Proppant immobilization facilitated by carbon nanotube mediated microwave treatment of polymer-proppant structures

A Multiwalled Carbon Nanotube-Based Polyurethane Nanocomposite-Coated Sand/Proppant for Improved Mechanical Strength and Flowback Control in Hydraulic Fracturing Applications

A novel resin-based nanocomposite-coated sand proppant is introduced to address the issue of proppant flowback in post-fracturing fluid flowback treatments and hydrocarbon production. Self-aggregation in the water environment is the most attractive aspect of these developed proppants. In this work, sand was sieve-coated with 0.1% multiwalled carbon nanotubes (MWCNTs) followed by optimized thin and uniform resin (polyurethane) spray coating in the concentration range of 2 to 10%. Quantitative and qualitative evaluations have been carried out to assess the self-aggregation capabilities of the proposed sand proppants where no flowback was witnessed at 4% polyurethane coating containing 0.1% MWCNTs. This applied resin incorporating MWCNT coating was characterized by field emission scanning electron microscopy, and energy-dispersive X-ray spectroscopy depicted the dispersed presence of MWCNTs into polyurethane resin corroborated by the presence of 38% elemental carbon on the sand substrate. Proppant crushing resistance tests were conducted, including proppant pack stress-strain response, compaction, and fines production. It was found that the proposed sand proppant decreased the proppant pack compaction by ∼25% compared to commonly used silica sand with the ability to withstand high closure stress as high as 55 MPa with less than 10 wt % fines production. The surface wettability was determined by the sessile drop method. The application of resin incorporating MWCNT coating layers changed the sand proppant wetting behavior to oil-wet with a contact angle of ∼124°. Thermogravimetric analyses revealed a significant increment in thermal stability, which reached up to 280 °C due to the addition of MWCNTs as reinforcing nanofillers.

Biomimicry Surface-Coated Proppant with Self-Suspending and Targeted Adsorption Ability

Proppant is a key material, which can increase the production of unconventional petroleum and gas. Excellent proppants with a long migration distance are required in the fracture network. Resin-coated proppants have been confirmed as a good choice because of the long migration and the self-suspending ability in fracturing fluids. However, the distribution of the resin-coated proppants in fracture networks is random. The design of proppants with targeted adsorption is urgently needed. In this study, a novel proppant coated with a phenolic resin shell doped with Fe₃O₄ nanoparticles on ceramic (coated proppant) was designed and investigated. Based on the results, the coated proppant was adsorbed on the magnetic component's parts of the fracture network surface, which helps in enhancing the uniform distribution of the proppant in the fracture rock cracks. Meanwhile, the self-suspending ability of the coated proppant is five times higher than that of the uncoated proppant and can migrate a longer distance in the fracture network. Moreover, the liquid conductivity of the coated proppant is 30% higher than that of the uncoated ones at a closure pressure of 6.9 MPa. In summary, new insights into the design of functional proppants and further guidelines on the production of unconventional petroleum and gas have been provided in this study.