Abstract

A method for manufacturing of light ceramic proppants made from a mixture of raw materials that is mechanically granulated in a granulator or that is granulated in a spray dryer from a pourable ceramic mass, to obtain granulate having a granule size of 150 –1700 μm (12 –100 U.S. Mesh, ASTM E11 –04, ISO 13503 -2), and next the granulate is fired and the fired granulate is fractioned. The mixture of raw materials is prepared from: illite-beidellite-kaolinite high-plastic clays of the Poznan series in the amount of 10% to 40% by weight; kaolinite clays in the amount of 10% to 45% by weight; kaolin in the amount of 20% to 40% by weight; fly ash from brown coal combusted in a power plant in the amount of 10% to 35% by weight; and treatment agents in the amount of up to 10% by weight. The mixture of raw materials is mixed and homogenized in a homogenizer, and the obtained granulate is fed to a fluidised bed dryer, in which it is dried to a moisture content below 3%, and the granulate is fired in a rotary furnace in a temperature from 1150°C up to 1410°C in time from 120 to 600 min, obtaining proppants which contain from 18% to 32% by weight of Al2O3, from 40% to 76% by weight of SiO2, and have a specific gravity from 2,15 Mg/m3 to 2,90 Mg/m3 and a bulk density from 1,35 Mg/m3 to 1,70 Mg/m3, depending on the firing time.

IPC Classes  ?

• C09K 8/80 - Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open
• C04B 33/135 - Combustion residues, e.g fly ash, incineration waste
• C04B 38/00 - Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof

Abstract

Ceramic proppants made of a mixture of raw components,characterized in that at least 90% of the mixture of raw components consists of: plastic kaolinite clay from 10% to 50% by weight of the mixture; white-firing clay loam from 10% to 50% by weight of the mixture; and bauxite from 40% to 60% by weight of the mixture.

IPC Classes  ?

• C04B 33/04 - Clay; Kaolin
• C04B 35/626 - Preparing or treating the powders individually or as batches
• C09K 8/80 - Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open

Abstract

Light ceramic proppants made from a mixture of clays, characterised in that they are manufactured from a mixture of raw materials consisting of: -illite-beidellite-kaolinite high-plastic clays of the Poznan series in the amount of 10% to 40% by weight; -kaoliniteclays in the amount of 30% to 45% by weight; -kaolin in the amount of 30% to 40% by weight; -fly ash from brown coal combusted in a power plantin the amount of 10% to 35% by weight; -and treatment agents in the amount of up to 10%by weight.

IPC Classes  ?

• C09K 8/80 - Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open
• C04B 33/04 - Clay; Kaolin
• C04B 33/132 - Waste materials; Refuse
• C04B 35/10 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides based on aluminium oxide
• C04B 35/14 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides based on silica