Proppant sand coating for dust reduction

Abstract

The present invention provides for coating proppants, such as sand, with a resin-containing dispersion which dramatically reduces the dust generated during handling, for example in hydraulic fracturing, by protecting the surface of the particle from abrasion and degradation. Such resin-containing dispersion coated-sand may also reduce the wear on metal parts used in transporting such proppants.

1 . A coated proppant comprising:
 a core; and   a polyacrylate containing dispersion coating disposed over at least a portion of the core,   
       wherein the coated proppant has at least about a 90% reduction in dust as compared to a comparable core in an uncoated state. 
     
     
         2 . The coated proppant according to  claim 1 , wherein the core comprises one selected from the group consisting of sand, mineral fiber, a ceramic particle, a bauxite particle, a glass particle, a metal bead, a walnut hull, a composite particle and coated sand. 
     
     
         3 . The coated proppant according to  claim 1 , wherein the resin-containing dispersion is applied at about 0.05 wt. % to about 2.0 wt. % resin solids based on the weight of the proppant. 
     
     
         4 - 7 . (canceled) 
     
     
         8 . The coated proppant according to  claim 1 , wherein the polyacrylate resin further comprises one or more selected from the group consisting of polyurethane dispersions and styrene butadiene rubber (“SBR”) latex dispersions. 
     
     
         9 . A process for coating a proppant comprising:
 disposing a polyacrylate-containing dispersion over at least a portion of a proppant core, wherein the coated proppant has at least about a 90% reduction in dust as compared to a comparable core in an uncoated state.   
     
     
         10 . The process according to  claim 9 , wherein the core comprises one selected from the group consisting of sand, mineral fiber, a ceramic particle, a bauxite particle, a glass particle, a metal bead, a walnut hull, a composite particle and coated sand. 
     
     
         11 . The process according to  claim 9 , wherein the polyacrylate-containing dispersion is applied at about 0.05 wt. % to about 2.0 wt. % resin solids based on the weight of the proppant. 
     
     
         12 - 15 . (canceled) 
     
     
         16 . The process according to  claim 9 , wherein the polyacrylate-containing dispersion further comprises one or more selected from the group consisting of polyurethane dispersions and styrene butadiene rubber (“SBR”) latex dispersions. 
     
     
         17 . A process for reducing dust from a proppant comprising;
 disposing a polyacrylate-containing dispersion over at least a portion of a proppant core, wherein the coated proppant core has at least about a 90% reduction in dust as compared to a comparable core in an uncoated state.   
     
     
         18 . The process according to  claim 17 , wherein the core comprises one selected from the group consisting of sand, mineral fiber, a ceramic particle, a bauxite particle, a glass particle, a metal bead, a walnut hull, a composite particle and coated sand. 
     
     
         19 . The process according to  claim 17 , wherein the polyacrylate-containing dispersion is applied at about 0.05 wt. % to about 2.0 wt. % resin solids based on the weight of the proppant. 
     
     
         20 - 23 . (canceled) 
     
     
         24 . The process according to  claim 17 , wherein the polyacrylate dispersion further comprises one or more selected from the group consisting of polyurethane dispersions and styrene butadiene rubber (“SBR”) latex dispersions.