A Comprehensive Review on the Characteristics, Challenges and Reuse Opportunities Associated with Produced Water in Fracturing Operations

Amid the rise in energy demand over recent years, natural gas from tight reservoirs has been targeted abundantly around the globe by different oil operators. Hydraulic fracturing technology has been instrumental in the successful exploitation of energy from tight formations. The process is associated with enormous usage of water. Hydraulic fracturing requires as little as 500,000 gallons of freshwater, and up to 6 million gallons per well depending on the type of well and the number of stages treated. Now operators, as well as service companies worldwide, have shown a desire to use produced water in field operations to enhance economics and reduce their environmental footprint. Reusing produced water in field operations appears to be a win-win proposition by transforming the industry's biggest waste product into a resource. This paper highlights the recent findings in published articles about formulating a fracturing fluid from produced water as a base fluid. The rheological properties and fluid performance requirements, such as proppant carrying capacity, mixing, fluid efficiency, ability to crosslink and break, and cleanup after treatment, will be evaluated in detail. This paper identified the critical parameters associated with high TDS fluids (produced water) such as pH, hydration time, ionic strength, and suspended solids, collected the corresponding optimal ranges for these parameters in laboratory tests, and reported some of the validity of the findings under actual conditions in field trials around the world. Most studies demonstrated the feasibility of using untreated produced water as a base fluid for crosslinked gel-based hydraulic fracturing. Through adjusting the hydration time, the gel loading, and the amount of breakers applied, it is conceivable that crosslinked gels with optimal rheological characteristics can be formulated with untreated produced water. Multiple generations of guar- and CMHPG-based crosslinked fracturing fluids, developed with 100% untreated produced water, exhibited optimal viscosities exceeding 200 cp at 40 s−1 for at least 60 minutes. The ability to provide fracturing fluids with high-salinity produced water can be a successful water conservation approach and an attractive solution for enhancing operation economics. Some studies indicated that using produced water can be better than freshwater because the produced water is more compatible with the reservoir and may be less likely to cause conditions such as salinity shock, which can damage the formation. More studies are needed to understand the associated technical challenges further.