The company is committed to the development, promotion and application of new wear-resistant materials, new technologies and new products, and has established long-term cooperative relationships with harbin boiler, dongguo, dongfang electric, wuxi huaguang, sichuan boiler, etc. It has been recognized as "henan province science and technology small and medium-sized enterprises" and "henan province innovative pilot enterprise" by the henan provincial department of science and technology; "henan province bauxite high temperature material engineering technology research center" recognized by the henan provincial department of industry and information technology; december 2019 it passed the integration certification of industrialization and informatization by the national industry and information technology commission in march; it was recognized as a "specialized, special and innovative" enterprise in 2020; it was recognized as a national high-tech enterprise in 2021.
Why Choose Us
Our factory
The company is committed to the development, promotion and application of new wear-resistant materials, new technologies and new products, and has established long-term cooperative relationships with harbin boiler, dongguo, dongfang electric, wuxi huaguang, sichuan boiler, etc.
Our products
High density and high strength ceramsite proppant,low density and high strength ceramsite proppant,medium density high strength ceramsite proppant,ultra low density and high strength ceramsite proppant.
Production market
Zheng nai petroleum's fracturing proppant products fully comply with the standards of the fracturing acidification center proppant evaluation laboratory of langfang branch of china petroleum exploration and development research institute, the american stim-lab, and the british frac-tech laboratory.
Our certificate
The product performance has reached the international leading level and passed american petroleum institute apiq1 certification.The laboratory of henan zhengnai new materials co., ltd. Has passed the national laboratory accreditation cnas certification.
Ceramsite sand plays an important role in the oil and gas extraction process. Its main function is to enter rock cracks as a filler during the fracturing process to support the cracks from closing due to stress release, thereby maintaining high conductivity, allowing oil and gas to flow smoothly, and increasing production.
The fracking proppant sand is made by fine processing with high content of bauxite, mixing some chemical agents and phase-changing agents to produce small round particles of different sizes, which are sintered at high temperature, the product has the characteristics of high strength, low crushing rate and good sphericity under closed pressure. It is a good product for fracturing and reforming formation in oil and gas field.
In the process of oil and gas extraction, after fracturing treatment of high closing pressure and low permeability mineral deposits, fluid needs to be injected into the rock base to exceed the fracture strength of the formation, causing cracks in the rock formations around the wellbore to form a channel with high-level flow capabilities. . During this process, oil fracturing proppant plays a role in supporting the fractures from closing due to stress release, thereby maintaining high conductivity, allowing oil and gas to flow smoothly, and increasing production.
Performance proppants are specialized materials used primarily in hydraulic fracturing operations within the oil and gas industry. Their primary function is to hold open fractures in subterranean rock formations, enabling enhanced flow of hydrocarbons such as oil and natural gas to extraction wells. These proppants come in various forms, including sand, ceramics, and resin-coated materials, each designed to withstand the extreme pressures and temperatures encountered in subsurface environments.
Increased Well Production
Performance proppants are small, solid particles that are injected into the fractures created during the refracking process to keep them open. By filling the fractures, performance proppants prevent them from closing back up, allowing for the efficient extraction of oil and gas.
Enhanced Fracture Conductivity
Performance proppants act as a support system for the fractures, preventing them from collapsing and maintaining a pathway for oil and gas to flow. The choice of performance proppants material is crucial in determining the conductivity of the fractures.
Optimal Proppant Placement
This is particularly important in unconventional reservoirs where the rock formations are complex and require careful engineering techniques to achieve effective stimulation. Performance proppants placement can be further enhanced through the use of advanced technologies such as diverters, which help to distribute the performance proppants evenly across the fractures.
Long-Term Well Integrity
By keeping the fractures open, performance proppants prevent the migration of sand and other formation materials into the wellbore, which can cause damage and reduce production. This is especially crucial in refracking operations, where the well has already experienced previous stimulation.
Working Principle of Performance Proppants
Before the advent of hydraulic fracturing, it was extremely challenging to exploit subsurface rock units containing natural gas, oil, and other hydrocarbons for their natural resources. The impermeable nature of the shale rock formations inhibits the natural flow of gas or oils into the wellbore.
Well treatment generates tiny cracks in the geologic formation during the drilling process that enables the movement of hydrocarbon resources. Chemically-treated water carrying proppants, such as frac sand, is then forced into the cracks. Pumps located on the surface serve to raise the water pressure in a sealed part of the well beyond the breaking point of the rocks resulting in further fracture propagation. This procedure may require thousands of tons of the fluid to prepare a single well.
After the pumps stop operating, the fractures begin to shrink. They are kept from closing completely by the frac sand remaining in the fissures. This enables any stranded oil and gas to flow out through the porous media into the well for extraction.
Besides water, fracking fluids consist of gel, slickwater, or foam. High viscosity fluids carry greater proppant concentrations. Other key fluid properties to be considered include ph, energy, and pressure demands for maintaining adequate pump flow rates to deliver the proppants into a well. The fluids are employed in large-scale hydraulic fracturing that requires several millions of gallons of water for a single well. This is in addition to the low-volume stimulation of sandstone wells utilizing between 20,000 and 80,000 gallons of fluid. Fracking fluids also contain numerous chemical additives, such as hydrochloric acid (effective at etching rocks), guar gum, and emulsifiers that aid in regulating the well's properties.
Ample space between the particles results in greater gas permeability under increased pressure while maintaining the compressive strength to bear the stress and stop the formed fractures from closing. Propping agents with greater mesh sizes feature greater permeability compared to materials with finer meshes under lower fracture-closure stress. However, larger elements are crushed under major loads generating extremely fine particulates (known as fines) that impair the overall porosity of the agent. As a result, small mesh proppants are more effective beyond a particular stress threshold.
Sand is the most common proppant; however, it can generate an extremely high fines content. Resin coating of the grains enhances the performance of sand-based material forming crcs (curable resin coated sand) or prcs (pre-cured resin coated sand). Alternate proppant components include ceramics made from sintered bauxite or small metal beads. Most fracking or frac sand comes from high-purity quartz sand with round grains. Demand for frac sand has climbed dramatically in recent years, reflecting the boom in shale oil and gas extraction.
Specifications of Performance Proppants
Buoyancy
Manufactured proppants are lighter and more buoyant than sand-based proppants. Precision in size and gravity make them suitable for the individual fracking fluids utilized in a well. Frac sand, on the other hand, features a variety of grain sizes and shapes as well as greater densities than manufactured proppants. This necessitates the use of fracking fluids with higher viscosity pumped at an increased pressure to embed the particles in the fractured formations.
Strength
Engineered proppants offer the advantage of strength over most natural sands. A rotary kiln, where powdered minerals are sintered at high temperatures, facilitates the production of highly durable beads. These beads are capable of resisting heavy loads without breaking and producing fines. The use of such proppants has the potential to dramatically improve well production given their added robustness.
Price
Sand-based proppants have a significant edge when it comes to cost. Quartz sand located near the earth's surface is the primary source for specialized sand used in fracking, resulting in lower costs associated with excavation and transportation. Proppant sintering employs sophisticated manufacturing equipment and process along with raw materials that are more expensive to acquire. As a result, the cost for ceramic proppants substantially exceeds the cost of sand-based products.
Resin-coated sand
The grains are industrially coated with resin to improve crush resistance and effective density while retaining the price advantage of using sand material. The resin coating helps resist flow back and capture fines if they separate from the grains when force is applied. Rcs is more expensive than untreated sand; however, it is more reasonably priced than proppants fabricated using the sintering process. Untreated sand is applied in shallower wells where less pressure is exerted while rcs and engineered proppants are preferred in deeper wells with higher levels of pressure.
How to Choose Performance Proppants
Size and shape
The size and shape of performance proppants play a crucial role in determining their effectiveness in enhancing well productivity. Larger proppants tend to create wider fractures, allowing for increased flow of oil and gas. However, smaller proppants can penetrate deeper into the fractures, providing better proppant pack conductivity. The shape of the proppants also affects their ability to maintain fracture width and prevent closure. Rounded proppants are often preferred as they offer better flow characteristics, while angular proppants provide greater mechanical strength. It is essential to carefully consider the size and shape of proppants based on the specific requirements of the well.
Strength and crush resistance
Performance proppants must possess sufficient strength and crush resistance to withstand the immense stress placed upon them during hydraulic fracturing and subsequent production. Higher strength proppants can maintain fracture width and prevent closure, ensuring sustained well productivity. Crush resistance is equally important as it determines the longevity of proppants within the fracture. Proppants that are prone to crushing under pressure can lead to reduced conductivity and ultimately result in decreased well productivity. Opting for proppants with superior strength and crush resistance is crucial for long-term success.
Conductivity and permeability
The conductivity and permeability of performance proppants directly impact the flow of oil and gas within the fractures. Proppants with high conductivity allow for efficient fluid flow and enhance the recovery of hydrocarbons. Permeability is closely related to conductivity and refers to the ability of proppants to transmit fluids through the fracture network. Proppants with high permeability contribute to increased production rates. It is vital to select proppants that offer optimal conductivity and permeability to maximize well productivity.
Chemical and thermal stability
Chemical and thermal stability are crucial factors to consider when choosing performance proppants, especially in refracking operations where the well may be subjected to harsh conditions. Proppants should be chemically inert to minimize any adverse reactions with the reservoir fluids or fracking fluids. Additionally, they should exhibit excellent thermal stability to withstand high temperatures encountered during production. Proppants that maintain their integrity under challenging conditions ensure sustained well productivity and minimize the need for frequent replacements.
Cost-effectiveness
While considering the various factors mentioned above, it is equally important to assess the cost-effectiveness of performance proppants options. Different types of proppants vary in terms of cost, and their performance should be evaluated against their price. It is essential to strike a balance between the quality and cost of proppants to achieve the best return on investment. Conducting a thorough cost-benefit analysis and considering long-term performance can help determine the most cost-effective proppant option for enhancing well productivity.
Choosing the right performance proppants is a critical decision that can significantly impact well productivity. By considering factors such as size and shape, strength and crush resistance, conductivity and permeability, chemical and thermal stability, and cost-effectiveness, operators can make informed choices. Evaluating these factors from different perspectives and comparing various options will lead to the selection of proppants that best meet the specific needs of each well, ultimately enhancing overall productivity and maximizing returns.
Successful Application of Performance Proppants in Refracking
Utilizing ceramic proppants
One commonly used proppant material is ceramic, known for its high strength and conductivity. In a refracking operation conducted in the permian basin, ceramic proppants were employed to prop open fractures in a previously underperforming well. The use of ceramic proppants resulted in a significant increase in well productivity, with a 30% rise in hydrocarbon production compared to the initial fracking operation. The durability and conductivity of ceramic proppants proved crucial in maintaining effective fracture conductivity over an extended period.
Optimizing proppant concentration
Another crucial aspect of successful refracking is determining the optimal proppant concentration. A case study conducted in the eagle ford shale demonstrated the impact of varying proppant concentrations on well productivity. The study compared three wells: One with low proppant concentration, one with medium concentration, and one with high concentration. The results revealed that the well with medium proppant concentration achieved the highest production rates, indicating the importance of finding the right balance. While high concentrations can lead to better fracture conductivity, excessive proppant usage may result in diminished reservoir contact and increased costs.
Evaluating different proppant sizes
The size of proppants used in refracking operations also plays a crucial role in determining well productivity. A case study conducted in the barnett shale compared the performance of different proppant sizes: 20/40 mesh, 40/70 mesh, and 100 mesh. The study found that wells utilizing 40/70 mesh proppants exhibited the highest production rates, indicating the optimal size range for achieving maximum conductivity. Smaller proppant sizes can lead to increased pressure drop and reduced conductivity, while larger sizes may result in inadequate proppant placement and lower fracture conductivity.
Exploring alternative proppant materials
While sand and ceramic proppants are commonly used in refracking operations, alternative materials have gained attention in recent years. For instance, resin-coated proppants have shown promising results in improving well productivity. In a case study conducted in the bakken formation, wells utilizing resin-coated proppants achieved a 20% increase in production compared to conventional proppants. The resin coating enhances proppant conductivity and prevents fines migration, leading to improved fracture stability and sustained well productivity.
Materials Used in Performance Proppants
Sand
Sand proppants have been widely used in the oil and gas industry for decades. They are cost-effective and readily available. However, their lower strength and limited conductivity can restrict their performance in certain formations.
Ceramic
Ceramic proppants offer higher strength and conductivity compared to sand. They are better suited for deep and high-pressure reservoirs. Although ceramic proppants are more expensive, their superior performance justifies the investment in many cases.
Resin-coated
Resin-coated proppants combine the benefits of both sand and ceramic. The resin coating enhances the strength and conductivity of sand particles, providing better proppant pack integrity. This type of proppant is often preferred when dealing with formations that require higher conductivity.
Certifications
Our Factory
The company is committed to the development, promotion and application of new wear-resistant materials, new technologies and new products, and has established long-term cooperative relationships with harbin boiler, dongguo, dongfang electric, wuxi huaguang, sichuan boiler, etc. It has been recognized as "henan province science and technology small and medium-sized enterprises" and "henan province innovative pilot enterprise" by the henan provincial department of science and technology; "henan province bauxite high temperature material engineering technology research center" recognized by the henan provincial department of industry and information technology; december 2019 it passed the integration certification of industrialization and informatization by the national industry and information technology commission in march; it was recognized as a "specialized, special and innovative" enterprise in 2020; it was recognized as a national high-tech enterprise in 2021.
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