measuring the size and shape of frac sand and other proppants

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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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Measuring PrincipleMeasuring Principle

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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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Two-Camera-System

Basic-Camera

Measuring Principle

Zoom-Camera

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Workers at the drill hole of the rig

Oil and Gas Exploration

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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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Natural Sand Proppants(Brown and White)

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Resin CoatedSand Proppant

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Loading Facilityof Sand Proppant Trucks

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Unloadingof a Proppant Railcar

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Ceramic Proppants

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Ceramic Proppants

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Resin Coated CeramicProppant

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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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Ceramic Proppant

CAMSIZER Measurement (Start)

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CAMSIZER Measurement

Ceramic Proppant

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Ceramic Proppant

CAMSIZER Measurement (End)

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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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Typical Grain Sizes of Proppants

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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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Proppant Flowback

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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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Visual Inspection and Comparisonwith Krumbein‘s Chart

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AutoSamplerFeatures

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Trend AnalysisAreas of Application

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Features

Quality Control

>90% within specification => API conform

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Maintenance-Free byVenturi-Flushing

Features

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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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Particle Size of Drilling Fluid

LA-950

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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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Slides ShownDuring the Q&A Session

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fitted result

CAMSIZER-measurement x (red)to sieving * (blue)


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)


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


Elementary - Fitting

New elementary fitting with single (narrow) sieve class and entire distribution{

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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


Q3 – Fitting

Elementary - Fitting

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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)


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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


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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

©Re

tsch

Tec

hnol

ogy

2012

-10

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

measuring the size and shape of frac sand and other proppants

Technology

accurate size measurement

shape analysis

shape of frac sands

camsizer analysis

example measurement

speed of proppant analysis

objective results

proppant industry