Methods to enhance silica sand proppant for use in fracking operations

• US 10,640,388 B2
• Filed: 07/29/2019
• Issued: 05/05/2020
• Est. Priority Date: 06/26/2018
• Status: Active Grant

• Current Assignee: Forecaster Chemicals, LLC
• Original Assignee: Forecaster Chemicals, LLC
• Inventors: Akbar, Syed, Rose, Jared
• Primary Examiner(s): Bergner, Erin F
• Application Number:
  US16/524,312
• Publication Number:
  US 20190389731A1
• Time in Patent Office: 281 Days
• CPC Class Codes: B02C 17/183 Feeding or discharging devices
• CPC Class Codes: B02C 25/00 Control arrangements specially adapted for crushing or disintegrating
• CPC Class Codes: C01B 33/18 Preparation of finely divided silica neither in sol nor in gel form; After-treatment thereof preparation of aerogels by dehydrating gels C01B33/158; treatment to enhance the pigmenting or filling properties C09C
• CPC Class Codes: C01P 2002/82 by IR- or Raman-data
• CPC Class Codes: C09K 8/80 Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open

Abstract

Methods for cost effectively transforming lower quality silica sands into higher quality silica sands for use as proppants in fracking operations involving subterranean hydrocarbon formations. A process of exposing silica sand proppants to locally-sourced electromagnetic radiation, and systems therefor, are disclosed and shown to increase the performance of those silica sands as proppants in hydrocarbon formation fracturing operations.

Claims

1. A method of increasing crush resistance of silica sand proppant used in fracturing operations involving one or more hydrocarbon formations, the method comprising:

positioning silica sand proppant in proximity to a local source of electromagnetic radiation, the silica sand proppant including individual particles having at least partial quartz crystalline structures; and

exposing the silica sand proppant to the electromagnetic radiation generated by the local source of electromagnetic radiation for a period of time, the period of time sufficient for the electromagnetic radiation to strengthen the at least partial quartz crystalline structures and to increase specific gravity of the silica sand proppant.

2. The method of claim 1, further comprising:

supplying the silica sand proppant, after electromagnetic radiation exposure, to a well fracturing site for use in the fracturing operations involving one or more hydrocarbon formations.

3. The method of claim 1, wherein the specific gravity of the silica sand proppant prior to being positioned in proximity to the local source of electromagnetic radiation is below about 2.50.

4. The method of claim 1 wherein the specific gravity of the silica sand proppant after exposure to the electromagnetic radiation is increased to above about 2.50.

5. The method of claim 1, wherein the period of time is at least about thirty seconds.

6. The method of claim 1, wherein the at least partial quartz crystalline structures are increasingly strengthened as the period of time increases.

7. The method of claim 1, wherein the electromagnetic radiation generated by the local source of electromagnetic radiation has a frequency between about 1200 MHz and about 2700 MHz.

8. The method of claim 7, wherein the period of time is no more than about two minutes.

9. The method of claim 1, wherein the silica sand proppant is positioned to expose each individual particle of the silica sand proppant to the electromagnetic radiation.

10. The method of claim 1, wherein positioning the silica sand proppant in proximity to the local source of electromagnetic radiation further comprises:

placing the silica sand proppant on a conveyor; and

operating the conveyor to pass the silica sand proppant thereon through the electromagnetic radiation generated by the local source.

11. The method of claim 10, wherein operating the conveyor to pass the silica sand proppant thereon through the electromagnetic radiation generated by the local source further comprises:

operating the conveyor to move the silica sand proppant positioned on the conveyor through a first suppression tunnel, into a heating chamber and then through a second suppression tunnel, the electromagnetic radiation emitted by the local source into the heating chamber, the first and second suppression tunnels positioned to reduce electromagnetic radiation leakage from the heating chamber.

12. The method of claim 10, wherein the silica sand proppant placed on the conveyor forms a thickness of the silica sand proppant atop the conveyor, the thickness selected to cause the electromagnetic radiation to penetrate through the thickness of the silica sand proppant atop the conveyor and to expose silica sand proppant in contact with the conveyor.

13. The method of claim 1, wherein the silica sand proppant has been sorted to have a preselected particle size range.

14. A method of increasing crush resistance of silica sand proppant used in fracturing operations involving one or more hydrocarbon formations, the method comprising:

positioning silica sand proppant on a conveyor to form a thickness of the silica sand proppant atop the conveyor;

operating the conveyor to pass the silica sand proppant in proximity to a local source of electromagnetic radiation that produces electromagnetic radiation at a frequency between about 1200 MHz and about 2700 MHz;

exposing the silica sand proppant to the electromagnetic radiation, the thickness of the silica sand proppant atop the conveyor selected to cause the electromagnetic radiation to penetrate through the thickness of the silica sand proppant atop the conveyor and to expose silica sand proppant in contact with the conveyor; and

controlling conveyor speed to expose the silica sand proppant to the local source of electromagnetic radiation for an exposure time, the exposure time sufficient for the electromagnetic radiation to increase crush resistance of silica sand proppant is decreased as the frequency of the electromagnetic radiation is increased.

15. The method of claim 14, further comprising:

supplying the silica sand proppant, after electromagnetic radiation exposure, to a well fracturing site for use in the fracturing operations involving one or more hydrocarbon formations.

16. The method of claim 14, wherein the exposure time is at least about thirty seconds.

17. The method of claim 14, wherein the silica sand proppant is positioned on the conveyor to cause exposure of each individual particle of the silica sand proppant to the electromagnetic radiation.

18. The method of claim 14, wherein operating the conveyor to pass the silica sand proppant in proximity to the local source of electromagnetic radiation further comprises operating the conveyor to move the silica sand proppant positioned on the conveyor into a heating chamber and through the electromagnetic radiation emitted into the heating chamber by the local source.

19. The method of claim 14, wherein operating the conveyor to pass the silica sand proppant in proximity to the local source of electromagnetic radiation further comprises operating the conveyor to move the silica sand proppant positioned on the conveyor through a first suppression tunnel, into a heating chamber and then through a second suppression tunnel, the electromagnetic radiation emitted by the local source into the heating chamber, the first and second suppression tunnels positioned to reduce electromagnetic radiation leakage from the heating chamber.

20. The method of claim 14, wherein the silica sand proppant positioned on the conveyor, prior to electromagnetic radiation exposure, has been sorted to have a preselected particle size range.