Improving long-term hydraulic fracture conductivity by alteration of rock minerals

Fracture conductivity is a measure of the fracture ability to transfer fluids from a hydrocarbon-bearing zone to a well. Proppant embedment in soft formations and rock weakening due to the acid/rock reaction limit the stimulation success resulting in sharp fracture conductivity decline. The focus of this study is to increase the rock strength by mineralogical alteration aimed at sustaining long-term fracture conductivity. To achieve these, several standard cylindrical Indian limestone plugs with diameters of 1.5 and 2.5 in and length of 3 in were treated with different types of zinc solutions to substitute calcium with zinc in calcite crystals. The goal of these mineral alterations is to change the principal component of limestone rocks surface, calcite (CaCO₃), into smithsonite (ZnCO₃). Smithsonite is harder than calcite and its lattice system is similar to calcite. The treatment was carried out by full immersion of samples into zinc solutions at a predetermined time intervals. The rock strength was measured from samples surface (Young's modulus) before and after the treatment by a non-destructive technique using an impulse hammer. Zinc sulfate solution was found to enhance the rock hardness by values ranging from 25% to 35% via the formation of a layer of smithsonite on the sample's surface. SEM, XRF, XPS and FIB-SEM experiments were conducted to understand the exchange mechanism that eventually led to the hardening. Also, effective porosity and permeability were measured before and after the chemical treatment to investigate its impact. A field-scale modeling study of rock hardness impact on productivity is provided as a preliminary proof of concept.