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Speaker: Dipl.-Ing. Gert BeckmannRetsch Technology GmbH
Host: Ian TreviranusHORIBA Scientific Inc.
CAMSIZER
CAMSIZER®Dynamic Image Analysis
ISO 13322-2 conform
Measuring the Size and Shape of Frac Sand and other Proppants
Webinar PresentationFriday, March 9th, 2012
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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 atthe desired conductivity. Learn how the CAMSIZER has greatly improved theaccuracy and speed of proppant analysis. This information will be useful for any petroleumengineer or proppant supplier referencingISO 13503-2 or API RP 56/58/60 standards.
This Webinar will cover the following topics:
* Faster, more accurate size measurement* Reporting sphericity and roundness* Objective results in only 3 minutes* Example measurement results
Abstract
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• 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 sphericityand 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 for the Proppant Industry
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CAMSIZER Principle (Two Cameras)
Advantages• Precise full-frame images• Wide dynamic range: 30µm to 30mm
Dynamic Factor:
Measuring Principle
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Oil and Gas Exploration
Principle draft of modern and effective oil and gas exploration
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Propped Frac & Acid Frac
1/2"
open fracture
during job(frac width
= wf)
fracture tends to close
once the pressure has beenreleased
proppantused to prop thefrac open
acid etched frac walls
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Different Types of Proppants
Image courtesy of CARBO Ceramics*original located here: http://www.carboceramics.com/hierarchy_of_conductivity/
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Different Types of Proppants
Frac Sand (<6,000psi)• Jordan • Ottawa• Brady
Resin-Coated Frac Sand (<8,000psi)• Cureable• Precured
Intermediate Strength Ceramics (<10,000psi)
High Strength Ceramics (<15,000psi)
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Different Principles to increasethe Oil and Gas Conductivity
Image courtesy of Schlumberger*original located here: http://www.slb.com/
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High Strength and High Roundness Resin Coated Proppants
• Ceramic Core
• Growth of Ceramic Proppantduring production process
• Resin Coating
Resin Coating
Growth of Ceramic Proppant
Starting Core
Applications – Proppants
Resin Coating
Growth of Ceramic Proppant
Starting Core
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Comparison of Methods: Sieving• robust and industrial-suited• easy handling• references available from user
Advantages
Disadvantages• high amount of time and work• low resolution,
small number of investigatable classes• limited sample amount• no shape analysis possible
Competing Measuring Methods
Worn out sieves
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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
Roundparticles are
capturedwithout
rerelease
Applications - Proppants
Sieving problems (here Overloading)
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xc_min [mm]0.2 0.4 0.6 0.8 1.0 1.20
10
20
30
40
50
60
70
80
90
Q3 [%]
#16-#30-Shipment – CAMSIZER Result – width xc_min.rdfSieve - Results - #16 - #30 — First time 1.refSieve - 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 CAMSIZER of Natural Brown Sand
xc min
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CAMSIZER Results of Different Natural (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.
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xc_min [µm]200 400 600 800 1000 12000
0.1
0.2
0.3
0.4
0.5
q3 [%/µm] 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
Size analysis of 9 different proppant (sand and ceramics) samples (#20/40). Some have wider, some have more narrow size distributions. One ceramic proppant sample had a bimodal distribution (red “Ceramic-Prop-EP-20-40-Mesh-40”).
Grain Size Comparison
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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.)
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xc_min [ASTM]#325 #230 #170 #120 #80 #60 #45 #35 #25 #180
10
20
30
40
50
60
70
80
90
passing [%]Ceramic-Proppant-16-30Mesh_xc_min_001.rdfCeramic-Proppant -20-40Mesh_xc_min_001.rdfCeramic-Proppant -20-40Mesh_xc_min_002.rdfCeramic-Proppant -20-40Mesh_xc_min_003.rdfCeramic-Proppant -30-60Mesh_xc_min_003.rdfCeramic-Proppant -30-60Mesh_xc_min_004.rdfBlasting Product -40-120Mesh_xc_min_001.rdfProppant + Interlocking Grains -10-20Mesh_xc_min.rdf
xc min
Grain Size Analysis of Ceramic Proppants
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Shape Analysis of Ceramic Proppants
AspctRatio0.3 0.4 0.5 0.6 0.7 0.80
10
20
30
40
50
60
70
80
90
Q3 [%] Ceramic-Proppant -16-30Mesh_xc_min_001.rdfCeramic-Proppant -20-40Mesh_xc_min_001.rdfCeramic-Proppant -20-40Mesh_xc_min_002.rdfCeramic-Proppant -20-40Mesh_xc_min_003.rdfCeramic-Proppant -30-60Mesh_xc_min_003.rdfCeramic-Proppant -30-60Mesh_xc_min_004.rdfBlasting-Product-40-120Mesh_xc_min_001.rdfProppant + Interlocking Grains-10-20Mesh_xc_min.rdf
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Hydraulic Fracturing
Principle draft of modern and effective oil and gas exploration
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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
Amounts of Proppant Beads and crushed interlocking particles in a mixture
Ceramic Proppantwith Interlocking Particles
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32.8%
67.2%
xFe max
xc min
Measurement Results
Q3 (round particles) =
CAMSIZER can find the mixing ratio of ProppantBeads and Angular Interlocking Grains
Ceramic Proppantwith Interlocking Particles
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0.2 %
1.6 %98 %
-20/+40-40/+70-70/+100-100
Ceramic Prop after API single cycle crush test at 6000 psi
Fines Migration & Plugging
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r rbroken particle
good product
Symm0.948 0.949 0.950 0.951 0.952
15
16
17
18
19
20
21
22
Q3 [%]TP-WS 0525_Probe1_BZ_0.5%_xc_min_001.rdfTP-WS 0525_Probe2_BZ_0.5%_xc_min_001.rdfTP-WS 0525_Probe3_BZ_0.5%_xc_min_001.rdfTP-WS 0525_Probe4_BZ_0.5%_xc_min_001.rdfTP-WS 0525_Probe5_BZ_0.5%_xc_min_001.rdfTP-WS 0525_Probe6_BZ_0.5%_xc_min_001.rdfTP-WS 0525_Probe7_BZ_0.5%_xc_min_001.rdfTP-WS 0525_Probe8_BZ_0.5%_xc_min_001.rdfTP-WS 0525_Probe9_BZ_0.5%_xc_min_001.rdfTP-WS 0525_Probe10_BZ_0.5%_xc_min_001.rdf
2
1min~rr
17.4% broken
20% broken
Symmetry
r1 r2
CAMSIZER – Advantages Measuring Broken Beads
Applications – Ceramic Proppants
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• Breadth-/Length-ratio
• Roundness
• Symmetry
• Convexity
xFe max
xc min
A
r1
r2
C
A convex
A real
Particle ShapeMeasurement Results
P
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Optical Process Controlanalysis for size and shape
Measurement Results
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12 Years CAMSIZER~ 600 installed CAMSIZER Instruments worldwide:Nearly on all continents
For many applications/industries:API conformity, Brown sand,
Ceramic proppants, Extrudates, Grains, Proppants, Resin coated
proppants, Sand, White sand ........
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Surface AreaSize, shape and specific
surface area (SSA) affect catalyst performance
Measure SSA using BET: SA-9600– Flowing gas BET method– Low price,operating costs,
maintenance– Easy to use, fastest
measurement time– No vacuum system required– Single or multi-point– Up to three samples
simultaneously
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Petroleum Analysis
Many instruments to measure the quality of oils, fuels, etc. SLFA-20 ASTM D4294 for crude
MESA-6000 ASTM D7220 for low ppm sulfur and chlorine
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CAMSIZERfor elongated particles (extrudates)
xMa min
xc min
x Fe
max
A/2
A/2
xMa min
2A
2A
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xFe max xlength xFe rec
xMa min
x Fe
rec =
xle
ngth
CAMSIZER® length definitionsfor elongated particles (extrudates)
xMa min
x Fe
rec
= x
leng
th
xMa min
x Fe
rec
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Length + Diameter of Implants
Length measurement xlength ~ 26mm
Diameter measurement Ø ~ 0.85mm
validation and test 1. with plastic and 2. steel cylinders
measurements of produced
implants (release time 1month)
Applications – Pharmaceuticals
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fitted result
CAMSIZER-measurement x (red)to sieving * (blue)
Competing Measuring Methods
Fitting of CAMSIZER result to Sieving
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x [mm]0.1 10
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Q3
Tinovetin-B-CA584A_BZ_xc_min_002.rdfSyngenta-1mm-2min-Sieb.ref
Digital Image Processing Measuring of Width Sieving
--- width measurement
-*- Sieving
comparison
CAMSIZER-measurement xc min (red)and sieving * (black)
Competing Measuring Methods
xcmin
xc min
“width”
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x [mm]0.2 0.4 0.6 10
10
20
30
40
50
60
70
80
Q3 [%]
Sample A_BZ_0.2%_xc_min_001.rdfSample A_.ref
Digitale Imaging Sieving
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x [µm]200 400 600 8000
10
20
30
40
50
60
70
80
90
Q3 [%]
RT669_3993_Z_LB_05%_xc_min_001.rdfRT669_RT_3993.ref
Digital Imaging SievingCubes / Angular Particles
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x0.5 1.0 1.5 2.00
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
y
10-16mm_BZ_05%_xc_min_001.Q3Real_10-16mm.Q3
x [µm]200 400 600 8000
10
20
30
40
50
60
70
80
90
Q3 [%]
RT669_3993_Z_LB_05%_xc_min_001.rdfRT669_RT_3993.ref
Digital Imaging Sieving
Examples of samples with edgy particles without fitting
CAMSIZER-result xc min (red)sieve analysis * (black)
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xc_min [mm]1.0 1.5 2.0 2.5 3.00
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Q3
Digital Imaging Sieving
Elementary - Fitting
New elementary fitting with single (narrow) sieve class and entire distribution{
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Digital Imaging Sieving
Elementary fitting =
Sieve Correlation with single (narrow)
sieve class
Samples with
similar shape
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xc_min [mm]1.0 1.5 2.0 2.5 3.00
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Q3
xc_min [mm]1.0 1.5 2.0 2.5 3.00
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Q3
xc_min [mm]1.0 1.5 2.0 2.5 3.00
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Q3
Digital Imaging Sieving
Q3 – Fitting
Elementary - Fitting
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Comparison betweenStatic Dynamic Image Analysis
ISO 13322-1 ISO 13322-2
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Sample Quantity in Mass or Volume in Relation to the Particle Size
A Sufficient Sample Quantity isBased on the Number of Particles
ISO 13322-1
Sampling and Sample Splitting
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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
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Separation of fine and coarse particles
Segregation (separation by size) happens during- Filling processes (silo)- Feeding processes (bulk pile)- Accumulation of fines in the middle of the pile
Sampling and Sample Splitting
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Different Production Methods, as well as Different Sizes and Shapes
Applications – Fertilizer
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CCD - Basic CCD - Zoom
Measuring Principle
Detection of particles
One pixel is element of a projection when at least half of the pixelis covered.
Resolution
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Advantages
fast reproducible
Measuring Principle
maintenance-free & robust
precise
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Particle SizeMeasurement Results
xcmin
xc min
“width”
A
A‘ = A
x are
a
“diameter overprojection surface”
xarea“length”
xFe max
xFemax
CAMSIZER results are
compatible with
sieve analysis
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xc min
width
xc min
xc min
leng
th
x Fe
max
Q3 ellipsoid
ellip
soid
-vol
ume
min2
maxellipsoid 6V cFe xx
width
Ellipsoid model leads to better results
Measurement Results
Volume Definition
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Additional Slides to betterexplain the Dispersion
Technology (against
static chargedparticles)
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Size, Shape & Density Measurement of Charged Coated Resin Beads using an Electric High Voltage Ionizer
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Dispersion ofcoated granules
with Ultrasonic orALU-C Aeroxide
How to separate thedust part from the
granules to measurethese singledispersed?
Applications – Fertilizer
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Additional Slides to betterexplain the Basics of theused Parameters and the
Calibration of theInstrument
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Particle DistributionsCumulative distribution Qr
Based on Index
r Number 0 Length 1 Area 2 Mass/Volume 3
x
Qr [%]
x50 x1x2 xmaxxmin
Qr(x2)
Qr(x1)
Qr(x1,x2)
0
50
100
Measurement Results
median
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x
q r
x min
2
1
x
xdx)x(qp rr
x)x,x(q)x,x(Q 2121 rr
x 1 x 2 x max
dx)x(dQ
)x(q rr
[%/mm]
Particle DistributionsFrequency distribution qr
Measurement Results
mean
Mv(x): mean value of x, determined from the distribution of all particles
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x [µm]400 600 800 1000 12000
5
10
15
20
25 p3 [%]
0
10
20
30
40
50
60
70
80
90
Q3 [%]
n
0iir,nr p = )x(xQ
n is the number of the fraction
Particle DistributionsHistogram fractions pr
Measurement Results
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Reproducibility
Calibration with traceable standard
=> Absolute accuracy
Measurement Results
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0
Glass Bead-Standard 500µm – 2000µm
1,25mm ± 24µm 95% (* Q3 75% )written in the calibration certificate
-- CAMSIZER
* Sieving
CAMSIZER and Sieving (72%)done with calibrated sieve by hand
Calibration Results