# US 10,118,863 B2 · Proppant particles formed from slurry droplets and methods of use

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- Number: US 10,118,863 B2
- Document ID: US10118863B2
- Status: Granted
- Kind: B2
- Application number: 15/607,771
- Filed: 2017-05-30
- Published: 2017-09-14
- Granted: 2018-11-06
- Earliest claimed: 2011-03-11
- Assignees: Carbo Ceramics Inc.
- Applicants: Carbo Ceramics Inc.
- Inventors: Benjamin T. Eldred; Brett A. Wilson; Clayton F. Gardinier; Robert Duenckel
- Web page: https://patentgrep.com/patent/US10118863B2

## CPC

- C04B 38/0009: {characterised by features relating to the cell walls, e.g. wall thickness or distribution of pores in the walls}
- C04B 33/04: Clay; Kaolin
- C04B 35/1115: {Minute sintered entities, e.g. sintered abrasive grains or shaped particles such as platelets (abrasives C09K3/14)}
- C04B 35/62695: {Granulation or pelletising (devices for shaping artificial aggregates from ceramic mixtures B28B1/004)}
- C04B 35/636: Polysaccharides or derivatives thereof
- C09K 8/62: Compositions for forming crevices or fractures
- C09K 8/68: containing organic compounds
- C09K 8/70: characterised by their form or by the form of their components, e.g. foams
- C09K 8/80: Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open
- C04B 40/00: Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability (active ingredients C04B22/00 - C04B24/00; hardening of a well-defined composition C04B26/00 - C04B28/00; making porous, cellular or lightening C04B38/00; mechanical aspects B28, e.g. conditioning the materials prior to shaping B28B17/02)
- C04B 2235/3217: Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
- C04B 2235/349: Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
- C04B 2235/5436: micrometer sized, i.e. from 1 to 100 micron
- C04B 2235/6023: Gel casting
- C04B 2235/95: Products characterised by their size, e.g. microceramics
- C04B 2235/963: Surface properties, e.g. surface roughness
- C09K 2200/026: Kaolin
- Y10T 428/2982: Particulate matter [e.g., sphere, flake, etc.]
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Proppant particles formed from slurry droplets and methods of use are disclosed herein. The proppant particles can include a sintered ceramic material and can have a size of about 80 mesh to about 10 mesh and an average largest pore size of less than about 20 microns. The methods of use can include injecting a hydraulic fluid into a subterranean formation at a rate and pressure sufficient to open a fracture therein and injecting a fluid containing a proppant particle into the fracture, the proppant particle including a sintered ceramic material, a size of about 80 mesh to about 10 mesh, and an average largest pore size of less than about 20 microns.

## Claims

### Claim 1

A proppant particle comprising a sintered ceramic material and having a size of about 80 mesh to about 10 mesh, an average largest pore size of less than about 20 microns, and a surface roughness of less than about 2 μm.

### Claim 2 (depends on 1)

The proppant particle of claim 1, wherein the sintered ceramic material comprises kaolin.

### Claim 3 (depends on 1)

The proppant particle of claim 1, wherein the sintered ceramic material comprises bauxite.

### Claim 4 (depends on 1)

The proppant particle of claim 1, wherein the sintered ceramic material comprises alumina.

### Claim 5 (depends on 1)

The proppant particle of claim 1, wherein when the proppant particle is subjected to impingement under a gas-entrained velocity of about 260 m/s onto a flat mild steel target, the target experiences an erosivity of about 1 mg/kg to about 100 mg/kg.

### Claim 6 (depends on 1)

The proppant particle of claim 1, wherein the surface roughness is from about 0.8 μm to about 1.6 μm.

### Claim 7 (depends on 1)

The proppant particle of claim 1, wherein the proppant particle has a long-term permeability greater than 130 darcies at a stress of 10,000 psi and a temperature of 250° F., as measured in accord with ISO 13503-5 when the proppant particle has a size of about 20-40 mesh and a specific gravity of about 2.7.

### Claim 8 (depends on 1)

The proppant particle of claim 1, wherein the proppant particle has a long-term permeability greater than 110 darcies at a stress of 14,000 psi and a temperature of 250° F., as measured in accord with ISO 13503-5 when the proppant particle has a size of about 20-40 mesh and a specific gravity of about 3.3.

### Claim 9 (depends on 1)

The proppant particle of claim 1, wherein the proppant particle has an appropriate strength, appropriate strength being defined as a decrease of less than 85% of long term fluid permeability, as measured in accord with ISO 13503-5 at 250° F., of a pack of test particles, the test particles having the same composition and method of making as the proppant particle, when a stress applied to the pack of test particles increases from 2,000 psi to 20,000 psi and the test particles are in the size range of 20-40 mesh and the test particles have a specific gravity above 3.5.

### Claim 10 (depends on 1)

The proppant particle of claim 1, wherein the proppant particle having a size of about 20-40 mesh with a specific gravity above 3.5 loses less than 15% of its long term liquid conductivity at 20,000 psi after being subjected to 5 cycles of cyclic loading under stresses from about 12,000 psi to about 20,000 psi.

### Claim 11 (depends on 1)

The proppant particle of claim 1, wherein the proppant particle in a size range of 20-40 mesh with a specific gravity above 3.5 has an increase in beta factor of less than 0.0005 at 20,000 psi after being subjected to 5 cycles of cyclic loading under stresses from about 12,000 psi to about 20,000 psi.

### Claim 12

A method of hydraulic fracturing a subterranean formation, comprising: injecting a hydraulic fluid into a subterranean formation at a rate and pressure sufficient to open a fracture therein; and
injecting a fluid containing a proppant particle into the fracture, the proppant particle comprising a sintered ceramic material and having a size of about 80 mesh to about 10 mesh, an average largest pore size of less than about 20 microns, and a surface roughness of less than about 2 μm.

### Claim 13 (depends on 12)

The method of claim 12, wherein the sintered ceramic material comprises kaolin.

### Claim 14 (depends on 12)

The method of claim 12, wherein the sintered ceramic material comprises bauxite.

### Claim 15 (depends on 12)

The method of claim 12, wherein the sintered ceramic material comprises alumina.

### Claim 16 (depends on 12)

The method of claim 12, wherein the surface roughness is from about 0.8 μm to about 1.6 μm.

### Claim 17

A proppant particle, comprising:
a ceramic material selected from sintered kaolin;
wherein the proppant particle has a size of about 40 mesh to about 20 mesh and a surface roughness of from about 0.8 μm to less than about 2 μm.

### Claim 18 (depends on 17)

The proppant particle of claim 17, wherein the surface roughness is from about 0.8 μm to about 1.6 μm.

### Claim 19 (depends on 17)

The proppant particle of claim 17, further comprising a porosity.

### Claim 20 (depends on 19)

The proppant particle of claim 19, further comprising a standard deviation in pore size of less than 4 μm.

### Claim 21

A proppant particle comprising a sintered ceramic material and having a spherical shape, a size of about 80 mesh to about 10 mesh, an average largest pore size of less than about 20 microns, and a surface roughness of less than about 2 μm.

### Claim 22 (depends on 21)

The proppant particle of claim 21, wherein the spherical shape is an oblate spheroid.

### Claim 23 (depends on 22)

A method of hydraulic fracturing a subterranean formation, comprising:
injecting a hydraulic fluid into a subterranean formation at a rate and pressure sufficient to open a fracture therein; and
injecting a fluid containing the proppant particle of claim 22 into the fracture.