Proppant particles formed from slurry droplets and method of use

A method for making proppant particles, comprising:

• providing a slurry of kaolin, the slurry containing a reactant comprising a polysaccharide, wherein the slurry has a solids content from about 25 wt % to about 75 wt %;
• flowing the slurry through a nozzle in a gas while vibrating the slurry to form droplets;
• receiving the droplets in a vessel containing a liquid having an upper surface in direct contact with the gas, the liquid containing a coagulation agent to react with the reactant in the slurry and cause coagulation of the reactant in the droplets;
• transferring the droplets from the liquid;
• drying the droplets to form green pellets;
• and
• sintering the green pellets in a selected temperature range to form the proppant particles, wherein the proppant particles have a long-term permeability greater than 85 darcies at a stress of 10,000 psi and a temperature of 250° F., as measured in accord with ISO 13503-5.