Importance of Size & Shape for Proppants · PDF fileAs already mentioned, the...

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Importance of Size & Shape for Proppants Quality

Ian Treviranus ASTM D18.26

Jacksonville, FL January 2013

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Measuring the Size and Shape of Frac Sand and other Proppants

The size and shape of frac sands and other proppants plays a critical role in keeping fractures open and at the desired conductivity. Learn how the CAMSIZER has greatly improved the accuracy and speed of frac sand and proppant analysis. This information will be useful for any petroleum engineer or proppant supplier referencing ISO 13503-2 or API RP 56/58/60 standards. This talk will cover the following topics:

* Faster, more accurate size measurement * Reporting sphericity and roundness * Objective results in only 3 minutes * Example measurement results

Summary


Benefits of Dynamic Image Analysis for Hydraulic Fracking

• Instead of size measurement with sieve shaker and shape analysis by visual inspection you can do a CAMSIZER analysis of both in a much shorter time

• Reproducible results because of high statistics and accurate calibration

• Measuring easily in compliance of API specifications of grain size (90%), oversize and dust (<1%), roundness and sphericity and measure the dust content before and after the crush resistance test

• Measure the increase of layer coating thickness and change of roundness because of the resin coating of sand grains or ceramic proppants

• Also possible: Measuring diameter and length of extrudates


Benefits of Dynamic Image Analysis for Hydraulic Fracking

Accurate Size and Shape results from Frac Sand and Ceramic Proppants

lead to better Proppant products for Hydraulic Fracturing

Better proppants make well production

more effective and avoid Additional Chemical Stimulation

of the oil and gas well


Different Types of Proppants

Image courtesy of CARBO Ceramics *original located here: http://www.carboceramics.com/hierarchy_of_conductivity/

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Proppant Packing


Classic Sizing Technique

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Classic Shape Technique

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Two-Camera-System

Basic-Camera

Measuring Principle

Zoom-Camera

Presenter

Presentation Notes

As already mentioned, the CAMSIZER-technique consists of two cameras. The basic-camera registers the big particles and masks the small ones and the zoom-camera registers the small particles. The two measuring ranges result in a very high resolution and a wide dynamic measuring range. The patented “two camera construction” is only reserved to the CAMSIZER and no other device.


CAMSIZER Measurement

Proppant


Features

Quality Control

>90% within specification => API conform

Presenter

Presentation Notes

Displaying results in Size Graph, Shape Graph, Table and Characteristics. Quality proof can be controlled by cumulative limits, fraction limits and raw data warnings.


Separation of fine and coarse particles

Separation happens during - Transport processes (container, train and truck) - Feeding processes (funnels, vibration feeders, belts) - and Storage (bulk pile, silo)

Sampling and Sample Splitting



Hell



Comparison to Sieving • easy and robust

Advantages

Disadvantages

• low resolution, high effort • limited sample amount • Many possible sources of error

Competing Measuring Methods

Worn out sieves

Presenter

Presentation Notes

Often the CAMSIZER is in direct competition to sieve analysis. Sieve analysis is a proven means to analyze particle sizes. It offers the following advantages: But also some big disadvantages which play a great role in times of staff shortage and lack of time.


F2

F1

1. Move

2. Sliding friction

3. Static friction

xc_min [mm]0.5 0.6 0.7 0.8 0.9 1.00

10

20

30

40

50

60

70

80

90

Q3 [%]

0

50

100

150

200

250

300

350

400

450

q3 [%/mm]5454_PT100_xc_min_008.rdf5454_random_xc_min_009.rdf5454_Huntsman-sieve.ref

Round particles

are captured without

rerelease

Applications - Proppants

Sieving Problems (Overloading)


Quality Monitoring Problems (Size)


Sampling problems: wrong sampling (pouring and “spooning“)

Sieve problems: overloading of sieves (blinding / blocking), cross contamination from trapped material, nominal size real sizes of meshes (wide specification and worn out sieves), sieving machines are not calibrated

Balance problems: low resolution (0.1 grams), not sensitive for small weights (contamination) of joints and moving parts, interference with air flow

Problems and Risks of Common Technologies for Industry


Systematic problems (sphericity & roundness): Multiple Krumbein charts, magnification and lighting of the microscope can vary, poor statistics (small number of particles) Operator/user effects (sphericity & roundness):

biased by last grain, roundness results vary between operators because of brightness of particles (Wisconsin white, Brady brown)

Problems and Risks of Common Technologies for Industry


CAMSIZER Results of Different Natural (Frac Sand) Proppants

xc_min [µm]500 1000 15000

0.1

0.2

0.3

0.4

0.5

0.6

q3 [%/µm]

Natural-Brown-Sand-C-#12-#20-2.rdfNatural-Brown-Sand-C-#12-#20-3.rdfNatural-Brown-Sand-C-#16-#30-1.rdfNatural-Brown-Sand-C-#16-#30-2.rdfNatural-Brown-Sand-C-#20-#40-3.rdfNatural-Brown-Sand-C-#20-#40-4.rdfNatural-Brown-Sand-C-#30-#50-43.rdfNatural-Brown-Sand-C-#30-#50-44.rdfNatural-White-Sand-US-#40-#70-1.rdf

xc min

Size analysis of 5 different natural sand proppant samples (#12/20, #16/30, #20/40 and #30/50). Each sample was measured twice. The repeatability is excellent. One sample of white sand #40/70 is shown for comparison.


xc_min [mm] 0.2 0.4 0.6 0.8 1.0 1.2 0

10

20

30

40

50

60

70

80

90

Q3 [%]

#16-#30-Shipment – CAMSIZER Result – width xc_min.rdf Sieve - Results - #16 - #30 — First time 1.ref Sieve - Results - #16 - #30 — Second time 2.ref

Comparison of sieve (* black) and CAMSIZER data (red). The agreement is excellent. The CAMSIZER measurement can directly replace the sieve analysis, without changing the product specifications.

Sieve Correlation

xc min


Natural Sand Proppants


Loading Facility for Frac Sand Proppant Trucks


Mining, Production, Storage and Truck Loading Facility for Frac Sand

For the quick load out for many trucks

at a high frequency a fast measurement

technology is required

For the size control of the continuous feeding of large stock a fast measurement

technology is required


Typical Sizes

90% to fall within range


Shape Comparison

AspctRatio0.3 0.4 0.5 0.6 0.7 0.80

10

20

30

40

50

60

70

80

90

Q3 [%]Ceramic-Prop-EP-20-40-Mesh-40.rdfCeramic-Prop-SB-20-40-Mesh1.rdfCeramic-Prop-SG-V-1.rdfSand-Prop-SIB-20-40-MIS-9.rdfNatural-Brown-Sand-C-20-40.rdfWhite-Sand-Prop-UNF-20-40-17.rdfWhite-Sand-Prop-SIB-20-40-CHF-10.rdfWhite-Sand-Prop-UNF-20-40-1.rdfWhite-Sand-Prop-UNF-20-40-8.rdf

l

w

Shape comparison between natural sand proppants and ceramic proppants. There are two clearly different ranges of Aspect Ratio (Krumbein’s Sphericity). Analysis of other shape parameters are possible as well (Convexity for ceramic bead twins, Symmetry for good and broken ceramic beads, Krumbein’s Roundness etc.)


Krumbein‘s* Chart

* & Sloss

API ≥ 0.6


2nd Krumbein‘s* Chart

* & Sloss

API ≥ 0.6


3rd Krumbein‘s* Chart

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4th Krumbein‘s* Chart

* & Sloss

API ≥ 0.6


5th Krumbein‘s* Chart


Danke

Gracias

Большое спасибо

Grazie Σας ευχαριστούμε اُشْكر

감사합니다 Obrigado

Tacka

谢谢 ขอบคณุครบั

ありがとうございました

धन्यवा நன்

Cảm ơn Dziękuję


Manual Roundness Measurement


• Breadth-/ Length- ratio

• Roundness

• Symmetry

• Convexity

xFe max

xc min

A

r1

r2

C

A convex

A real

Particle Shape Measurement Results

P

Presenter

Presentation Notes

The CAMSIZER can also measure particle shape, which is divided into four measuring methods: Width-/length ratio Roundness (round: value = 1; not round: value < 1 -> this means: longish or rough) Symmetry: the CAMSIZER scans a particle in 64 directions. The software is searching for the biggest difference between r1 and r2. By this, the software can detect if broken particles are existing. convexity: imagine a rubber band would be spanned around a particle – the result is a convex area. The real area is compared with the convex one. The (root) ratio is the convexity. Hereby one can determine doubles or overlays.


Measurement Results

b/l0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.90

10

20

30

40

50

60

70

80

90

Q3 [%]AK_22,15g_0,3%_BZ_LB_n Ü_xc_min_001.rdfIA_22,15g_0,3%_BZ_LB_n Ü_mit Aerosil_xc_min_001.rdfIA + AK_je 22,15g_0,3%_BZ_LB_n Ü_als Mischung_xc_min_001.rdf

B

A

80

90

Q3 [%]

A B A + B

B A

Measurement of the

Amounts of Proppant

Beads and crushed interlocking particles in a

mixture

Mixture of Ceramic Proppant with Interlocking Particles


Proppant Flowback


Conductivity of Proppants


High Strength and High Roundness Resin Coated Proppants

• Ceramic Core • Resin Coating

Applications – Proppants

Starting Core Resin Coating

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