First Implementation of Dry Friction Reducer Using Fit-For-Purpose Unit in the Middle East

Slickwater is the most commonly used fracturing fluid system for completing wells in unconventional reservoirs. Traditionally, the friction reducer used to formulate slickwater is a polyacrylamide transported in liquid form, either as a slurry or an emulsion mixture, to facilitate fluid hydration and wellsite delivery using standard equipment. The objective of this work is to implement a dry friction reducer additive that meets the fluid requirements, and it is injected with a fit-for-purpose unit, ensuring flawless operations. The first step consisted of laboratory work conducted to screen several dry friction reducer options and select materials that could deliver adequate hydration time, drag reduction, viscosity, and regained permeability. Secondly, a fit-for-purpose skid, specifically designed to inject friction reducers in powder form, was deployed for the first time in the Middle East. This new unit allows for the automatic control of the desired friction reducer concentration, reduces the operational footprint, and mitigates dust-related health and environmental risks. A series of sensors are installed to closely monitor the product delivery. Lastly, a yard test is conducted to calibrate the unit with the actual material selected from the laboratory screening process. Laboratory results indicated that the selected dry friction reducer offers a drag reduction of around 70%, regained permeability close to 100%, and viscosities between 3 cp and 30 cp at 511 sec⁻¹ at ambient temperature, using concentrations from 3.5 ppt to 35 ppt. Complete hydration was observed within 60 seconds. Two horizontal wells were completed using the selected dry friction reducer and the fit-for-purpose skid. A total of ninety-two hydraulic fracturing stages were pumped as per design at a rate above ninety-five barrels per minute. The average tubular friction observed during the operation was similar to or slightly lower than stages pumped using legacy friction reducers in liquid form in offset wells under similar conditions. Physical material balance demonstrated that the unit precisely delivered the product, with a maximum deviation of within one percent. It is proven that dry friction reducers can be effectively implemented at a large scale for unconventional operations in the Middle East. This innovative solution can benefit operators and service companies by reducing material and transportation logistics, CO2 emissions, and storage requirements while maintaining a flawless operation delivery.