Grain-scale analysis of proppant crushing and embedment using calibrated discrete element models

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Abstract

Proppant crushing and embedment in hydraulically-induced fractures is a major drawback to the recovery of unconventional oil/gas and geothermal energy production. This study provides a grain-scale analysis of the fracture evolution mechanisms of proppant crushing, rock fracture damage during proppant embedment, the influence of realistic reservoir/fracture fluid on proppant embedment, and the behaviour of proppant packs subjected to in-situ stresses using a discrete element modelling (DEM) approach. The results of this study reveal that the selection of an appropriate proppant type based on the nature of the reservoir formation plays a vital part in quantifying the degree of proppant crushing and embedment within fractures. The utilisation of frac-sand proppants instead of ceramic proppants in shallow soft sedimentary-based siltstone formations reduces proppant embedment up to 88%. However, whatever the depth of the fracture, the injection of ceramic proppants into granite-based geothermal formations is preferred to that of frac-sand proppants due to their lower proppant embedment and greater crush resistance. DEM analysis detected rock-spalling during the proppant embedment process, which ultimately led to the initiation of tensile-dominant secondary fractures in rocks. Fracture initiation, propagation, and coalescence during proppant crushing are analysed using calibrated DEM proppant-rock assemblies. Importantly, this study reveals that the saturation of formation rocks with fracturing/reservoir fluids may cause a significant increase in proppant embedment. Furthermore, proppant crushing, embedment, and re-arrangement mechanisms in proppant packs with different proppant distributions are analysed in this comprehensive numerical study.

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APA

Bandara, K. M. A. S., Ranjith, P. G., Zheng, W., Tannant, D. D., De Silva, V. R. S., & Rathnaweera, T. D. (2022). Grain-scale analysis of proppant crushing and embedment using calibrated discrete element models. Acta Geotechnica, 17(11), 4837–4864. https://doi.org/10.1007/s11440-022-01575-9

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