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Sand consisting of round quartz grains is widely used as a proppant during hydraulic fracturing to produce natural gas from tight shale formations. This paper presents results from sand characterization and crushing tests on Jordan Formation frac sand. It includes an assessment of grain-size reduction, changes in particle shape, and reduction in void ratio. It also examines the implications for permeability reduction through a sand pack caused by the closure stress on a hydraulic fracture. The sand from two size ranges (0.6 to 0.71 mm and 0.5 to 0.6 mm) was tested dry under applied compressive stresses of up to 40 MPa in a crushing cup. The overall sand pack stress–strain response becomes softer as grains are crushed. The particle shape shifts from nearly spherical grains to diametrically split grains and then to small elongated and angular fragments for the smaller particle sizes. The permeability of the sand pack reduces by more than 40% at a 20 MPa stress, which is mainly caused by a decrease in void r...

Frac sand crushing characteristics and morphology changes under high compressive stress and implications for sand pack permeability