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US 9,175,210 B2Granted
Proppant particles formed from slurry droplets and method of use
AssigneeCarbo Ceramics Inc.
InventorsBenjamin T. Eldred, Brett A. Wilson, Clayton F. Gardinier, Robert J. Duenckel
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Abstract
Proppant material for hydraulic fracturing is provided. The particles of the proppant are formed by drip casting. A slurry of finely divided ceramic particles is flowed through nozzles and formed into droplets under the influence of vibration. Uniform sized, smooth surface, spherical green particles are formed. The green particles are dried and sintered to form the proppant. The proppant is used in the process of hydraulic fracturing of wells.
Claims27
A method for making proppant particles, comprising:
- providing a slurry of ceramic raw material, 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 in the gas, wherein the slurry of ceramic raw material flows through the nozzle at a rate of about 1 to about 15 kg/(mm2×hr);
- utilizing a surface tension of the slurry with the gas to cause the droplets to acquire and maintain a spherical shape until contact with an upper surface of a liquid, wherein gelling commences in the droplets upon contact with the liquid to provide gelled droplets, and wherein the liquid contains a coagulation agent that reacts with the reactant in the slurry to cause gelling of the reactant in the droplets;
- transferring the gelled droplets from the liquid;
- drying the gelled droplets to form green pellets;
- and
- sintering the green pellets in a selected temperature range to form the proppant particles.
4 more elements
A method for making proppant particles, comprising:
- providing a slurry of alumina, 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 in the gas, wherein the slurry of alumina flows through the nozzle at a rate of about 1 to about 15 kg/(mm2×hr);
- utilizing a surface tension of the slurry with the gas to cause the droplets to acquire and maintain a spherical shape until contact with an upper surface of a liquid, wherein gelling commences in the droplets upon contact with the liquid to provide gelled droplets, and wherein the liquid contains a coagulation agent that reacts with the reactant in the slurry to cause gelling of the reactant in the droplets;
- transferring the gelled droplets from the liquid;
- drying the gelled droplets to form green pellets;
- and
- sintering the green pellets in a selected temperature range to form the proppant particles.
4 more elements
Dependencies are inferred from the claim text.