Method of treating subterranean formations with porous particulate materials

• US 7,426,961 B2
• Filed: 09/02/2003
• Issued: 09/23/2008
• Est. Priority Date: 09/03/2002
• Status: Active Grant

• Current Assignee: Baker Hughes Holdings LLC (Baker Hughes Company)
• Original Assignee: BJ Services Company
• Inventors: Gupta, D. V. Satyanarayana, Brannon, Harold Dean, Rickards, Allan Ray, Stephenson, Christopher John
• Primary Examiner(s): Bates; Zakiya W.
• Application Number:
  US10/653,521
• Publication Number:
  US 20040040708A1
• Time in Patent Office: 1,848 Days
• Field of Search: 166/295, 166/308.1, 166/280.1, 166/280.2, 166/305.1, 166/300, 166/276, 166/278, 166/281, 507/924, 507/269
• US Class Current: 166/280.2
• CPC Class Codes: C09K 8/805 Coated proppants
• CPC Class Codes: E21B 43/267 reinforcing fractures by propping
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]
• CPC Class Codes: Y10T 428/2991 Coated
• CPC Class Codes: Y10T 428/2993 Silicic or refractory material containing [e.g., tungsten oxide, glass, cement, etc.]
• CPC Class Codes: Y10T 428/2995 Silane, siloxane or silicone coating
• CPC Class Codes: Y10T 428/2996 Glass particles or spheres
• CPC Class Codes: Y10T 428/2998 including synthetic resin or polymer

Abstract

Methods and compositions useful for subterranean formation treatments, such as hydraulic fracturing treatments and sand control that include porous materials. Such porous materials may be selectively configured porous material particles manufactured and/or treated with selected glazing materials, coating materials and/or penetrating materials to have desired strength and/or apparent density to fit particular downhole conditions for well treating such as hydraulic fracturing treatments and sand control treatments. Porous materials may also be employed in selected combinations to optimize fracture or sand control performance, and/or may be employed as relatively lightweight materials in liquid carbon dioxide-based well treatment systems.

Claims

1. A method for treating a well penetrating a subterranean formation under conditions of from 2,500 to 10,000 psi closure stress, comprising introducing into the well a proppant of a selectively configured porous particulate material, the selectively configured porous particulate material being a porous particulate material manufactured with a glazing material or treated with a penetrating layer, coating layer or glazing material, wherein the selectively configured porous particulate material exhibits crush resistance under the closure stress conditions and further wherein the strength of the selectively configured porous particulate material is greater than the strength of the porous particulate material.

2. The method of claim 1, wherein the porous particulate material is a porous ceramic.

3. The method of claim 2, wherein the porous ceramic is a relatively lightweight and/or substantially neutrally buoyant particle.

4. The method of claim 2, wherein the selectively configured porous particulate material is a porous ceramic coated or penetrated with a liquid resin, plastic, cement, sealant, or binder.

5. The method of claim 4, wherein the penetrating material and/or coating of the selectively configured porous particulate material is capable of trapping or encapsulating a fluid having an apparent specific gravity less than the apparent specific gravity of the matrix of the porous ceramic.

6. The method of claim 5, wherein the fluid is a gas.

7. The method of claim 4, wherein the coating layer or penetrating material is an ethyl carbamate-based resin.

8. The method of claim 2, wherein the selectively configured porous particulate material is a porous ceramic coated or penetrated with a phenol, phenol formaldehyde, melamine formaldehyde, urethane, or epoxy resin.

9. The method of claim 2, wherein the selectively configured porous particulate material is a porous ceramic penetrated with nylon, polyethylene or polystyrene or a combination thereof.

10. The method of claim 2, wherein the selectively configured porous particulate material comprises a multitude of coated porous ceramic particulates bonded together and coated or penetrated with a curable resin.

11. The method of claim 2, wherein the porous ceramic has a maximum length-based aspect ratio of equal to or less than about 5.

12. The method of claim 1, wherein the porous particulate material has a porosity and permeability such that a fluid may be drawn at least partially into its porous matrix by capillary action.

13. The method of claim 1, wherein the porous particulate material has a porosity and permeability such that a penetrating material may be drawn at least partially into its porous matrix using a vacuum and/or may be forced at least partially into its porous matrix under pressure.

14. The method of claim 1 wherein the well is a deviated well having an angle with respect to the vertical of between about 30 degrees and about 90 degrees.

15. The method of claim 1, wherein the glazing material, penetrating layer or coating layer is non-porous.

16. The method of claim 1 wherein the apparent specific gravity of the selectively configured porous particulate material is less than the apparent specific gravity of the porous particulate material.

17. The method of claim 1, wherein the porous particulate material is a polyolefin.

18. The method of claim 1 wherein the selectively configured porous particulate material has an apparent density from about 1.1 g/cm³ about 2.6 g/cm³ and a bulk apparent density from about 1.03 g/cm³ to about 1.4 g/cm³.

19. The method of claim 1 wherein the size of the selectively configured porous particulate material is between from about 200 mesh to about 8 mesh.

20. The method of claim 1 wherein the selectively configured porous particulate material has a coating layer or penetrating material in an amount of from about 0.5 to about 10% by weight of total weight.

21. The method of claim 20, wherein the thickness of the coating layer of the selectively configured porous particulate material is from about 1 to about 5 microns.

22. The method of claim 1 wherein the selectively configured porous particulate material is introduced or pumped into the well as neutrally buoyant particles in a carrier fluid.

23. The method of claim 22, wherein the carrier fluid is a completion or workover brine.

24. The method of claim 22, wherein the carrier fluid is salt water, fresh water, a liquid hydrocarbon, or a gas or a mixture thereof.

25. The method of claim 24, wherein the gas is nitrogen or carbon dioxide.

26. The method of claim 22, wherein the fluid pumped into the well further comprises a gelling agent, crosslinking agent, gel breaker, surfactant, foaming agent, demulsifier, buffer, clay stabilizer, acid or a mixture thereof.

27. The method of claim 1 wherein the permeability of the selectively configured porous particulate material is less than the permeability of the porous particulate material.

28. The method of claim 1 wherein the selectively configured porous particulate material is introduced into the well with a liquefied gas or foamed gas carrier fluid or a mixture thereof.

29. The method of claim 28, wherein the liquefied gas or foamed gas carrier fluid is a liquid carbon dioxide based system.

30. The method of claim 28, wherein the liquefied gas or foamed gas carrier fluid is nitrogen.

31. The method of claim 28, wherein the liquefied gas or foamed gas carrier fluid is a mixture of liquid carbon dioxide and nitrogen.

32. The method of claim 1 wherein the selectively configured porous particulate material is a porous particulate material having a glazed surface.

33. The method of claim 32, wherein the glazed surface of the porous particulate material enhances the ease of multi-phase fluid flow through a particulate pack.

34. The method of claim 32, wherein the glazed surface of the porous particulate material enhances the ease of high rate turbulent gas flow through a particulate pack.

35. The method of claim 1, wherein the apparent specific gravity of the porous particulate material is less than or equal to 1.75.

36. The method of claim 35, wherein the apparent specific gravity of the porous particulate material is less than or equal to 1.25.

37. The method of claim 1, wherein the closure stress conditions are from 3,000 to 10,000 psi.

38. The method of claim 1, wherein the selectively configured porous particulate material is introduced into the well at concentrations sufficient to achieve apartial monolayer fracture.

39. The method of claim 1, wherein the selectively configured porous particulate material is introduced into the well as a slick water fracturing fluid.

40. A method for treating a well penetrating a subterranean formation, comprising introducing into the well a proppant of a selectively configured porous particulate material in a non-gelled carrier fluid, the selectively configured porous particulate material comprising a composite of a porous particulate material and a non-porous glazing material or a porous particulate material treated with a penetrating material, coating layer or glazing layer such that the porous particulate material of the selectively configured porous particulate material is at least partially filled with air or a gas.

41. The method of claim 40, wherein the selectively configured porous particulate material exhibits crush resistance under conditions from about 250 to about 8,000 psi closure stress.

42. The method of claim 40, wherein the non-gelled carrier fluid contains a friction reducer.

43. The method of claim 40, wherein the apparent specific gravity of the selectively configured porous particulate material is less than the apparent specific gravity of the porous particulate material.

44. The method of claim 40, wherein the well is horizontal or is a deviated well having an angle with respect to the vertical of between about 0 degrees and about 90 degrees.

45. The method of claim 40, wherein the selectively configured porous particulate material comprises a porous particulate material coated or penetrated with a liquid resin, plastic, cement, sealant, or binder.

46. The method of claim 45, wherein the liquid resin, plastic, cement, sealer, or binder is selected from the group consisting of a phenol, phenol formaldehyde, melamine formaldehyde, urethane, epoxy resin, nylon, polyethylene or polystyrene or a combination thereof.

47. The method of claim 40, wherein the porous particulate material is introduced into the well with a liquefied gas or foamed gas carrier fluid or a mixture thereof.

48. The method of claim 47, wherein the liquefied gas or foamed gas carrier fluid is a liquid carbon dioxide based system.

49. The method of claim 48, wherein the liquefied gas or foamed gas carrier fluid is a mixture of liquid carbon dioxide and nitrogen.

50. The method of claim 47, wherein the liquefied gas or foamed gas carrier fluid is nitrogen.

51. The method of claim 47, wherein the liquefied gas or foamed gas carrier fluid is a foam of nitrogen in liquid carbon dioxide.

52. The method of claim 40, wherein the selectively configured porous particulate material is introduced into the well at concentrations sufficient to achieve a partial monolayer fracture.

53. The method of claim 40, wherein the strength of the selectively configured porous particulate material is greater than the strength of the porous particulate material.

54. The method of claim 40, wherein the porous particulate material is a porous ceramic.

55. The method of claim 54, wherein the porous ceramic is a substantially neutrally buoyant particle and is introduced or pumped into the well as a suspension in a storage fluid wherein the density of the storage fluid and porous ceramic is of near orsubstantially equal density.

56. The method of claim 40, wherein the selectively configured porous particulate material is introduced into the well as a slick water fracturing fluid.

57. The method of claim 40, wherein the selectively configured porous particulate material has an apparent density from about 1.1 g/cm³ about 2.6 g/cm³ and a bulk apparent density from about 1.03 g/cm³ to about 1.4 g/cm^3.

58. The method of claim 40, wherein the permeability of the selectively configured porous particulate material is less than the permeability of the porous particulate material.

59. The method of claim 40, wherein the selectively configured porous particulate material is a porous particulate material having a glazed surface.

60. The method of claim 59, wherein the glazed surface of the selectively configured porous particulate material enhances the ease of high rate turbulent gas flow through a particulate pack.

61. The method of claim 40, wherein the apparent specific gravity of the porous particulate material is less than or equal to 1.75.

62. The method of claim 40, wherein the selectively configured porous particulate material is introduced into the well as a slick water fracturing fluid.

63. A method for treating a well penetrating a subterranean formation, comprising introducing into the well a selectively configured porous particulate material, wherein the selectively configured porous particulate material is a porous particulate material treated with a penetrating or coating layer wherein the penetrating or coating layer penetrates the porous particulate and encapsulates air within the pores of the particulate.

64. The method of claim 63, wherein the selectively configured porous particulate material is suspended in a carrier fluid.

65. The method of claim 63, wherein the selectively configured porous particulate material has a coating layer or penetrating material which is a liquid having an apparent specific gravity less than the apparent specific gravity of the matrix of the porous particulate material.

66. The method of claim 63, wherein the selectively configured porous particulate material, when introduced into the well, forms a fluid-permeable gravel pack in an annular area defined between the exterior of a screen assembly and the interior of the weilbore.

67. The method of claim 63, wherein the apparent specific gravity of the selectively configured porous particulate material is less than the apparent specific gravity of the porous particulate material.

68. The method of claim 63, wherein the porous particulate material is a relatively lightweight and/or substantially neutrally buoyant particle.

69. The method of claim 63, wherein the selectively configured porous particulate material exhibits crush resistance under conditions from 2,500 psi to 10,000 psi closure stress.

70. The method of claim 63, wherein the selectively configured porous particulate material is a porous particulate coated or penetrated with a liquid resin, plastic, cement, sealant, or binder.

71. The method of claim 70, wherein the liquid resin is a curable resin and further wherein the selectively configured porous particulate material comprises a multitude of coated particulates bonded together.

72. The method of claim 63, wherein the selectively configured porous particulate material is introduced into the well at concentrations sufficient to achieve a partial monolayer fracture.

73. The method of claim 63, wherein the coating layer or penetrating layer is present in the selectively configured porous particulate material in an amount of from about 0.5 to about 10% by weight of total weight.

74. The method of claim 63, wherein the apparent specific gravity of the porous particulate material is less than or equal to 1.75.

75. The method of claim 63, wherein the porous particulate material is a porous ceramic.

76. A method of fracturing a hydrocarbon-bearing formation comprising introducing into the formation a selectively configured porous particulate material in a transport fluid, wherein the selectively configured porous particulate material comprises a composite of a porous organic polymeric material treated with a penetrating and/or coating material and further wherein the penetrating and/or coating material penetrates the organic polymeric material to effectively encapsulate air within the porosity of the organic polymeric material.

77. The method of claim 76 wherein the porosity and permeability of the porous organic polymeric material is such that a fluid may be drawn at least partially into its porous matrix by capillary action.

78. The method of claim 76, wherein the selectively configured porous particulate material is introduced into the well at concentrations sufficient to achieve a partial monolayer fracture.

79. The method of claim 76, wherein the porous organic polymeric material is a relatively lightweight and/or substantially neutrally buoyant particle.

80. The method of claim 76, wherein the porous organic polymeric material is an ultra-lightweight organic polymeric material.

81. The method of claim 76, wherein the selectively configured porous particulate material, when introduced into the well, is suspended in a transport fluid.

82. The method of claim 81, wherein the transport fluid is salt water, fresh water, a liquid hydrocarbon, or a gas or a mixture thereof.

83. The method of claim 81, wherein the transport fluid further comprises a gelling agent, crosslinking agent, gel breaker, surfactant, foaming agent, demulsifier, buffer, clay stabilizer, acid or a mixture thereof.

84. The method of claim 76, wherein the apparent density or apparent specific gravity of the selectively configured porous particulate material is less than the apparent density or apparent specific gravity of the porous organic polymeric material.

85. The method of claim 76, wherein the selectively configured porous particulate material is introduced into the well as a slick water fracturing fluid.