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.