Advancements in Proppant Coating Technologies for Enhanced Hydraulic Fracturing Efficiency: A Comprehensive Review on Nanocomposites and Surface Modifications

• Advances in nanocomposite coatings improve strength, wear resistance, and thermal stability, using graphene and CNTs. • Coatings like polymer, resin, and ceramic enhance durability, prevent embedding, and aid recovery. • Focus on environmentally friendly, stable coatings for industrial use. • Future research aims to optimize carbon-based nanocomposites for harsh conditions. Hydraulic fracturing is a vital method for enhancing productivity in unconventional reservoirs by creating pathways called fractures that enable hydrocarbon flow. Proppants, which hold these fractures open, have progressed significantly in terms of materials and coating technologies. This review aims to bridge gaps in existing studies by providing a in-depth analysis of cutting-edge proppant coating technologies, with a focus on nanomaterials utilization and surface modifications to improve hydraulic fracturing efficiency. While previous researchers have identified challenges with uncoated proppants, including reduced fracture conductivity and declined hydrocarbon production, it is crucial to comprehensively review how resin and resin-based nanocomposite coatings tackle these technical challenges. Through amalgamation of recent developments, this review critically highlights the role of nanocomposite coatings in enhancing proppant performance under extreme downhole conditions. It emphasizes improvements in fracture conductivity and mechanical resilience, particularly noting significant gains in crush resistance and the mitigation of fines generation. These enhancements not only boost fracture conductivity but also address challenges like proppant embedment and thermal degradation. Additionally, this study discusses recent advancements in proppant surface modifications and their impact on fluid conductivity and hydrocarbon recovery. This review also emphasizes the need for continued research into innovative coatings that promote environmental sustainability and operational efficiency, hence ensuring the long-term viability of hydraulic fracturing.