Solid
particles coated by cross-linked polymer layers find applications
in many areas, including hydraulic fracturing operations. In this
study, a hot-melt resin coating process for solid particles is developed
and optimized for hydraulic fracturing applications. Phenolic resin
is used to coat the particles above its melting point and is subsequently
cured in situ by hexamethylenetetramine (HMTA). The
coating quality is then characterized by the surface morphology, acid
solubility, and crush resistance of the resin-coated particles. The
effects of various operating parameters on the coating performance
are systematically studied. Among them, temperature is shown to play
an especially important role. The coating process involves intricate
coupling between resin rheology, HMTA mass transfer, and curing kinetics,
all of which are profoundly influenced by temperature. Different constant
temperature levels as well as controlled temperature ramps are investigated,
and the results show a complex dependence. Higher temperature leads
to stronger coating layers with better barrier properties, whereas
lower temperature is preferable for better surface morphology. These
two trends can be partially reconciled with ramping temperature profiles;
the improvement is, however, eventually limited by the rate of heat
transfer. This study not only provides insight into the physical and
chemical processes underlying the resin coating operation, it also
demonstrates a generalizable strategy suitable for various particle
coating processes.