Additive fabrication of proppants

• US 9,969,930 B2
• Filed: 08/12/2014
• Issued: 05/15/2018
• Est. Priority Date: 08/15/2013
• Status: Expired due to Fees

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Florio, Steven, Coker, Christopher E.
• Primary Examiner(s): WASHVILLE, JEFFREY D
• Application Number:
  US14/908,708
• Publication Number:
  US 20160168453A1
• Time in Patent Office: 1,372 Days
• Field of Search: None
• CPC Class Codes: C04B 2235/6026 Computer aided shaping, e.g. rapid prototyping
• CPC Class Codes: C04B 2235/665 Local sintering, e.g. laser sintering
• CPC Class Codes: C04B 35/622 Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
• CPC Class Codes: C09D 11/30 Inkjet printing inks
• CPC Class Codes: C09K 8/80 Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open
• CPC Class Codes: C09K 8/805 Coated proppants

Abstract

Ceramic inks formulated for additive formation of proppants are provided, as well as methods of manufacturing such ink and ink systems including such ink. The proppant formed can contain a proppant core, a proppant shell, a proppant outer coating or any combination thereof. Additive methods for forming proppants are also provided. The ceramic ink can be applied drop-wise, linearly, in a planar fashion, or any combination thereof to form proppants. Additive fabricators configured to produce proppant are further provided, as are systems including the same and software for running the same.

Claims

1. An additive method for forming proppants comprising:

applying a ceramic ink to a green proppant core through a printer head to produce a green proppant, wherein the ceramic ink comprises a ceramic material and a glass material; and

sintering the green proppant to produce a proppant wherein the proppant comprises a sintered shell and the proppant core, wherein the sintered shell comprises a glass-ceramic that is at least 50% crystalline.

2. The method of claim 1, wherein the ceramic ink is applied drop-wise, linearly, in a planar fashion, or any combination thereof.

3. The method of claim 1, further comprising forming at least one layer of the green proppant from the application of the ceramic ink.

4. The method of claim 3, further comprising curing the at least one layer after formation of the layer and before formation of a subsequent layer.

5. The method of claim 1, wherein the ceramic ink comprises at least one binding agent.

6. The method of claim 5, wherein the at least one binding agent comprises at least one monomer and further comprises at least one polymerization initiator.

7. The method of claim 5, further comprising debindering the green proppant.

8. The method of claim 6, further comprising applying energy to the applied ceramic ink to generate polymerization.

9. The method of claim 1, wherein at least two ceramic inks differing from one another are applied.

10. The method of claim 9, wherein the at least two ceramic inks comprise a first ink comprising ceramic material and a second ink comprising a binding agent, and the first ink is applied before applying the second ink.

11. The method of claim 10, wherein the application of the first and second inks are repeated multiple times to form the green proppant.

12. The method of claim 9, wherein the at least two ceramic inks comprise a first ink comprising a first ceramic material and a second ink comprising a second ceramic material differing in chemical composition from the first ceramic material.

13. The method of claim 1, wherein the green proppant further comprises a green proppant outer coating.

14. The method of claim 13, wherein the at least one ceramic ink comprises a first ceramic ink, and the first ceramic ink is applied to form the proppant core.

15. The method of claim 14, wherein the at least one ceramic ink comprises a second ceramic ink, the second ceramic ink is applied to form the green proppant shell.

16. The method of claim 15, wherein the at least one ceramic ink comprises a third ceramic ink, and the third ceramic ink is used to form the green proppant outer coating.

17. The method of claim 16, wherein at least two of the three ceramic inks differ from each other in respect to chemical property and/or physical property.

18. The method of claim 1, further comprising at least one subtractive process, herein the subtractive process comprises milling, lathing, stamping, crushing, etching, carving, or any combination thereof.