A low-carbon pathway for proppants production using solid waste recycling

Abstract

The growing need for sustainable hydraulic fracturing requires the development of proppants that align operational efficiency with environmental management. This paper analyses advances in low-carbon propping technologies, such as ultra-low-density proppants (ULDPs), multifunctional proppants, and traditional ceramic proppants. Integrating industrial by-products such as fly ash, slag, and drilling cuttings has resulted in substantial energy and carbon emissions savings. For example, microwave sintering techniques reduced energy consumption by 30%, while life cycle CO₂ emissions were reduced by 55% to 68% compared to conventional proppants. Mechanical tests confirm that these alternative promoters meet API standards for closing stress at 52 MPa, with a crushing resistance of ≤ 8% and a fracture conductivity of more than 90%, aided by self-healing coatings. In addition, non-combustion methods, including geopolymerisation and additive sintering, have allowed temperature reductions of up to 300ºC. This enhances the sustainability of fuel production. Despite these promising advances, challenges remain in standardising feedstock quality and adapting to evolving regulatory frameworks. However, the annual conversion of 1.1 billion tonnes of industrial by-products into high-performance proppants offers an opportunity for decarbonisation. To achieve this potential, we must continue to address critical gaps in field validation and standardisation of life cycle assessment. This underlines the need for interdisciplinary collaboration to integrate circular economy principles into unconventional resource extraction practices.

Keywords: Proppants, Sustainable Hydraulic Fracturing, Low-Carbon Technologies, Solid Waste Utilization, Environmental Impact

DOI: 10.7176/JETP/15-1-05

Publication date: April 28th 2025