It may seem hard to believe, but in the history of energy production in America we find ourselves but two decades short of the centenary of hydraulic fracturing. This process, commonly referred to as frac’ing, had its origins in the 1940s but has evolved into a major technology used in the oil and gas industry today. Practiced across a variety of basins, reservoirs, and geological formations, frac’ing is a diverse enterprise, and all applications and approaches have played a part in advancing respective frac’ing technology.
With so many operators and constant iteration and improvements in this space we will focus on just three key areas that are representative of larger trends at play. As we examine the areas of (1) advancing proppants, (2) sand separating downhole, and (3) overall electrification/automation deployment, we will discern the directions that hydraulic fracturing is taking and get some ideas of the shape of the frac not only in 2025 but in years to come.
Looking Back to Move Forward
Frac’ing dates back to 1947, when Stanolind Oil, a division of Standard Oil of Indiana, first experimented with injecting high-pressure fluid into a well, in this case in the Hugoton gas field in Kansas. This early attempt involved using gelled gasoline to stimulate the well by creating fractures in the rock to allow oil and gas to flow more freely. However, this initial trial was not commercially successful. The real breakthrough came in 1949 when Halliburton received the first commercial hydraulic fracturing patent and performed the first successful frac job in Duncan, Okla. Over the next few decades, hydraulic fracturing gradually gained momentum as oil companies began using it to boost well productivity.
The 1960s and 1970s saw increased use of fracturing as technology improved, making it more efficient and cost-effective. Companies began experimenting with different fluids, such as water mixed with chemicals and sand (known also as “proppant” for the fact that it “props” open the cracks created by the fracturing process, allowing for better flow of hydrocarbons). The development of horizontal drilling in the 1980s was another key innovation. When horizontal drilling was employed with fracturing, as it would be in 21st century, the practice allowed operators to achieve greater wellbore exposure to payzones—strata that extend horizontally in the subsurface—significantly boosting the amount of oil and gas that could be extracted from each lateral.
The modern era of hydraulic fracturing took off in the early 2000s with the advent of shale frac’ing. This method, largely pioneered by George P. Mitchell and his company Mitchell Energy in the Barnett Shale of Texas, combined horizontal drilling with hydraulic fracturing to unlock vast reserves of previously untapped natural gas and oil from shale formations. The success of frac’ing in the Barnett Shale sparked a broader shale revolution, leading to widespread adoption across U.S. shale basins like the Marcellus, Eagle Ford, and the Permian Basin.
Ever since George Mitchell gave it a go and the industry since found success with silica-based proppant, it’s been “game on” in the sand industry. Meanwhile, as Calder Hendrickson, CEO of AquaSmart says, “Everyone wants to transport sand more effectively.”
The Dry Friction Reducer Revolution
In recent years, the oil and gas industry has made significant advancements in frac technology, and one of the most promising developments has come from the integration of dry friction reducer (FR) technology with proppant. This breakthrough allows for more efficient sand delivery and higher performance during the frac’ing process, offering substantial benefits in terms of pressure management, frac stage times, and overall operational efficiency.
Hydrating Proppant with Dry Friction Reducer
A significant leap forward in frac technology has been the ability to hydrate the proppant with a dry friction reducer before it is sent to the frac blender or the hopper that feeds the blender. The introduction of dry FR into the frac’ing mix helps reduce the friction that typically occurs between the fluid and the wellbore during the high-pressure frac’ing process. This advancement allows operators to pump at higher rates, with a 10 percent increase in rate at the same well pressure. In some cases, operators see a decrease in pressure at the same rate, which can go as high as 200-1,000 barrels per minute (bpm).
Dr. Oliver Mulamba, Chief Technology Officer of AquaSmart, highlighted these advantages in his recent presentation on September 18, 2024, titled Delivering Dry Friction Reducer via Coated Proppant. According to Mulamba, coated proppant technology enables higher pumping rates without increasing well pressure, which in turn allows for shorter frac stages by 10 to 15 minutes—a critical time-saving factor in large-scale operations.
AquaSmart, founded in 2010 by CEO Calder Hendrickson, initially developed this coated sand technology for a completely different market: lawn care. Their proppant coating was designed to help retain water in soil, which led to the technology being used in Major League stadiums, including Yankee Stadium. The transition from turf management to frac’ing is a testament to the versatility not only of the technology, but Hendrickson himself and his ability to think in novel ways to maximize efficiencies.
The delivery system of this advancement is AquaSmart’s PropCoater, an on-pad mobile unit capable of coating proppant with dry FR right at the well site. This mobile unit can be positioned near sand silos or adapted easily to sand boxes, reducing logistical challenges and improving efficiency. The PropCoater is also undergoing constant iteration, with a focus on minimizing the on-pad footprint, making it an ideal tool for modern, high-intensity frac’ing operations where space and time are critical resources.
Increasing Efficiencies and Shaving Time
The ability to increase pumping rates without increasing pressure directly impacts frac’ing efficiency. Operators can complete more frac stages in less time, which reduces overall operation time and lowers costs. By shortening frac stages by 10 to 15 minutes, operators can optimize their use of equipment and personnel, a significant cost-saving factor for high stage count frac. Additionally, the reduction in well pressure during high pumping rates contributes to better well integrity, reducing the risk of equipment failure and downtime. Beyond improving operational efficiency, this technology also opens the door to environmental benefits by decreasing the amount of energy needed to maintain high pumping rates, which indirectly reduces the carbon footprint of frac’ing operations.
As AquaSmart and other companies continue to iterate on proppant technology, the future of frac’ing looks more efficient and cost-effective than ever. The application of dry friction reducer-coated proppants will likely expand, offering oil and gas operators a way to increase well output, reduce environmental impact, and save on costs.
With technological advances like this it is no wonder that the rest of the oil and gas producing world look to the Permian Basin for leadership and tech. Matthew Hill, Vice President at Knight Fire Specialists in Oklahoma, says this of operators in Saudi Arabia: “They love our technologies and services to improve their own production.” Indeed. The Permian Basin continues to be the center of design and innovation for technologies that have spread globally, with countries like Canada, Argentina, Saudi Arabia, and China now employing frac’ing in their oil and gas industries.
Innovative Downhole Technology: FET’s Cyclone ESP
The oil and gas industry continues to evolve as technology plays an increasingly critical role in optimizing production and operational efficiency. One of the most exciting recent developments comes from Forum Energy Technology (FET) with their latest advance, the Cyclone ESP (Electric Submersible Pump), which is set to revolutionize downhole performance and enhance production in challenging environments.
Derrick Black, Senior Business Development at Forum Energy Technology, informs me that the Cyclone ESP was designed to improve production in oil and gas wells, particularly in fields where traditional methods may struggle to keep up with the demands of modern operations. Developed over the course of three years, this cutting-edge technology has already exited field trials with key industry partners, resulting in adoption by major operators.
FET constructs its Cyclone ESP to handle high-volume, high-stress environments. Black says Forum is working closely with field teams, providing hands-on training to ensure that operators are equipped to get the most out of the technology.
Black says FET seeks to provide a complete lifecycle service, going “From Drill to Kill.” The product is now in full-scale deployment with major operators, Black asserted, though he declined to name them as the arrangement was “proprietary.”
The Rise of the E-Frac Fleet
Recent advances in hydraulic fracturing technology are reshaping its future. The rise of electric-powered fracturing (e-frac) fleets and water-saving solutions are not least among the advances.
In the first half of 2024, ProPetro Holding Corp. began deploying electric hydraulic fracturing fleets for ExxonMobil’s Permian operations. These e-frac fleets offer significant environmental benefits, reducing emissions and operating costs by using electricity generated from natural gas. According to ProPetro CEO Sam Sledge, this move marks a major step toward a “more sustainable and industrialized future” for frac’ing operations. The adoption of such technology aligns with the industry’s growing focus on efficiency and environmental stewardship. Sustainability is not a party politics issue: it is a critical thinking issue. Asking “How long can I keep doing what I’m doing, the way I’m doing it?” is a rational, long-term approach to addressing current and future potential issues.
While traditional fracturing operations rely heavily on diesel-powered equipment, it consumes vast amounts of fuel and contributes to significant carbon emissions on pad. E-frac, on the other hand, replaces diesel pumps with electric ones powered by modular gas turbine generators. This shift not only cuts fuel costs but also lowers noise pollution at work sites, making operations safer and more operator-friendly. Of course, the reduction of emissions on pad is offset by the manufacturing processes for the new E-frac fleets. Regardless, there will be a significant shift overall to E-frac, given the distinctive advantages and cost savings. It must be noted, however, that no two physical locations and fracs are the same. Some locations are near industrial infrastructure, and yet many more are in the hinterlands of the Permian Basin. There will long be a role for diesel generators and equipment when it comes to completions.
E-frac is gaining significant momentum as a cleaner, more efficient alternative to traditional diesel-powered frac’ing in the Permian Basin and beyond. Here are the key impacts of e-frac technology on the industry:
Environmental Benefits. One of the most notable impacts of e-frac is its ability to reduce greenhouse gas emissions. Traditional frac’ing relies on diesel engines to power fracturing pumps, contributing heavily to carbon emissions. In contrast, e-frac uses electric pumps powered by natural gas turbine generators, significantly cutting emissions and improving air quality. ProPetro, a leader in the deployment of e-frac fleets, has introduced these electric-powered fleets to ExxonMobil’s Permian operations, reducing carbon footprints while maintaining operational efficiency.
Fuel Cost Savings. Fuel savings is another major benefit of e-frac technology. Diesel fuel accounts for a significant portion of operational costs in traditional frac’ing. For instance, a single diesel-powered frac’ing unit consumes $200,000 to $300,000 worth of diesel per well. In contrast, electric fleets can reduce these costs by as much as 90 percent, primarily through the use of on-site natural gas. This shift not only cuts costs but also aligns with the energy industry’s push toward utilizing cleaner and more readily available fuel sources like natural gas.
Noise Reduction and Safety. Traditional frac’ing operations generate high noise levels, often exceeding 115 decibels, which can pose health risks to workers and disrupt nearby communities. E-frac technology dramatically reduces noise pollution, with noise levels dropping to around 85 decibels at the well site. This makes the work environment safer, enhances communication on-site, and reduces the overall environmental disturbance.
Operational Efficiency. Electric fracturing also offers operational benefits as well. E-frac fleets require less maintenance than diesel-powered ones, resulting in reduced downtime and more consistent production. Additionally, e-frac technology allows for more precise control of the fracturing process, leading to improved well performance and better resource extraction.
There is little doubt that regions like Saudi Arabia continue to invest in advanced hydraulic fracturing technology, while the use of e-frac in the Permian Basin helps keeps U.S. producers competitive. Saudi Arabia’s focus on multi-well completions and high-efficiency frac’ing mirrors similar efforts in the United States, showcasing how global advancements push local operators to adopt innovative technologies. The race to become more efficient in production operations will not abate.
The Permian Basin’s operators will continue to lead the way not just in frac technology, but all areas of energy exploration and production. While many of today’s advances are built on the shoulders of the giants that came before us, we can see the trajectory. It is one of reaching maximal efficiency, while keeping costs low, reducing emissions, and increasing yield. Sounds like a true Permian Basin story to me. George Mitchell would be suitably proud of the advances he kicked off 30 years ago.
Christian Lombardini, who has work experience in the oilfield, is also an author, father, and entrepreneur. He’s founder and host of the Oil Field Leader Podcast. Christian shares insights and content on LinkedIn.
SOURCES:
Delivering Dry FR Presentation: https://vimeo.com/1010745511, Halliburton (www.halliburton.com), ProPetro, (www.propetro.com), Permian Basin Oil & Gas Magazine, (https://pboilandgasmagazine.com), World Oil (worldoil.com), OilPrice.com (www.oilprice.com), US Energy Information Agency (www.eia.gov)