SUN OMNIPROP® – Thermoset Nanocomposite Beads

Background & Innovation

• Challenge in Conventional Proppants:
  Traditional frac sand tends to settle quickly in fractures due to higher specific gravity, leaving large sections unpropped. Resin-coated or ceramic proppants provide more strength, but they are heavier, costlier, and environmentally taxing.

• Solution – OMNIPROP®:
  SUN Specialty Products developed OMNIPROP®, a thermoset nanocomposite bead engineered as an ultra-lightweight proppant (ULWP). Unlike resin-coated sands, OMNIPROP® is inherently lightweight, does not rely on coatings, and is non-toxic, dust-minimized, and eco-conscious.

Material & Environmental Benefits

• Composition: Thermoset nanocomposite beads with near-neutral buoyancy (Apparent Specific Gravity ~1.06).

• Eco-advantages:

  • Free of resin coatings → avoids dust hazards and resin degradation by-products.

  • Requires smaller volumes (3–5% by weight) compared to sand-only designs.

  • Recyclable handling and reduced transport intensity due to lightweight nature.

Performance Characteristics

• Near-Neutral Buoyancy

  • Unlike sand (ASG ~2.65), OMNIPROP® remains suspended in slickwater and brine for longer periods.

  • Ensures better far-field transport, reaching distal portions of fractures where sand cannot.

• Strength & Durability

  • High crush resistance, retaining fracture width at closure stresses.

  • Minimal embedment in fracture faces, preserving conductivity (tested up to ~12,500 psi and 325°F).

• Conductivity Retention

  • Laboratory flow tests confirm superior conductivity retention compared to both sand and resin-coated proppants.

Field Application & Results

Trial Location:

• Andrews County, Texas – San Andres Formation (carbonate reservoir).

Design & Mix:

• Wells completed using slickwater + sand with 2–5% OMNIPROP® blended by weight.

• Example: ~7,500 lb OMNIPROP® mixed with ~250,000 lb frac sand.

Results:

• Fracture Area Coverage:

  • Sand-only: ~25% effective propped area.

  • Sand + OMNIPROP®: ~85% propped area.

• Production Impact:

  • Average 30% increase in first-year cumulative oil production compared to offset sand-only wells.

  • In some wells, uplift exceeded 50,000 additional barrels within the first year.

• Operational Ease:

  • Pumped as standard slurry with no special equipment required.

  • No handling or safety issues reported due to dustless, non-resin composition.

Read Also: Proppants Market 

Comparative Advantages

Industry Recognition

• SPE Publications: Several technical papers presented at SPE Hydraulic Fracturing Technology Conference and referenced in Search.SPE.org, validating lab and field performance.

• Independent Studies (AOGR): Field trial analysis documented improved recovery and fracture optimization in carbonate formations.

• Adoption by Service Companies: Incorporated in treatments delivered by leading OFS players such as Baker Hughes and independent frac operators for unconventional plays.

Strategic Implications

• Economic Uplift: Small additions (3–5% blend) deliver outsized ROI, making it a cost-effective option compared to full ceramic substitution.

• Sustainability Positioning: Eco-conscious operators (especially in North America and Middle East) can align OMNIPROP® usage with ESG reporting and sustainability KPIs.

• Future Expansion: AI-driven fracture modeling is being integrated to simulate OMNIPROP® transport in complex formations, optimizing blend ratios well-by-well.

SUN OMNIPROP® is a proven case of eco-friendly, ultra-lightweight proppant technology. Its buoyant nanocomposite design overcomes transport and conductivity issues of sand, while requiring minimal volumes to yield significant production uplift (≈30%+). This makes it a strong candidate for future sustainable fracturing operations, especially in unconventional and carbonate reservoirs.

Contact Us