Leveraging Produced Water to Reduce Freshwater Demand in Hydraulic Fracturing Operations

Abstract

Abstract This study aims to enable the reuse of produced water in hydraulic fracturing by evaluating the performance of high-viscosity friction reducers (HVFRs) in high total dissolved solids (TDS) produced brines. The goal is to reduce the dependence on freshwater resources. Produced water samples from the Permian Basin and freshwater were used to formulate HVFR and PEO fluids. Laboratory investigations were conducted to assess viscosity, friction reduction, breaker compatibility, and formation damage at temperatures up to 280°F. Field trials validated the performance. Engineered HVFRs achieved effective rheological profiles and 78% friction reduction in in 121,000 ppm salinity brine, comparable to freshwater. Compatibility with breakers was demonstrated with complete degradation at 150°F. Regained conductivity testing showed HVFR fluids caused less permanent formation damage compared to polyethylene oxide (PEO) gels. Minimal formation damage was observed. Field implementations exhibited reduced operational risks, lower chemical costs, and eliminated freshwater demand. With customized HVFR systems, produced water can reliably replace freshwater for hydraulic fracturing. This reduces environmental impacts and water management costs. The study provides guidance on developing optimized fracturing fluids from produced water. Field evidence demonstrates that transitioning to these sustainable produced water systems is operationally feasible. This is the first study to systematically optimize and validate HVFR and PEO chemistry in high TDS produced water from unconventional assets. The tailored formulations enable the effective reuse of produced water in fracturing operations, reducing reliance on freshwater. This provides a more sustainable, low risk, and cost-effective alternative to conventional fracturing fluids.