectively reduces the fiber escape rate,increases the proppant volume in the slickwater,and boosts the proppant placement height,conveyance distance and fracture conductivity,while also decreasing the proppant backflow.Experimental results indicate an optimal SS mass fraction of 0.3%.The application of this SS in over 80 wells targeting tight gas,shale oil,and shale gas reservoirs has substantiated its strong adaptability and general suitability for meeting the production enhancement,cost reduction,and sand control requirements of such wells.

Factors Influencing Proppant Transportation and Hydraulic Fracture Conductivity in Deep Coal Methane Reservoirs

The gas production of deep coalbed methane wells in Linxing-Shenfu block decreases rapidly,the water output is high,the supporting effect is poor,the effective supporting fracture size is limited,and the migration mechanism of proppant in deep coal reservoir is not clear at present.To investigate the migration behavior of proppants in complex fractures during the volume reconstruction of deep coal and rock reservoirs,an optimization test on the conductivity of low-density proppants and simulations of proppant migration in complex fractures of deep coal reservoirs were conducted.The study systematically analyzed the impact of various fracture geometries,proppant types and fracturingfluid viscosities on proppant distribution.Furthermore,the study compared the outcomes of dynamic proppant transport experiments with simulation results.The results show that the numerical simulation is consistent with the results of the proppant dynamic sand-carrying experiment.Under the conditions of low viscosity and large pumping-rate,a high ratio of 40/70 mesh proppant can facilitate the movement of the proppant to the depths of fractures at all levels.The technical goal is to create comprehensive fracture support within intricate trapezoidal fractures in deep coal and rock reservoirs without inducing sand plugging.The sand ratio is controlled at 15%–20%,with a proppant combination ratio of 40/70:30/50:20/40=6:3:1.Proppant pumping operations can effectively address the issue of poor support in complex fractures in deep coal formations.The research results have been successfully applied to the development of deep coalbed methane in the Linxing-Shenfu block,Ordos Basin.

Evaluating the stability and volumetric flowback rate of proppant packs in hydraulic fractures using the lattice Boltzmann-discrete element coupling method

The stability and mobility of proppant packs in hydraulic fractures during hydrocarbon production are numerically investigated by the lattice Boltzmann-discrete element coupling method(LB-DEM).This study starts with a preliminary proppant settling test,from which a solid volume fraction of 0.575 is calibrated for the proppant pack in the fracture.In the established workflow to investigate proppant flowback,a displacement is applied to the fracture surfaces to compact the generated proppant pack as well as further mimicking proppant embedment under closure stress.When a pressure gradient is applied to drive the fluid-particle flow,a critical aperture-to-diameter ratio of 4 is observed,above which the proppant pack would collapse.The results also show that the volumetric proppant flowback rate increases quadratically with the fracture aperture,while a linear variation between the particle flux and the pressure gradient is exhibited for a fixed fracture aperture.The research outcome contributes towards an improved understanding of proppant flowback in hydraulic fractures,which also supports an optimised proppant size selection for hydraulic fracturing operations.

Impacts of proppant distribution on development of tight oil reservoirs with threshold pressure gradient

Field evidence indicates that proppant distribution and threshold pressure gradient have great impacts on well productivity.Aiming at the development of unconventional oil reservoirs in Triassic Chang-7 Unit,Ordos Basin of China,we presented an integrated workflow to investigate how(1)proppant placement in induced fracture and(2)non-linear flow in reservoir matrix would affect well productivity and fluid flow in the reservoir.Compared with our research before(Yue et al.,2020),here we extended this study into the development of multi-stage fractured horizontal wells(MFHWs)with large-scale complicated fracture geometry.The integrated workflow is based on the finite element method and consists of simulation models for proppant-laden fluid flow,fracture flow,and non-linear seepage flow,respectively.Simulation results indicate that the distribution of proppant inside the induced cracks significantly affects the productivity of the MFHW.When we assign an idealized proppant distribution instead of the real distribution,there will be an overestimation of 44.98%in daily oil rate and 30.63%in cumulative oil production after continuous development of 1000 days.Besides,threshold pressure gradient(TPG)also significantly affects the well performance in tight oil reservoirs.If we simply apply linear Darcy’s law to the reservoir matrix,the overall cumulative oil production can be overrated by 77%after 1000 days of development.In general,this research provides new insights into the development of tight oil reservoirs with TPG and meanwhile reveals the significance of proppant distribution and non-linear fluid flow in the production scenario design.

Characteristics of proppant transport and placement within rough hydraulic fractures

A three-dimensional reconstruction of rough fracture surfaces of hydraulically fractured rock outcrops is carried out by casting process,a large-scale experimental setup for visualizing rough fractures is built to perform proppant transport experiments.The typical characteristics of proppant transport and placement in rough fractures and its intrinsic mechanisms are investigated,and the influences of fracture inclination,fracture width and fracturing fluid viscosity on proppant transport and placement in rough fractures are analyzed.The results show that the rough fractures cause variations in the shape of the flow channel and the fluid flow pattern,resulting in the bridging buildup during proppant transport to form unfilled zone,the emergence of multiple complex flow patterns such as channeling,reverse flow and bypassing of sand-carrying fluid,and the influence on the stability of the sand dune.The proppant has a higher placement rate in inclined rough fractures,with a maximum increase of 22.16 percentage points in the experiments compared to vertical fractures,but exhibits poor stability of the sand dune.Reduced fracture width aggravates the bridging of proppant and induces higher pumping pressure.Increasing the viscosity of the fracturing fluid can weaken the proppant bridging phenomenon caused by the rough fractures.

A novel dandelion-based bionic proppant and its transportation mechanism in different types of fractures

Low-permeability reservoirs are generally characterized by low porosity and low permeability.Obtaining high production using the traditional method is technologically challenging because it yields a low reservoir recovery factor.In recent years,hydraulic fracturing technology is widely applied for efficiently exploiting and developing low-permeability reservoirs using a low-viscosity fluid as a fracturing fluid.However,the transportation of the proppant is inefficient in the low-viscosity fluid,and the proppant has a low piling-up height in fracture channels.These key challenges restrict the fluid(natural gas or oil)flow in fracture channels and their functional flow areas,reducing the profits of hydrocarbon exploitation.This study aimed to explore and develop a novel dandelion-bionic proppant by modifying the surface of the proppant and the fiber.Its structure was similar to that of dandelion seeds,and it had high transport and stacking efficiency in low-viscosity liquids compared with the traditional proppant.Moreover,the transportation efficiency of this newly developed proppant was investigated experimentally using six different types of fracture models(tortuous fracture model,rough fracture model,narrow fracture model,complex fracture model,large-scale single fracture model,and small-scale single fracture model).Experimental results indicated that,compared with the traditional proppant,the transportation efficiency and the packing area of the dandelion-based bionic proppant significantly improved in tap water or low-viscosity fluid.Compared with the traditional proppant,the dandelionbased bionic proppant had 0.1-4 times longer transportation length,0.3-5 times higher piling-up height,and 2-10 times larger placement area.The newly developed proppant also had some other extraordinary features.The tortuosity of the fracture did not influence the transportation of the novel proppant.This proppant could easily enter the branch fracture and narrow fracture with a high packing area in rough surface fractures.Based on the aforementioned characteristics,this novel proppant technique could improve the proppant transportation efficiency in the low-viscosity fracturing fluid and increase the ability of the proppant to enter the secondary fracture.This study might provide a new solution for effectively exploiting low-permeability hydrocarbon reservoirs.

Thermal conductive proppant with self-suspension ability

The in situ mining technology is applied to the exploitation of medium-and low-maturity shale oil,which can use heaters to warm up the oil shale formations and pyrolyze the kerogen.Due to the low thermal conductivity of oil shale,electric heaters need extra equipment to improve heat transfer efficiency.In this study,a thermally conductive proppant is fabricated by coating epoxy-resin and graphite on ceramic proppants for the first time,which could support the fracturing crack and transfer heat.The thermal conduction property of epoxy-resin and graphite coated proppants(EGPs)is 245%higher than that of uncoated proppants,which can transfer more heat to the oil shale formation and accelerate the conversion of kerogen.The adhesive property of EGPs is improved by 47.9%under the load force of 1500 nN,which prolongs the time for the fracture to close.In summary,this novel proppant is expected to assist in-situ mining technology in the production of medium and low-maturity shale oil.

Modeling of Crack Development Associated with Proppant Hydraulic Fracturing in a Clay-Carbonate Oil Deposit

Survey and novel research data are used in the present study to classify/identify the lithological type of Verey age reservoirs’rocks.It is shown how the use of X-ray tomography can clarify the degree of heterogeneity,porosity and permeability of these rocks.These data are then used to elaborate a model of hydraulic fracturing.The resulting software can take into account the properties of proppant and breakdown fluid,thermal reservoir conditions,oil properties,well design data and even the filtration and elastic-mechanical properties of the rocks.Calculations of hydraulic fracturing crack formation are carried out and the results are compared with the data on hydraulic fracturing crack at standard conditions.Significant differences in crack formation in standard and lithotype models are determined.It is shown that the average width of the crack development for the lithotype model is 2.3 times higher than that for the standard model.Moreover,the coverage of crack development in height for the lithotype model is almost 2 times less than that for the standard model.The estimated fracture half-length for the lithotype model is 13.3%less than that of for the standard model.A higher dimensionless fracture conductivity is also obtained for the lithotype model.It is concluded that the proposed approach can increase the reliability of hydraulic fracturing crack models.

Fracture propagation,proppant transport and parameter optimization of multi-well pad fracturing treatment

This paper establishes a 3D multi-well pad fracturing numerical model coupled with fracture propagation and proppant migration based on the displacement discontinuity method and Eulerian-Eulerian frameworks,and the fracture propagation and proppant distribution during multi-well fracturing are investigated by taking the actual multi-well pad parameters as an example.Fracture initiation and propagation during multi-well pad fracturing are jointly affected by a variety of stress interference mechanisms such as inter-cluster,inter-stage,and inter-well,and the fracture extension is unbalanced among clusters,asymmetric on both wings,and dipping at heels.Due to the significant influence of fracture morphology and width on the migration capacity of proppant in the fracture,proppant is mainly placed in the area near the wellbore with large fracture width,while a high-concentration sandwash may easily occur in the area with narrow fracture width as a result of quick bridging.On the whole,the proppant placement range is limited.Increasing the well-spacing can reduce the stress interference of adjacent wells and promote the uniform distribution of fractures and proppant on both wings.The maximum stimulated reservoir volume or multi-fracture uniform propagation can be achieved by optimizing the well spacing.Although reducing the perforation-cluster spacing also can improve the stimulated reservoir area,a too low cluster spacing is not conducive to effectively increasing the propped fracture area.Since increasing the stage time lag is beneficial to reduce inter-stage stress interference,zipper fracturing produces more uniform fracture propagation and proppant distribution.

Proppant transport in rough fractures of unconventional oil and gas reservoirs

A method to generate fractures with rough surfaces was proposed according to the fractal interpolation theory.Considering the particle-particle,particle-wall and particle-fluid interactions,a proppant-fracturing fluid two-phase flow model based on computational fluid dynamics(CFD)-discrete element method(DEM)coupling was established.The simulation results were verified with relevant experimental data.It was proved that the model can match transport and accumulation of proppants in rough fractures well.Several cases of numerical simulations were carried out.Compared with proppant transport in smooth flat fractures,bulge on the rough fracture wall affects transport and settlement of proppants significantly in proppant transportation in rough fractures.The higher the roughness of fracture,the faster the settlement of proppant particles near the fracture inlet,the shorter the horizontal transport distance,and the more likely to accumulate near the fracture inlet to form a sand plugging in a short time.Fracture wall roughness could control the migration path of fracturing fluid to a certain degree and change the path of proppant filling in the fracture.On the one hand,the rough wall bulge raises the proppant transport path and the proppants flow out of the fracture,reducing the proppant sweep area.On the other hand,the sand-carrying fluid is prone to change flow direction near the contact point of bulge,thus expanding the proppant sweep area.

Proppant transport law in multi-branched fractures induced by volume fracturing

To further clarify the proppant transport and placement law in multi-branched fractures induced by volume fracturing, proppant transport simulation experiments were performed with different fracture shapes, sand ratios, branched fracture opening time and injection sequence of proppants in varied particle sizes. The results show that the settled proppant height increases and the placement length decreases in main fractures as the fracturing fluid diverts gradually to the branched fractures at different positions. The flow rate in branched fractures is the main factor affecting their filling. The diverion to branched fractures leads to low flow rate and poor filling of far-wellbore branched fractures. The inclined fracture wall exerts a frictional force on the proppant to slow its settlement, thus enhancing the vertical proppant distribution in the fracture. The increase of sand ratio can improve the filling of near-wellbore main fracture and far-wellbore branched fracture and also increase the settled proppant height in main fracture. Due to the limitation of fracture height, when the sand ratio increases to a certain level, the increment of fracture filling decreases. When branched fracture is always open(or extends continuously), the supporting effect on the branched fractures is the best, but the proppant placement length within the main fractures is shorter. The fractures support effect is better when it is first closed and then opened(or extends in late stage) than when it is first opened and then closed(or extends in early stage). Injecting proppants with different particle sizes in a specific sequence can improve the placement lengths of main fracture and branched fracture. Injection of proppants in an ascending order of particle size improves the near-wellbore fracture filling, to a better extent than that in a descending order of particle size.

Crushing and embedment of proppant packs under cyclic loading: An insight to enhanced unconventional oil/gas recovery

Crushing and embedment are two critical downhole proppant degradation mechanisms that lead to a significant drop in production outputs in unconventional oil/gas stimulation projects. These persistent production drops due to the non-linear responses of proppants under reservoir conditions put the future utilization of such advanced stimulation techniques in unconventional energy extraction in doubt. The aim of this study is to address these issues by conducting a comprehensive experimental approach. According to the results, whatever the type of proppant, all proppant packs tend to undergo significant plastic deformation under the first loading cycle.Moreover, the utilization of ceramic proppants(which retain proppant pack porosity up to 75%), larger proppant sizes(which retain proppant pack porosity up to 15.2%) and higher proppant concentrations(which retain proppant pack porosity up to 29.5%) in the fracturing stimulations with higher in-situ stresses are recommended to de-escalate the critical consequences of crushing associated issues. Similarly, the selection of resin-coated proppants over ceramic and sand proppants may benefit in terms of obtaining reduced proppant embedment.In addition, selection of smaller proppant sizes and higher proppant concentrations are suggested for stimulation projects at depth with sedimentary formations and lower in-situ stresses where proppant embedment predominates. Furthermore, correlation between proppant embedment with repetitive loading cycles was studied.Importantly, microstructural analysis of the proppant-embedded siltstone rock samples revealed that the initiation of secondary induced fractures. Finally, the findings of this study can greatly contribute to accurately select optimum proppant properties(proppant type, size and concentration) depending on the oil/gas reservoir characteristics to minimize proppant crushing and embedment effects.

Occupational Health Surveillance: Pulmonary Function Test in Proppant Exposures

Workers involved in hydraulic fracking processes are exposed to various types of chemicals and dusts in their workplaces, such as proppants, which hold open the fissures created in the fracking process. Recently, ceramic proppants have been developed that may be less hazardous to workers than traditional proppants. Pulmonary function testing of workers producing ceramic proppant was used to assess the potential inhalation hazards of ceramic proppant. 100 male workers from a producer of ceramic proppant were evaluated with pulmonary function test data collected and evaluated using The American Thoracic Society (ATS) acceptability criteria. A comparison group was selected from the Third National Health and Nutrition Examination Survey (NHANES III) spirometry laboratory subset. No pulmonary function deficits were found in the worker group in comparison to the NHANES III population. Mean FEV1 and FVC values in workers were 3.8 and 4.8 liters respectively, and were greater as compared to the NHANES III population of similar demographics. An FEV1/FVC ratio of less than 0.8, when compared to the NHANES III group, produced an odds ratio of 0.44 in worker group, indicating less risk of preclinical pulmonary dysfunction. Overall, exposure to ceramic proppant was not found to produce an adverse impact on pulmonary function in workers engaged in the manufacture of ceramic proppant.

A comprehensive review of ultralow‑weight proppant technology

Proppant plays a critical role in the exploitation of oil and gas,especially in the development of nonconventional oil and gas resources.Proppants are small spheres that have adequate strength to withstand high closure stresses to keep cracks open;therefore,hydrocarbon fows smoothly into the wellbore.However,traditional proppants are prone to settling in hydraulic fracturing operations,which seriously afects the operation efect.To this end,ultralow-weight proppants have been extensively employed in the petroleum industry.One of the widespread forms of ultralow-weight proppant application in the oil and gas industry is related to light density.Ultralow-weight proppants will provide substantial fow paths with a considerably high propped surface area and remarkably reduce fne generation and scaling.This paper presents a comprehensive review of over 50 papers published in the past several decades on ultralow-weight proppants.The purpose of this study is to provide an overview of the current ultralow-weight proppant development status in raw materials,manufacturing process,performance characteristics,hydrophobic and lipophilic capabilities,and feld application to promote the research of new ultralow-weight proppants.Lastly,this study analyzes the current challenges and emphasizes the development direction of fractured proppants.

Numerical simulation on proppant migration and placement within the rough and complex fractures

Hydraulic fracturing is a key technology for the development of unconventional hydrocarbon resources.The proppant placement morphology determines the fracture conductivity,thus affecting the reservoir stimulation effect.In this paper,the proppant migration and placement within complex fractures was studied by considering the fracture wall roughness through computational fluid mechanics-discrete element method(CFD-DEM)in numerical simulation,which is a key approach to study the proppant migration and placement.The results show that the proppant placement non-uniformity,proppant migration capacity,and proppant volume filled in the far-end and the secondary branched fracture are enhanced within the rough fracture compared with those within smooth fractures.The proppant migration capacity is increased within the fracture at low inclination angles(<60°)and low approach angles(<90°),and the proppant placement area is larger in the inclined fracture than that in the vertical fracture.The rise of injection rate and fracturing fluid viscosity causes more proppants migrate to far-end or secondary fractures,resulting in a non-proppant area within the near-wellbore fracture.An increase by 1.3 times in the injection rate and 3 times in the fracturing fluid viscosity leads to a decrease by 26.6%and 27%,respectively,in the proppant placement area within the near-wellbore fracture.The staged injection with small size proppants followed by large size proppants increases the proppant placement area in the primary fracture by 13%-26%,and that with large size proppants followed by small size proppants increases the proppant placement area by 19%-25%,which is due to that the latter method facilitates filling of the secondary branched fracture.The injection location mainly affects the proppant filling degree within the near-wellbore fractures.Compared with the upper injection,the middle and lower injection is not beneficial to filling of proppants within the near-wellbore fracture.

Numerical Modelling of Proppant Transport in Hydraulic Fractures

The distribution of proppant injected in hydraulic fractures significantly affects the fracture conductivity and well performance.The proppant transport in thin fracturing fluid used during hydraulic fracturing in the unconventional reservoirs is considerably different from fracturing fluids in the conventional reservoir due to the very low viscosity and quick deposition of the proppants.This paper presents the development of a three-dimensional Computational Fluid Dynamics(CFD)modelling technique for the prediction of proppant-fluid multiphase flow in hydraulic fractures.The proposed model also simulates the fluid leak-off behaviour from the fracture wall.The Euler-Granular and CFD-Discrete Element Method(CFD-DEM)multiphase modelling approach has been applied,and the equations defining the fluid-proppant and inter-proppant interaction have been solved using the finite volume technique.The proppant transport in hydraulic fractures has been studied comprehensively,and the computational modelling results of proppant distribution and other flow properties are in good agreement with the published experimental study.The parametric study is performed to investigate the effect of variation in proppant size,fluid viscosity and fracture width on the proppant transport.Smaller proppants can be injected early,followed by larger proppants to maintain high propping efficiency.This study has enhanced the understanding of the complex flow phenomenon between proppant and fracturing fluid and can play a vital role in hydraulic fracturing design.

Experimental investigation and correlations for proppant distribution in narrow fractures of deep shale gas reservoirs

Hydraulic fracturing is a crucial stimulation for the development of deep shale gas reservoirs.A key challenge to the effectiveness of hydraulic fracturing is to place small proppants in complex narrow fractures reasonably.The experiments with varied particle and fluid parameters are carried out in a narrow planar channel to understand particle transport and distribution.The four dimensionless parameters,including the Reynold number,Shields number,density ratio,and particle volume fraction,are introduced to describe the particle transport in narrow fractures.The results indicate that the narrow channel probably induces fluid fingers and small particle aggregation in a highly viscous fluid,leading to particle settlement near the entrance.The low viscous fluid is beneficial to disperse particles further into the fracture,especially in the high-speed fluid velocity.The linear and natural logarithmic laws have relationships with dimensionless parameters accurately.The multiple linear regression method developed two correlation models with four dimensionless parameters to predict the bed equilibrium height and covered area of small particles in narrow fractures.The study provides fundamental insight into understanding small size proppant distribution in deep reservoirs.

Characterization of the fracture compressibility and its permeability for shale under the effects of proppant embedment and compaction:A preliminary study

Hydraulic fracturing technology plays a key role in improving the recovery rate of shale gas.The improvement of permeability in relation to hydraulic fracturing depends on changes brought about by the proppant on the fracture structure in reservoirs.Then it is of great significance to describe the microscopic changes during this process by means of an accurate theoretical model.In this study,based on the heterogeneity of shale fracture and the compaction and embedment of a proppant,we proposed a permeability model to examine the combined effects of a proppant and stress to describe the change mechanism in permeability.Further,changes in fracture width and porosity were considered,and a calculation model of fracture compressibility under proppant compaction and embedment was proposed.The difference from previous studies is that the compressibility and permeability of supported fractures can be further quantified and analyzed by this model.Moreover,its rationality was verified by publicly released test data.The results show that,the compressive effect of stress and the embedding of proppant both have a negative impact on shale permeability.

Solidification and utilization of water-based drill cuttings to prepare ceramsite proppant with low-density and high performance

Water-based drill cuttings(WBDC)and bauxite are used as raw materials to prepare proppants with low density and high performance.The effects of sintering temperature,sintering period,mixture ratios of materials,doping with iron oxide,and acid modification of WBDC on the properties of proppants are discussed.The proppant performance is evaluated according to the national standard SY/T5108-2014.The morphology of the proppant is analyzed using scanning electron microscopy(SEM).The crystal phase structure of the proppant is studied using X-ray diffraction(XRD).Thermal analysis of the proppant sintering process is performed using thermogravimetry(TG).Proppant Z-23 completely satisfied the SY/T5108-2014 standard.This study provides a new perspective for the resource utilization of water-based drill cuttings and preparation of low-density proppants.

Hydrophobic epoxy resin coated proppants with ultra-high self-suspension ability and enhanced liquid conductivity

Proppant is a key material for enhancing unconventional oil and gas production which requires a long distance of migration and efficient liquid conductivity paths within the hydraulic fracture.However,it is difficult to find a proppant with both high self-suspension ability and liquid conductivity.Here,a simple method is developed to coat epoxy resin onto the ceramic proppant and fabricate a novel coated proppant with high hydrophobicity,self-suspension,and liquid conductivity performance.Compared with uncoated ceramic proppants,the epoxy resin coated(ERC) proppant has a high self-suspension ability nearly 16 times that of the uncoated proppants.Besides,the hydrophobic property and the liquid conductivity of the ERC proppant increased by 83.8% and 16.71%,respectively,compared with the uncoated proppants.In summary,this novel ERC proppant provides new insights into the design of functional proppants,which are expected to be applied to oil and gas production.