LABORATORY PROGRAMME · TRL 3 → 4

From reactive phase to qualified particle

A controlled experimental route for manufacturing, stabilising and validating DISE droplets under measurable transport, thermal-dose and load-bearing conditions.

EXPERIMENTAL QUESTION

One integrated formulation. Three critical functions.

The programme tests whether DISE can combine low-viscosity delivery, a calibrated induction period and droplet-confined polymerisation without assuming that component-level precedent proves system-level performance.

Reproducible droplets

Generate a controlled 70–600 µm population and quantify D10, D50, D90, span, sphericity, doublets and agglomerates.

Controlled induction

Calibrate radical initiation against the complete temperature-time history, targeting a 25–75 minute operational window.

Functional particle pack

Measure morphology, fines, closure-stress endurance and retained hydraulic conductivity as development gates.

LABORATORY PATHWAY

Seven linked stages with stop/go criteria

Material release

Continuous phase

Reactive phase

Droplet generation

QC and transport

Thermal-dose cure

Mechanical and flow

DROPLET PREPARATION CHEMISTRY

Two phases, one protected microreactor

Continuous aqueous phase

Qualified water or brine establishes the carrier. PVA-type protective colloid supplies steric stabilisation, while pre-wetted surface-modified silica forms Pickering interfacial armour. Salinity, pH, temperature and viscosity are recorded before release.

Transport target: η ≤ 10 cP

Reactive dispersed phase

Styrene/DVB provides the benchmark crosslinkable network. An oil-soluble initiator remains inside the droplets, while a separately controlled induction package protects storage stability and delivery time.

I → 2R• | k_d(T)=A·e^−E_a/RT

ANIMATED THERMAL-DOSE CONTROL

Delay is governed by accumulated exposure

The formulation is evaluated against the complete temperature-time history. Initiation becomes measurable only after the inhibitor capacity is depleted and the required thermal dose is reached.

Animated DISE thermal-dose activation sequence

QUALIFICATION GATES

Targets are hypotheses to be tested

DISE is an integrated TRL 3 platform transitioning towards TRL 4. These are development criteria, not claims of completed validation.

70–600 µm
Particle-size envelope

≤10 cP
Transport viscosity

25–75 min
Induction window

<5 wt%
Fused multiplets

4,500–6,000 psi
Closure-stress test

≥70%
Retained flow target

EDITORIAL LABORATORY REPORT

The complete experimental manuscript

The 20-page report contains the batch record, preparation sequence, QC methods, transport and thermal-dose tests, mechanical and conductivity protocols, DOE structure, acceptance criteria, failure modes and references.

Download Laboratory Report (PDF)View document page

Safety and governance: Chemistry and HPHT work must proceed under an approved risk assessment, current safety data sheets, calibrated equipment and trained supervision. HPHT testing begins only after ambient behaviour and runaway controls have been bounded.

PEER-REVIEWED EVIDENCE LIBRARY

The scientific basis behind the laboratory programme

Ten verified references connect DISE to in-situ proppant precedent, suspension-polymerisation physics, transport rheology, particle mechanics and fracture conductivity. Each evidence page states both its contribution and its limitations.

01 · LANDSCAPE & NOVELTY

Recent developments on in-situ generated proppants for hydraulic fracturing operations: A critical review

Krishnan, M.R., Li, W., Alharbi, B. and Alsharaeh, E. (2024). Geoenergy Science and Engineering. DOI: 10.1016/j.geoen.2024.213227

Why this reference matters →

02 · OPERATIONAL PRECEDENT

Innovative thermo-responsive in-situ generated proppant: Laboratory tests and field application

Zhang, N., Luo, Z., Zhao, L., Zhu, R., Chen, W., Liu, G., Chen, X., Xie, Y. and Cheng, L. (2022). Journal of Petroleum Science and Engineering. DOI: 10.1016/j.petrol.2021.109514

Why this reference matters →

03 · RECENT DIRECT COMPARATOR

On-Demand In Situ Proppant Generation via Temperature-Induced Solidification of Fracturing Fluid

Bai, S., Yang, Y., Wang, L., Yang, Z. and Lu, H. (2025). Industrial & Engineering Chemistry Research. DOI: 10.1021/acs.iecr.5c03553

Why this reference matters →

04 · CORE PROCESS PHYSICS

Suspension Polymerization Processes

Brooks, B.W. (2010). Chemical Engineering & Technology. DOI: 10.1002/ceat.201000210

Why this reference matters →

05 · TERMINOLOGY & MECHANISM

Fundamentals of Emulsion Polymerization

Lovell, P.A. and Schork, F.J. (2020). Biomacromolecules. DOI: 10.1021/acs.biomac.0c00769

Why this reference matters →

06 · MATERIAL ARCHITECTURE

Styrene-divinylbenzene copolymers for high-performance proppant applications

Perez, C.J., Rueda, F., Pettarin, V., Tomba, J.P. and Carella, J.M. (2025). Polymer Engineering & Science. DOI: 10.1002/pen.27211

Why this reference matters →

07 · TRANSPORT RHEOLOGY

Effects of droplet deformability on emulsion rheology

Saiki, Y., Prestidge, C.A. and Horn, R.G. (2007). Colloids and Surfaces A: Physicochemical and Engineering Aspects. DOI: 10.1016/j.colsurfa.2006.11.022

Why this reference matters →

08 · TRIGGER PRECEDENT

Thermoresponsive in Situ Generated Proppant Based on Liquid–Solid Transition of a Supramolecular Self-Propping Fracturing Fluid

Luo, Z., Zhang, N., Zhao, L., Pei, Y., Liu, P. and Li, N. (2019). Energy & Fuels. DOI: 10.1021/acs.energyfuels.9b02501

Why this reference matters →

09 · PHASE SEPARATION & TESTING

Synthesis and Characterization of a Novel Self-Generated Proppant Fracturing Fluid System

Chen, Y., Sang, Y., Guo, J., Yang, J., Chen, W., Liu, F., Zeng, J. and Tang, B. (2022). Energies. DOI: 10.3390/en15228737

Why this reference matters →

10 · PERFORMANCE QUALIFICATION

A Comprehensive Review of Proppant Selection in Unconventional Reservoirs

Shafiq, M.U., Alajmei, S., Aljawad, M.S., Wang, L. and Bahri, A. (2025). ACS Omega. DOI: 10.1021/acsomega.4c09936

Why this reference matters →

References use Cite Them Right Harvard formatting and DOI links. Inclusion indicates relevance, not proof that DISE has already met its qualification targets.