Field applications of a high-strength fracture proppant

Exxon Production Research Co. (EPRC) developed a laboratory procedure for testing propping materials under conditions that closely simulate reservoir conditions. Continuing research resulted in sintered bauxite particles that show greatly improved resistance to crushing over any material available in the past. Sintered bauxite has now been tested in over 20 wells, all of which have been deeper than 10,000 ft. Any proppant considered as a replacement for silica sand will likely cost more and must have benefits that more than offset the increased cost. Detailed economic analyses of the costs and benefits of a high-strength proppant have been developed as a part of the field testing of sintered bauxite. These analyses have shown that the economic benefits of a high-strength material are appreciable. The field results have shown that the benefits predicted from laboratory studies can be realized. This study briefly summarizes the laboratory studies that have led to the development of the new, high-strength bauxite proppant, describes field applications of it, and discusses the results of a detailed economic analysis for a particular field. It is expected that widespread use of the new proppant will be economically justified in the future.