POLYMER-BASED PROPPANT FOR UNCONVENTIONAL COMPLETIONS

A method of forming polymeric proppants in-situ during a fracturing operation. The method includes the steps of delivering reagents downhole and combining the reagents in a first mixing chamber to initiate polymerization; atomizing the combined reagents by passing them through an atomizer as they exit the first mixing chamber to form partially polymerized polymeric bodies; pumping water down a production casing; mixing the partially polymerized polymeric bodies and the water in a second mixing chamber; completing polymerization and forming solid polymeric proppants upon exiting the second mixing chamber; and passing the solid polymeric proppants through perforations in the casing and into fractures within the formation. A system for forming polymeric proppants in-situ during a fracturing operation and a method for forming solid polymeric proppants at the surface of a formation for use in a fracturing operation is also provided.