CN111620673A - High-strength low-density ceramsite proppant and preparation method thereof - Google Patents
High-strength low-density ceramsite proppant and preparation method thereof Download PDFInfo
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Abstract
The invention discloses a high-strength low-density ceramsite proppant and a preparation method thereof. The ceramsite proppant comprises the following components in percentage by mass: 47-60% of low-grade bauxite, 25-40% of porcelain stone, 5-15% of ceramsite proppant production waste, 0.3-0.5% of industrial boric acid, 3-10% of magnesia clay and 2.5-3.6% of silica fume. The raw materials adopted by the ceramsite proppant are generally low in price, so that the production cost is greatly reduced; the volume density of the obtained ceramsite proppant is 1.42-1.50g/cm3Apparent density of 2.61-2.68g/cm3The breaking rate is lower than 5% under the closing pressure of 52Mpa, which is beneficial to reducing the fracturing cost and increasing the yield of oil and gas fields.
Description
Technical Field
The invention belongs to the technical field of petrochemical industry, and particularly relates to a high-strength low-density ceramsite proppant and a preparation method thereof.
Background
In the fracturing process of deep well exploitation of petroleum and natural gas, ceramsite proppant is needed, after fracturing treatment is carried out on a high-closure-pressure low-permeability deposit, an oil-gas-containing rock stratum is cracked, oil gas is collected from a channel formed by the cracks, the ceramsite proppant material enters the stratum along with a high-pressure solution and is filled in the rock cracks, and the high-pressure solution startsThe supporting crack is not closed due to stress release, so that high flow conductivity is maintained, oil and gas are smooth, and the yield is increased. The bulk density is not more than 1.65g/cm in China's petroleum industry3Apparent density of not more than 3.00g/cm3The ceramsite proppant with the breaking rate not more than 9.0 percent under the closing pressure of 52MPa is called low-density ceramsite proppant. The low-density ceramsite proppant is adopted in the fracturing process, and has the characteristics of small using amount, convenience in construction and low cost.
Patent application CN200910102878.5 discloses a low-density ceramsite proppant. The low-density ceramsite proppant is prepared from the following raw materials in percentage by weight according to a conventional method: kaolin 62-75%, Al2O317-30% of bauxite with the content of 80-85%, 1-6% of manganese dioxide and 0.5-2% of magnesium oxide. Patent application document CN01108604.1 discloses a method for manufacturing a high-strength ceramsite proppant, which comprises the following auxiliary materials, 2-15 parts of bentonite, 1-10 parts of lanthanide metal oxide, 0.3-3 parts of manganese dioxide and 0.1-3 parts of magnesium oxide, wherein 100 parts by weight of bauxite (the content of aluminum oxide is 75%) is taken as a base material; mixing the base material and the auxiliary material, grinding into fine powder, adding water to loosen, preparing into pellets in a ball forming mill, feeding into a kiln at the sintering temperature of 1100 ℃ and 1500 ℃, sintering for 0.5-5 hours, and firing to obtain the finished product.
It can be seen that the method for preparing the high-strength low-density ceramsite proppant at present mainly uses high-quality kaolin or bauxite with high aluminum oxide content as a main raw material (the aluminum oxide content is generally more than 70 weight percent), and the high-strength low-density ceramsite proppant is produced by adding additives such as magnesium oxide or manganese oxide and the like for blending, but the high-quality kaolin or bauxite has limited resource distribution and needs to be added with the additives such as magnesium oxide or manganese oxide and the like, so that the prepared high-strength low-density ceramsite proppant has high cost. How to obtain the high-strength low-density ceramsite proppant and reduce the production cost at the same time becomes a problem to be solved urgently in the field.
Disclosure of Invention
The invention aims to: aiming at the problem that the high-strength low-density ceramsite proppant in the prior art is high in raw material cost, the invention provides a high-strength low-density ceramsite proppant and a preparation method thereof.
The technical scheme adopted by the invention is as follows:
a high-strength low-density ceramsite proppant. The ceramsite proppant comprises the following components in percentage by mass:
in the technical scheme of the invention, Al is adopted2O3The low-grade bauxite with the content of 55-65 percent has large resource storage amount and low price, and is compared with high-grade bauxite (such as Al)2O3The content is more than 73 percent), and the cost of raw materials can be greatly reduced. Meanwhile, porcelain stone with lower price than bauxite is adopted to replace part of bauxite, and the cost of production raw materials is reduced again. The invention has no special limitation on the type of the adopted porcelain stone, and the chemical composition of the porcelain stone generally comprises the following components in percentage by mass: al (Al)2O312-17％，SiO270-75％，K2O+Na2O 3-7％，Fe2O3Is less than 1%. In addition, the ceramsite proppant provided by the invention also takes production waste products as raw materials to be added again, so that the recycling of waste materials is realized, and the ceramsite proppant production waste products comprise the following components in percentage by mass: al (Al)2O370-75％，SiO220-25％，Fe2O32-3％，TiO22-3.5％。
The industrial boric acid is white powdery crystal or triclinic scaly gloss crystal, has greasy hand feeling and no odor, 0.3-0.5% of the industrial boric acid can reduce the firing temperature of the ceramsite proppant in the invention, and when the content of the industrial boric acid is higher than 0.5%, the firing temperature cannot be further reduced. The magnesium clay comprises the following components in percentage by mass: SiO 2259-63％，MgO 21-25％，Al2O32-3.5％，CaO 1-2.4％，Fe2O30.8-1.2% of magnesium clay and 20.1-0.5% of TiO20, wherein the magnesium clay is used for bonding and forming. The silica fume is also called as silicon micropowder, micro silicon powder or silicon dioxide ultrafine powder, and the silica fume is produced in the process of smelting ferrosilicon alloy and industrial siliconRaw SiO2And Si gas and oxygen in air are quickly oxidized and condensed to form a superfine silicon powder material, which contains 75-96% of SiO2In the technical scheme of the invention, the activity of each material can be improved, and the volume density and the apparent density of the ceramsite proppant can be reduced.
In the oil and gas exploitation fracturing construction, the use design of the ceramsite proppant is calculated according to the cube, the purchase is calculated according to the ton, the larger the volume density is, the higher the adoption cost per unit volume is; the apparent density is the main reference data for preparing the fracturing fluid, the higher the apparent density is, the higher the cost for preparing the fracturing fluid is, and the fracturing fluid is inconvenient to carry in the process of injecting the fracturing fluid into the stratum of the oil-gas well; the higher the breaking rate is, the more broken particles are generated by fracturing, the poorer the effect of improving the flow conductivity is, and on the contrary, the lower the breaking rate is, the more beneficial to fracturing production increase is. The volume density of the ceramsite proppant is 1.42-1.50g/cm3Apparent density of 2.61-2.68g/cm3The breaking rate is lower than 5% under the closing pressure of 52Mpa, and the fracturing fluid is convenient to carry in the fracturing construction of oil and gas exploitation, can reduce the preparation cost of the fracturing fluid, saves resources, and accords with the national policy of energy conservation and consumption reduction.
In addition, the invention also provides a preparation method of the high-strength low-density ceramsite proppant. The preparation method comprises the following steps:
(1) weighing the components according to the mass percentage, mixing uniformly and then ball-milling into fine powder for later use;
(2) mixing atomized water and the fine powder obtained in the step (1) to prepare spherical particles;
(3) and (3) putting the spherical particles obtained in the step (2) into a rotary kiln, sintering at the temperature of 1120-1250 ℃, and cooling to obtain the ceramsite proppant.
Further, the granularity of the fine powder in the step (1) is 380-420 meshes, so that the appearance smoothness of the product can be improved.
Further, the particle size of the spherical particles in the step (2) is 0.425-0.85mm, and when the prepared ceramsite proppant has the particle size within the range, the fracturing propping effect of keeping low breakage rate under the closing pressure of 52MPa can be obtained.
Compared with the prior art, the invention has the beneficial effects that:
(1) the volume density of the ceramsite proppant is 1.42-1.50g/cm3Apparent density of 2.61-2.68g/cm3The breaking rate is lower than 5% under the closing pressure of 52Mpa, which is beneficial to reducing the fracturing cost and increasing the yield of oil and gas fields;
(2) the ceramsite proppant adopts low-grade bauxite, porcelain stone and production waste products of the ceramsite proppant as main raw materials, so that the production cost of the ceramsite proppant is greatly reduced;
(3) the ceramsite proppant is added with industrial boric acid, so that the sintering temperature is reduced, and the energy consumption is reduced.
Detailed Description
The present invention will be described in more detail below with reference to examples and comparative examples. The present invention is not limited to the following examples.
Example 1
The ceramsite proppant comprises the following components in percentage by mass: 49% of low-grade bauxite, 30% of porcelain stone, 10.5% of ceramsite proppant production waste, 0.5% of industrial boric acid, 7% of magnesia clay and 3% of silica fume.
The preparation of the ceramsite proppant comprises the following steps:
(1) respectively crushing the low-grade bauxite, porcelain stone and ceramsite proppant production waste products into particles of 30mm by a jaw crusher, then loading the particles into a proportioning bin, setting the proportioning of the bins according to a proportion, then loading industrial boric acid, magnesia clay and silica fume into the proportioning bin, setting the proportioning, feeding the bins into a ball mill according to a set proportion, and grinding the materials into fine powder with the granularity of 400 meshes for later use;
(2) sending the fine powder ground in the step (1) to a ball forming mill, adding water into the ball forming mill after atomizing the water, adding the fine powder while adding water until the particles reach the required particle size of 0.425-0.85mm, and then screening the particles by a roller screen to complete the forming process;
(3) and (3) feeding the semi-finished product of the granules formed in the step (2) into a rotary kiln through a feeding system for sintering, wherein the sintering temperature is 1120 ℃, the sintering time is 1.5 hours, and screening the sintered material discharged from the kiln by using a linear vibrating screen after cooling the sintered material in a cooling kiln to obtain a finished product of the ceramsite proppant.
Example 2
The ceramsite proppant comprises the following components in percentage by mass: 54 percent of low-grade bauxite, 25 percent of porcelain stone, 15 percent of ceramsite proppant production waste, 0.5 percent of industrial boric acid, 3 percent of magnesia clay and 2.5 percent of silica fume.
The preparation of the ceramsite proppant comprises the following steps:
(1) respectively crushing the low-grade bauxite, porcelain stone and ceramsite proppant production waste products into particles of 30mm by a jaw crusher, then loading the particles into a proportioning bin, setting the proportioning of the bins according to a proportion, then loading industrial boric acid, magnesia clay and silica fume into the proportioning bin, setting the proportioning, feeding the bins into a ball mill according to a set proportion, and grinding the materials into fine powder with the granularity of 400 meshes for later use;
(2) sending the fine powder ground in the step (1) to a ball forming mill, adding water into the ball forming mill after atomizing the water, adding the fine powder while adding water until the particles reach the required particle size of 0.425-0.85mm, and then screening the particles by a roller screen to complete the forming process;
(3) and (3) feeding the semi-finished product of the granules formed in the step (2) into a rotary kiln through a feeding system for sintering, wherein the sintering temperature is 1120 ℃, the sintering time is 1.5 hours, and screening the sintered material discharged from the kiln by using a linear vibrating screen after cooling the sintered material in a cooling kiln to obtain a finished product of the ceramsite proppant.
Example 3
The ceramsite proppant comprises the following components in percentage by mass: 48.1 percent of low-grade bauxite, 40 percent of porcelain stone, 5 percent of ceramsite proppant production waste, 0.3 percent of industrial boric acid, 3 percent of magnesia clay and 3.6 percent of silica fume.
The preparation of the ceramsite proppant comprises the following steps:
(1) respectively crushing the low-grade bauxite, porcelain stone and ceramsite proppant production waste products into particles of 30mm by a jaw crusher, then loading the particles into a proportioning bin, setting the proportioning of the bins according to a proportion, then loading industrial boric acid, magnesia clay and silica fume into the proportioning bin, setting the proportioning, feeding the bins into a ball mill according to a set proportion, and grinding the materials into fine powder with the granularity of 400 meshes for later use;
(2) sending the fine powder ground in the step (1) to a ball forming mill, adding water into the ball forming mill after atomizing the water, adding the fine powder while adding water until the particles reach the required particle size of 0.425-0.85mm, and then screening the particles by a roller screen to complete the forming process;
(3) and (3) feeding the semi-finished product of the granules formed in the step (2) into a rotary kiln through a feeding system for sintering, wherein the sintering temperature is 1250 ℃, the sintering time is 1.5 hours, and the sintered material discharged from the kiln is cooled by a cooling kiln and then screened by a linear vibrating screen to obtain a finished product of the ceramsite proppant.
Example 4
The ceramsite proppant comprises the following components in percentage by mass: 59.8 percent of low-grade bauxite, 26 percent of porcelain stone, 7 percent of ceramsite proppant production waste, 0.4 percent of industrial boric acid, 4 percent of magnesia clay and 2.8 percent of silica fume.
The preparation of the ceramsite proppant comprises the following steps:
(1) respectively crushing the low-grade bauxite, porcelain stone and ceramsite proppant production waste products into particles of 30mm by a jaw crusher, then loading the particles into a proportioning bin, setting the proportioning of the bins according to a proportion, then loading industrial boric acid, magnesia clay and silica fume into the proportioning bin, setting the proportioning, feeding the bins into a ball mill according to a set proportion, and grinding the materials into fine powder with the granularity of 400 meshes for later use;
(2) sending the fine powder ground in the step (1) to a ball forming mill, adding water into the ball forming mill after atomizing the water, adding the fine powder while adding water until the particles reach the required particle size of 0.425-0.85mm, and then screening the particles by a roller screen to complete the forming process;
(3) and (3) feeding the semi-finished granular product formed in the step (2) into a rotary kiln through a feeding system for sintering, wherein the sintering temperature is 1180 ℃, the sintering time is 1.5 hours, and the sintered material discharged from the kiln is cooled by a cooling kiln and then is screened by a linear vibrating screen to obtain a finished ceramsite proppant.
Comparative example 1
The ceramsite proppant comprises the following components in percentage by mass: 50.2 percent of low-grade bauxite, 30 percent of porcelain stone, 10.5 percent of ceramsite proppant production waste, 0.5 percent of industrial boric acid, 7 percent of magnesia clay and 1.8 percent of silica fume.
The preparation of the ceramsite proppant comprises the following steps:
(1) respectively crushing the low-grade bauxite, porcelain stone and ceramsite proppant production waste products into particles of 30mm by a jaw crusher, then loading the particles into a proportioning bin, setting the proportioning of the bins according to a proportion, then loading industrial boric acid, magnesia clay and silica fume into the proportioning bin, setting the proportioning, feeding the bins into a ball mill according to a set proportion, and grinding the materials into fine powder with the granularity of 400 meshes for later use;
(2) sending the fine powder ground in the step (1) to a ball forming mill, adding water into the ball forming mill after atomizing the water, adding the fine powder while adding water until the particles reach the required particle size of 0.425-0.85mm, and then screening the particles by a roller screen to complete the forming process;
(3) and (3) feeding the semi-finished product of the granules formed in the step (2) into a rotary kiln through a feeding system for sintering, wherein the sintering temperature is 1120 ℃, the sintering time is 1.5 hours, and screening the sintered material discharged from the kiln by using a linear vibrating screen after cooling the sintered material in a cooling kiln to obtain a finished product of the ceramsite proppant.
Comparative example 2
The ceramsite proppant comprises the following components in percentage by mass: 51.1 percent of low-grade bauxite, 30 percent of porcelain stone, 10.5 percent of ceramsite proppant production waste, 0.5 percent of industrial boric acid, 7 percent of magnesia clay and 0.9 percent of silica fume.
The preparation of the ceramsite proppant comprises the following steps:
(1) respectively crushing the low-grade bauxite, porcelain stone and ceramsite proppant production waste products into particles of 30mm by a jaw crusher, then loading the particles into a proportioning bin, setting the proportioning of the bins according to a proportion, then loading industrial boric acid, magnesia clay and silica fume into the proportioning bin, setting the proportioning, feeding the bins into a ball mill according to a set proportion, and grinding the materials into fine powder with the granularity of 400 meshes for later use;
(2) sending the fine powder ground in the step (1) to a ball forming mill, adding water into the ball forming mill after atomizing the water, adding the fine powder while adding water until the particles reach the required particle size of 0.425-0.85mm, and then screening the particles by a roller screen to complete the forming process;
(3) and (3) feeding the semi-finished product of the granules formed in the step (2) into a rotary kiln through a feeding system for sintering, wherein the sintering temperature is 1120 ℃, the sintering time is 1.5 hours, and screening the sintered material discharged from the kiln by using a linear vibrating screen after cooling the sintered material in a cooling kiln to obtain a finished product of the ceramsite proppant.
Comparative example 3
The ceramsite proppant comprises the following components in percentage by mass: 34% of low-grade bauxite, 45% of porcelain stone, 10.5% of ceramsite proppant production waste, 0.5% of industrial boric acid, 7% of magnesia clay and 3% of silica fume.
The preparation of the ceramsite proppant comprises the following steps:
(1) respectively crushing the low-grade bauxite, porcelain stone and ceramsite proppant production waste products into particles of 30mm by a jaw crusher, then loading the particles into a proportioning bin, setting the proportioning of the bins according to a proportion, then loading industrial boric acid, magnesia clay and silica fume into the proportioning bin, setting the proportioning, feeding the bins into a ball mill according to a set proportion, and grinding the materials into fine powder with the granularity of 400 meshes for later use;
(2) sending the fine powder ground in the step (1) to a ball forming mill, adding water into the ball forming mill after atomizing the water, adding the fine powder while adding water until the particles reach the required particle size of 0.425-0.85mm, and then screening the particles by a roller screen to complete the forming process;
(3) and (3) feeding the semi-finished product of the granules formed in the step (2) into a rotary kiln through a feeding system for sintering, wherein the sintering temperature is 1120 ℃, the sintering time is 1.5 hours, and screening the sintered material discharged from the kiln by using a linear vibrating screen after cooling the sintered material in a cooling kiln to obtain a finished product of the ceramsite proppant.
Comparative example 4
The ceramsite proppant comprises the following components in percentage by mass: 49.5 percent of low-grade bauxite, 30 percent of porcelain stone, 10.5 percent of ceramsite proppant production waste, 7 percent of magnesia clay and 3 percent of silica fume.
The preparation of the ceramsite proppant comprises the following steps:
(1) respectively crushing the low-grade bauxite, porcelain stone and ceramsite proppant production waste products into particles of 30mm by a jaw crusher, then loading the particles into a proportioning bin, setting the proportioning of the bins according to a proportion, then loading industrial boric acid, magnesia clay and silica fume into the proportioning bin, setting the proportioning, feeding the bins into a ball mill according to a set proportion, and grinding the materials into fine powder with the granularity of 400 meshes for later use;
(2) sending the fine powder ground in the step (1) to a ball forming mill, adding water into the ball forming mill after atomizing the water, adding the fine powder while adding water until the particles reach the required particle size of 0.425-0.85mm, and then screening the particles by a roller screen to complete the forming process;
(3) and (3) feeding the semi-finished product of the granules formed in the step (2) into a rotary kiln through a feeding system for sintering, wherein the sintering temperature is 1420 ℃, the sintering time is 1.5 hours, and screening the sintered material discharged from the kiln by using a linear vibrating screen after cooling the sintered material in a cooling kiln to obtain a finished product of the ceramsite proppant.
The ceramsite proppants prepared in examples 1-4 and comparative examples 1-4 were tested according to the oil and gas industry standard SY/T5108-2014 of proppant performance test method for hydraulic fracturing and gravel packing operation in the people's republic of China, and the performance parameters are detailed in the following tables 1 and 2.
TABLE 1 Performance parameters of the ceramsite proppants of examples 1-4
| Item | Industry Standard | Example 1 | Example 2 | Example 3 | Example 4 |
| Firing temperature (. degree. C.) | / | 1120 | 1120 | 1250 | 1180 |
| Bulk Density (g/cm)3) | ≤1.65 | 1.42 | 1.49 | 1.50 | 1.45 |
| Apparent density (g/cm)3) | ≤3.00 | 2.61 | 2.66 | 2.68 | 2.64 |
| Roundness degree | ≥0.7 | 0.8 | 0.8 | 0.8 | 0.8 |
| Sphericity | ≥0.7 | 0.8 | 0.8 | 0.8 | 0.8 |
| Turbidity (FTU) | ≤100 | 70 | 73 | 78 | 74 |
| Acid solubility (%) | ≤7 | 4.2 | 4.4 | 4.5 | 4.3 |
| Percentage of breakage (%) | ≤9 | 4.4 | 4.5 | 5.0 | 4.3 |
TABLE 2 Performance parameters of the ceramsite proppants of comparative examples 1-4
| Item | Industry Standard | Comparative example 1 | Comparative example 2 | Comparative example 3 | Comparative example 4 |
| Firing temperature (. degree. C.) | / | 1120 | 1120 | 1120 | 1420 |
| Volume densityDegree (g/cm)3) | ≤1.65 | 1.68 | 1.71 | 1.73 | 1.42 |
| Apparent density (g/cm)3) | ≤3.00 | 3.1 | 3.3 | 3.4 | 2.61 |
| Roundness degree | ≥0.7 | 0.8 | 0.8 | 0.8 | 0.8 |
| Sphericity | ≥0.7 | 0.8 | 0.8 | 0.8 | 0.8 |
| Turbidity (FTU) | ≤100 | 70 | 71 | 78 | 70 |
| Acid solubility (%) | ≤7 | 4.3 | 4.4 | 4.5 | 4.2 |
| Percentage of breakage (%) | ≤9 | 4.5 | 4.5 | 6.7 | 4.4 |
As can be seen from the comparison of the performance parameters of the ceramsite proppants in tables 1 and 2, the content of the silica fume in the comparative example 1 and the comparative example 2 is lower than the content required by the invention, so that the volume density and the apparent density of the prepared ceramsite proppants are both higher and do not meet the industrial standard; in the comparative example 3, the content of the porcelain stone is higher than the content required by the invention, and the content of the low-grade bauxite is lower than the content required by the invention, so that the volume density and the apparent density of the prepared ceramsite proppant are higher, the ceramsite proppant does not meet the industrial standard, and the crushing rate is obviously increased; the lack of industrial boric acid in comparative example 4 resulted in a higher firing temperature for the ceramsite proppant.
Claims (9)
1. The high-strength low-density ceramsite proppant is characterized by comprising the following components in parts by mass:
2. the high-strength low-density ceramsite proppant according to claim 1, wherein Al in the low-grade bauxite2O3The content is 55-65%.
3. The high-strength low-density ceramsite proppant according to claim 1, wherein the ceramsite proppant production waste comprises the following components in parts by weight: al (Al)2O370-75％，SiO220-25％，Fe2O32-3％，TiO22-3.5％。
4. The high-strength low-density ceramsite proppant according to claim 1, wherein the ceramsite proppant has a bulk density of 1.42-1.50g/cm3。
5. The high-strength low-density ceramsite proppant according to claim 1, wherein the ceramsite proppant has an apparent density of 2.61-2.68g/cm3。
6. The high strength, low density ceramsite proppant of claim 1, wherein said ceramsite proppant has a fracture rate of less than 5% at a closure pressure of 52 MPa.
7. The method for preparing high-strength low-density ceramsite proppant according to any one of claims 1-6, wherein the method comprises the following steps:
(1) weighing the components according to the mass percentage, mixing uniformly and then ball-milling into fine powder for later use;
(2) mixing atomized water and the fine powder obtained in the step (1) to prepare spherical particles;
(3) and (3) putting the spherical particles obtained in the step (2) into a rotary kiln, sintering at the temperature of 1120-1250 ℃, and cooling to obtain the ceramsite proppant.
8. The method for preparing high-strength low-density ceramsite proppant according to claim 7, wherein the particle size of the fine powder in step (1) is 380-420 meshes.
9. The method for preparing high-strength low-density ceramsite proppant according to claim 7, wherein the spherical particles in step (2) have a particle size of 0.425-0.85 mm.
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