Oct. 07, 2024
At the forefront of the proppant industry, Carbo Ceramics and Saint-Gobain Proppants are set to compete fiercely for the title of crush test supremacy. During the recent SPE Annual Technical Conference and Exhibition (ATCE), both companies unveiled a revolutionary class of ultra-heavy proppants designed to withstand the extreme stresses encountered in deepwater exploration.
If you're seeking further details, please visit AnYiCheng.
Next year, these companies aim to start mass production of ceramic grains anticipated to be the strongest available, capable of enduring pressures exceeding 20,000 psi. The innovative materials and production techniques developed to achieve a crush test limit increase from around 15,000 psi will pave the way for higher-performing proppants, especially in lower stress environments.
According to Gary Kolstad, the CEO and president of Carbo, the new processes will revolutionize their production strategies. The new product, Kryptosphere, features a remarkable uniformity in size and shape, resembling tiny ping pong balls. This innovative design marks a shift from the traditional sintered bauxite long used in extreme conditions.
At their ATCE exhibit, Saint-Gobain showcased their new high-performance proppant, Titan, claiming it could withstand pressures up to 30,000 psi.
Both companies are using new materials and distinct manufacturing methods, though details remain undisclosed. Their target customers include operators in regions like the Lower Tertiary trend in the US Gulf of Mexico, where fracturing is necessary in wells that can reach depths beyond 30,000 feet below the mudline in water nearly 10,000 feet deep.
Additional advancements in proppant technology were also spotted at the ATCE. Oxane Materials introduced the first field test data for their proppant created using novel materials, which reportedly yield significantly stronger particles. Santrol demonstrated its newly acquired buoyant coating technology for proppants that aids in deeper penetration into formations. This subsidiary of Fairmount Minerals acquired self-suspending proppant technology earlier this year, modifying it for humid environments and beginning field tests this November.
Testing conducted by Stim-Lab indicated that the buoyant coating doesn't interfere with equipment like blenders. According to Michael Conway, president of Core Labs Stim-Lab division, the initial results are promising. He remarked, "We will find out soon if it makes a material difference in production."
However, despite advancements, comparisons of large material discrepancies, like sand versus ceramic, in actual field conditions don’t consistently reflect expected performance differences observed in laboratory settings. Tim Stephens, R&D director at Saint-Gobain Proppants, noted that variations in well outputs and numerous influencing factors complicate the assessment of proppant effectiveness.
In high-demand scenarios, particularly in the Lower Tertiary formations that require higher performance solutions, ceramic options prove worthwhile, often justifying their higher costs against lower-priced alternatives like sand.
Carbo's new Kryptosphere, left, and Saint-Gobain Proppants Titan, right, both offer a crush strength of minimum 20,000 psi. Photos courtesy of Carbo and Saint-Gobain.
There exists a significant market for the new ultra-strong proppants in the Lower Tertiary due to the high pressure and temperature conditions necessitating advanced completion technologies. The creation of Kryptosphere started after an operator requested a proppant that could withstand the harsh reservoir conditions. According to Don Conkle, Carbo's vice president of marketing and sales, a major request specified a proppant capable of providing double the conductivity at 20,000 psi.
This project began in earnest, leading to two additional years of refining the internal structure of the grains after discovering material changes alone were insufficient. Testing from Stim-Lab confirmed that Kryptosphere not only meets but exceeds the 20,000 psi goal, achieving results of 22,000 psi with confidence in closure stresses.
Saint-Gobain's ultra-strong proppant also underwent lab testing and proved robust at 30,000 psi, with development efforts commencing upon customer interest.
Both manufacturers project sufficient production levels to enable field testing starting next year, with Carbo expecting a monthly output of 500,000 pounds to rise to 1.5 million pounds by year-end. Meanwhile, Saint-Gobain is also gearing up for production.
The likely composition of both new proppants includes alumina, known as aluminum oxide, a standard component in producing aluminum and ceramics. Although details remain scant, Conkle confirmed a high alumina content for Carbo's material.
Both companies aim for production processes yielding fewer internal pores, enhancing performance by reducing the chances of fractures leading to "fines," which impede conductivity.
A magnified look at the internal structure of the new proppants from Carbo Ceramics, left, and Saint-Gobain Proppants, reveals minimal pore space. Photos courtesy of Carbo and Saint-Gobain.
Producing a proppant that meets the rigorous needs of Lower Tertiary producers reflects considerable technical progress, albeit with limited payoff, as projections suggest only about eight wells will require approximately 40 million pounds of proppant in the Gulf of Mexico next year, per Carbo's insights.
For leaders in the industry, one of the objectives remains to cater to all market segments, particularly the ultradeepwater market where producers invest heavily in high-stakes drilling. "Those wells are so expensive, you cannot afford to have proppant failures," emphasized Don Herndon from Saint-Gobain Proppants.
Nonetheless, the deepwater sector remains significantly smaller compared to the onshore shale market, which has wells clustered on pads to maximize output. Herndon noted, "Deepwater operations do not compare to managing 30-well pads that need 6 million pounds of proppant each; they are critical wells."
Both firms anticipate that insights gathered from their offshore operations will translate well into broader product lines.
For further details, check out our page on China smooth ceramic proppant supplier.
Carbo’s Kryptosphere brand is set to impact visual perception within the industry. The enhanced production process leads to uniform grain shapes and sizes, where cuts reveal a smoother texture devoid of excessive pore space.
According to Conkle, this minimized pore structure within Kryptosphere translates to merely 1% to 2% internally, as opposed to 5% in Carbo's existing offerings and up to 25% in lesser quality ceramic proppants. Enhanced performance attributes hinge on reduced pore space to avoid fractures that yield fines obstructing flow.
Both Oxane and Saint-Gobain claim their manufacturing processes yield equally high-strength particles with visually distinct attributes.
While discussions surrounding the performance of smooth spherical proppants versus their rougher counterparts continue, expert opinion emphasizes the importance of conducting controlled tests to definitively ascertain performance metrics in real-world applications.
The ultra-strong proppants presented this season are denser than traditional sintered bauxite variants used in the deepest wells. Carbo and Saint-Gobain’s new offerings boast a specific gravity of 3.9, compared to the 3.6 characteristic of sintered bauxite, the previously strongest material available. However, this higher density may complicate deeper fracture penetration due to settling tendencies.
Both manufacturers assert that lessons learned will enhance the strength of existing product lines moving forward. Oxane claims that their top-performing variant at 15,000 psi maintains a relative low specific gravity of 2.9, contrasting with comparable offerings from sintered bauxite.
Looking ahead, Saint-Gobain plans to launch an advanced version of its lightweight proppant next year. This double-layer ceramic particle with resin will have a specific gravity below 2, aiming to balance weight and performance.
Among collaborators within the space, Frank Syfan from Go Frac cautioned against overly focusing on singular metrics, such as maximum closure stress. Optimal proppant choices entail balancing trade-offs across strength, conductivity, pricing, and logistics, as a universally ideal proppant is unattainable.
Amidst a surge of low-cost entrants into the proppant market, established manufacturers are launching high-performance solutions. The catalyst for this demand stems from the unconventional drilling boom in North America that once led to shortages. There are currently around 20 to 30 notable proppant manufacturers operating in China, as indicated by analyses from Industrial Minerals.
Carbo recently reported a 7% decline in ceramic proppant sales volume year-over-year, offset by a rise in resin-coated sand sales, thus reducing average selling prices per pound. The company noted a growing emphasis on well cost reduction versus the inherent proppant properties.
However, the landscape shifted by the third quarter, when Carbo witnessed a 33% increase in ceramic proppant volumes compared to the previous year, attributed to market share gains across North America and increased usage in regions like the Bakken.
The international market remains challenging, with notable competition stemming from Chinese providers. Carbo executives consistently critique Chinese ceramic proppant quality, citing higher internal porosity compared to domestic offerings.
Notably, Mike O'Driscoll from Industrial Minerals recognizes transformations underway in Chinese production capabilities, indicating equipment upgrades that could elevate product standards. As competition persists, US-based companies actively enhance ceramic proppant manufacturing capabilities to grapple with price-sensitive market dynamics.
Lastly, low-priced sand holds about 80% of the market, with remaining segments evenly divided between ceramics and resin-coated sands. Ultimately, ceramics must distinguish by performance in deep wells, managing stress beyond the capabilities of cheaper alternatives.
The challenge lies in convincing operators who require superior performance to justify cost differentials against more economical options.
Before initiating your search for a dependable Chinese smooth ceramic proppant provider, it's essential to clearly define your specific needs. Different scenarios may call for unique types of proppants, each varying in size, shape, and strength. Compile a detailed list encompassing your specifications, including required quantities, desired grain size, and any relevant performance criteria. Additionally, consider the environmental conditions in which the proppant will be utilized; high-pressure and high-temperature settings may necessitate tougher materials. Such clarity will aid discussions with potential suppliers, facilitating informed decisions.
A manufacturer's reputation is a vital indicator of reliability. Begin by conducting online searches for potential suppliers, assessing their histories, customer reviews, and case studies. Platforms like Alibaba or industry-focused forums may offer valuable insights into other companies' experiences. Seek suppliers with credentials, such as ISO certification, reflecting adherence to international quality standards. Networking with peers can also reveal trustworthy manufacturers—word-of-mouth recommendations can guide you toward suppliers with proven records of positive customer interactions.
Quality control is fundamental when choosing a ceramic proppant manufacturer. Investigate their quality assurance protocols and their approach to product evaluation throughout production stages. Manufacturers dedicated to quality should employ stringent testing processes and be transparent in their practices. Inquire about types of tests conducted on the products, including crush resistance and sphericity assessments. Reliable suppliers should readily provide test certificates and product samples for evaluation. If feasible, visiting their manufacturing facilities can offer direct insights into operational processes and quality checkpoints.
Effective communication plays a crucial role in enhancing your experience with a supplier. An ideal partner should promptly respond to inquiries, offer clear and informative feedback, and exhibit a genuine commitment to accommodating your requirements. Assess their customer service by evaluating their initial engagement with inquiries and follow-up correspondences. A trustworthy supplier typically has dedicated support staff available to assist clients from order placement to delivery. Establishing transparent lines of communication can mitigate misunderstandings and ensure your needs are effectively met. Moreover, manufacturers prioritizing customer engagement may provide further assistance, such as technical advice, delivery tracking, and after-sales support, ultimately enhancing your overall experience and fostering successful partnerships.
Ultimately, choosing a credible Chinese smooth ceramic proppant manufacturer necessitates systematic consideration and thorough research. By clarifying your requirements, exploring the reputation of prospective manufacturers, analyzing their quality assurance measures, and evaluating their communication and customer service standards, you can make more informed decisions. For further assistance or to discuss specific needs, feel free to reach out.
For more insights, visit China smooth ceramic proppant wholesaler.
If you are interested in sending in a Guest Blogger Submission,welcome to write for us!
All Comments ( 0 )