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

Abstract

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.