PROPPANT SAND COATING FOR DUST REDUCTION
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 styrene butadiene rubber (“SBR”) latex 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 styrene butadiene rubber (“SBR”) latex-containing dispersion further comprises one or more selected from the group consisting of polyurethane dispersions and polyacrylate dispersions.
9 . A process for coating a proppant comprising:
disposing a styrene butadiene rubber (“SBR”) latex 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 styrene butadiene rubber (“SBR”) latex 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 styrene butadiene rubber (“SBR”) latex-containing dispersion further comprises one or more selected from the group consisting of polyurethane dispersions and polyacrylate dispersions.
17 . A process for reducing dust from a proppant comprising;
disposing a styrene butadiene rubber (“SBR”) latex 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 styrene butadiene rubber (“SBR”) latex 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 styrene butadiene rubber (“SBR”) latex-containing dispersion further comprises one or more selected from the group consisting of polyurethane dispersions and polyacrylate dispersions.