EP4045474A1 - Procédé de production d'agents de soutènement - Google Patents

Procédé de production d'agents de soutènement

Info

Publication number
EP4045474A1
EP4045474A1 EP20833906.9A EP20833906A EP4045474A1 EP 4045474 A1 EP4045474 A1 EP 4045474A1 EP 20833906 A EP20833906 A EP 20833906A EP 4045474 A1 EP4045474 A1 EP 4045474A1
Authority
EP
European Patent Office
Prior art keywords
red mud
mixture
weight
moisture content
fly ash
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP20833906.9A
Other languages
German (de)
English (en)
Inventor
Natalia Schwamm
Ralph Enderle
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP4045474A1 publication Critical patent/EP4045474A1/fr
Pending legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
    • C04B33/132—Waste materials; Refuse; Residues
    • C04B33/1321—Waste slurries, e.g. harbour sludge, industrial muds
    • C04B33/1322—Red mud
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/60—Compositions for stimulating production by acting on the underground formation
    • C09K8/80—Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
    • C04B33/132—Waste materials; Refuse; Residues
    • C04B33/135—Combustion residues, e.g. fly ash, incineration waste
    • C04B33/1352—Fuel ashes, e.g. fly ash
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/528—Spheres
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5427—Particle size related information expressed by the size of the particles or aggregates thereof millimeter or submillimeter sized, i.e. larger than 0,1 mm
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/66—Specific sintering techniques, e.g. centrifugal sintering
    • C04B2235/661—Multi-step sintering
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/74—Physical characteristics
    • C04B2235/77—Density
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/94—Products characterised by their shape
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes

Definitions

  • the invention relates to a method for the production of proppants and the use of red mud.
  • Proppants are ceramic support granules. Such Stützgra nulate z. B. used in crude oil or natural gas production to support cavities in the rock.
  • DE 16 71 229 A discloses a method for the production of porous ceramic's substances from red mud and fly ash.
  • the porous ceramic materials have a density of at most 0.8 g / cm 3 . Their strength is at most 0.5 MPa.
  • the known ceramic materials are not suitable for the use of proppants.
  • WO 2013/153 115 A2 discloses a method for wet-chemical separation of at least some of the iron-containing constituents from red mud.
  • a method for producing a free-flowing sintered material is also known from US Pat. No. 9,587,170 B2.
  • the known material is used as proppant or proppant in the extraction of petroleum by means of fracking.
  • fly ash, bauxite and clay are mixed to produce the sintered material.
  • the mixture is granulated.
  • the granulate is then coated with bauxite, then calcined and sintered.
  • the known process requires the use of valuable raw materials. It is relatively complex.
  • the object of the invention is to provide a method for producing a free-flowing sintered material that can be carried out as simply and inexpensively as possible.
  • the sintered material is said to be particularly suitable for use as a proppant.
  • red mud or “red mud” is understood to mean a bauxite residue which arises from the extraction of aluminum oxide from aluminum-containing ores, in particular bauxite. More than 95% of the aluminum produced worldwide oxides are manufactured using the Bayer process. About 1 to 1.5 tons of red mud are produced per ton of aluminum oxide.
  • red mud Because of the caustic soda used in the Bayer process, the red mud has a pH value of at least 11. In addition to iron oxide, red mud contains heavy metal oxides and heavy metal hydroxides. Overall, red mud poses a significant threat to the environment.
  • fly ash is understood to mean a solid, disperse residue which arises during combustion in thermal power plants and / or waste incineration plants and is separated from the flue gas by means of dedusting devices. Fly ash usually has mean particle sizes in the range from 3 to 20 ⁇ m and a residual moisture content of less than 1% by weight.
  • free-flowing material is understood to mean a granular material whose grain size, grain size distribution and surface properties are formed in such a way that it is flowable.
  • the flowability of a material can be determined with a device according to DIN EN ISO 6186. To do this, a predetermined amount of the free-flowing material is placed in a standardized funnel and the time it takes for the material to pass through the funnel is measured.
  • the method proposed according to the invention enables the production of a free-flowing sintered material using red mud and fly ash in a simple and inexpensive manner.
  • the sintered material has a pH less than about 8.8. It is not harmful to the environment and is particularly suitable for use as a proppant.
  • the method according to the invention on the one hand, enables the disposal of highly toxic red mud and, on the other hand, inexpensive production, in particular of proppants.
  • the first moisture content in the mixture is 10 to 21% by weight.
  • the red mud has a second moisture content of at least 10% by weight, preferably at least 15% by weight.
  • the second moisture content in the red mud is expediently a maximum of 30% by weight.
  • a red mud with the aforementioned second moisture content is ideally suited for the production of the granules.
  • the mixture expediently contains 50 to 90% by weight, preferably 60 to 75% by weight, of red mud.
  • special proppants can be produced with a high strength.
  • the second moisture content in the red mud is reduced by adding fly ash to the red mud.
  • a separate energy-intensive drying process for setting the first moisture content in the mixture can be dispensed with. This further increases the efficiency of the proposed method.
  • the red mud expediently has a pFI value of at least 10, preferably at least 11.
  • the process enables the use of red mud without its pFI value first having to be reduced by neutralization.
  • the proposed method is therefore simple and inexpensive.
  • the fly ash has a third moisture content of at most 2% by weight, preferably at most 1% by weight.
  • Customary fly ashes have the aforementioned third moisture contents. They can be used to make the mixture without changing the third moisture content beforehand. Fly ashes with an average particle size D50 in the range from 1 to 15 ⁇ m have proven to be expedient for producing the mixture. An addition of the like fly ash leads to a particularly strong sintered material.
  • the granulate is expediently dried, then a predetermined grain fraction, for example in a diameter range of 0.2 to 2.0 mm, is separated from the granulate by means of sieving. The remainder can in turn be used to manufacture the granulate.
  • the granulate is calcined at a temperature of 700 to 1050 ° C before sintering.
  • the sintering of the granules is expediently carried out at a temperature in the range from 1050 ° to 1300 ° C.
  • the step of calcining and sintering can take place in a rotary kiln with different heating zones.
  • the sintered material is expediently formed from spherical particles with a mean diameter of 0.1 to 2.4 mm, preferably 0.1 to 1.5 mm. Such a material is particularly suitable for use as a proppant.
  • the sintered material is also suitable as an aggregate for building materials, in particular concrete, bricks, tiles, roof tiles and the like.
  • the sintered material is particularly suitable as molding sand for making casting molds or as an aggregate for a molding sand.
  • highly toxic red mud with a pH value of at least 11 is suitable as a raw material for the production of a free-flowing sintered mud Materials.
  • the sintered material has a pFI value in the range from 7 to 8.8.
  • the metals contained in the red mud are bound as metal oxides.
  • the sintered material is environmentally friendly.
  • the proppants produced by the process according to the invention have a strength of at least 30 MPa, preferably at least 40 MPa, particularly preferably at least 70 MPa.
  • the process according to the invention can also be used to produce proppants with a strength of at least 80 MPa.
  • DIN EN ISO 13503-2 For the determination of the strength of proppants, reference is made to DIN EN ISO 13503-2.
  • the density of the proppants produced is preferably from 1.0 to 3.8 g / cm 3 , in particular from 1.5 to 3.2 g / cm 3 , particularly preferably from 2 to 2.8 g / cm 3 .
  • Table 1 shows the chemical compositions of the red sludge used.
  • Table 1 Chemical composition of red sludge The red mud has a second moisture content in the range from 22 to 26% by weight.
  • the mean grain size D50 is about 1.7 gm.
  • Table 2 below shows the chemical compositions of the fly ash used.
  • the fly ashes have a third moisture content of about 0.6% by weight.
  • a mean grain diameter D50 of the fly ash is around 4.1 ⁇ m.
  • fly ash is stirred into the red mud until a first moisture content of the mixture is about 10 to 18% by weight, preferably 11 to 16% by weight.
  • the mixture is then poured into an Eirich R02 mixer.
  • Eirich R02 mixer granulating mixers with a high shear field, similar to an Eirich mixer. It is also possible to granulate the mixture, for example by means of spray drying or in granulating pans.
  • steps 2 and 3 water is added.
  • step 4 the mixture is first micro-granulated for a period of 120 seconds.
  • step 5 the grains of the microgranulate grow. Step 5 is carried out until the grains have grown to the desired size. In steps 6 to 8, the formed grains are rounded. In step 8, the surface of the grains is smoothed.
  • the granules can advantageously be produced without the use of a binder.
  • the granules produced have a fourth moisture content in the range from 7 to 11% by weight.
  • the granulate is advantageously dried and then optionally sieved, a grain fraction in the range from 0.2 to 2.0 mm, preferably 0.2 to 1.0 mm, being separated off.
  • a vibrating sieve with a sieve combination of 30/50 mesh is expediently used to separate the aforementioned grain fraction.
  • Suitable sieve combinations are, for example, 16/30 mesh, 40/70 mesh and the like.
  • the granules z. B. in a rotary kiln initially at a temperature in the range of 750 to 850 ° C for a period of 5 to 30 Minu th, preferably 5 to 15 minutes, calcined.
  • the calcined granulate is then sintered at a temperature in the range from 1100 to 1300 ° C. for a period of from 5 to 30 minutes, preferably from 5 to 15 minutes.
  • the sintered material consists of spherical particles.
  • the sintered material can be classified again by means of sieves.
  • a suitable grain fraction can advantageously be separated by means of a 30/50 mesh sieve combination.
  • Fig. 1 shows the grain size distribution of a sintered material produced in this way as.
  • the sintered material is suitable for use as a proppant.
  • a mean grain diameter D50 of the proppants is 0.66 mm here.
  • FIG. 2 shows the proppants according to FIG. 1.
  • a rounding of the proppants is 0.8 here, their sphericity 0.9.
  • the proppants met the necessary requirements of a rounding of at least 0.6 and a sphericity of at least 0.6.
  • the roundness and sphericity of the proppants are determined according to the standard DIN EN ISO 13503-2 according to Krumbein and Schloss.
  • FIGS 3 and 4 show results of comparative leaching experiments.
  • Figure 3 shows Cr leaching over time.
  • Figure 4 shows Na leaching over time.
  • fly ash, red mud (bauxite remnant) and sand (sand) are given.
  • the sintered material "RM / IF 60/40” has 60% by weight of red mud and 40% by weight of fly ash in the mixture.
  • the other sintered materials "RM / IF 70/30 batch 1" and “RM / IF 70/30 batch 2" have been produced from a mixture which contained 70% by weight of red mud and 30% by weight of fly ash.
  • Fig. 3 shows that Cr is excellently bonded in the sintered material. Even after a period of 600 hours, Cr le is leached from the sintered material in a concentration of well below 10.0 ppb.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Structural Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Processing Of Solid Wastes (AREA)
  • Treatment Of Sludge (AREA)
  • Glanulating (AREA)
  • Compounds Of Alkaline-Earth Elements, Aluminum Or Rare-Earth Metals (AREA)

Abstract

L'invention concerne un procédé de fabrication d'agents de soutènement, comprenant les étapes suivantes: fournir des boues rouges, fournir des cendres volantes, produire un mélange à partir des boues rouges et des cendres volantes de sorte que le mélange présente une première teneur en humidité dans la plage de 7 à 30 % en poids, produire un produit granulaire à partir du mélange, et fritter le produit granulaire.
EP20833906.9A 2020-01-31 2020-12-22 Procédé de production d'agents de soutènement Pending EP4045474A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102020102489.4A DE102020102489A1 (de) 2020-01-31 2020-01-31 Verfahren zur Herstellung eines rieselfähigen gesinterten Materials und Verwendung von Rotschlamm
PCT/EP2020/087699 WO2021151597A1 (fr) 2020-01-31 2020-12-22 Procédé de production d'agents de soutènement

Publications (1)

Publication Number Publication Date
EP4045474A1 true EP4045474A1 (fr) 2022-08-24

Family

ID=74106053

Family Applications (1)

Application Number Title Priority Date Filing Date
EP20833906.9A Pending EP4045474A1 (fr) 2020-01-31 2020-12-22 Procédé de production d'agents de soutènement

Country Status (7)

Country Link
US (1) US11905463B2 (fr)
EP (1) EP4045474A1 (fr)
AU (1) AU2020426186A1 (fr)
BR (1) BR112022010631A2 (fr)
DE (1) DE102020102489A1 (fr)
SA (1) SA522433160B1 (fr)
WO (1) WO2021151597A1 (fr)

Family Cites Families (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1671229A1 (de) 1951-01-28 1971-09-02 Vaw Ver Aluminium Werke Ag Verfahren zur Herstellung von poroesen keramischen Stoffen aus den in der Aluminiumindustrie anfallenden Bauxitrueckstaenden
DE2150677A1 (de) 1971-10-12 1973-04-19 Giulini Gmbh Geb Verfahren zur herstellung von ziegeln aus rotschlamm
US5624491A (en) * 1994-05-20 1997-04-29 New Jersey Institute Of Technology Compressive strength of concrete and mortar containing fly ash
WO2013152796A1 (fr) 2012-04-12 2013-10-17 Krsys Gmbh Procédé et dispositif d'obtention de produit valorisable à partir d'un résidu de bauxite
CN103205248B (zh) * 2013-04-25 2016-04-13 鹤壁天瑞石油支撑剂有限公司 一种粉煤灰及废陶瓷制石油压裂支撑剂及其制备方法
CN103396784A (zh) 2013-08-15 2013-11-20 贵州林海陶粒制造有限公司 用赤泥制备的低密度高强度石油压裂支撑剂及其制备方法
US9587170B2 (en) 2013-08-20 2017-03-07 Epropp, Llc Proppant material incorporating fly ash and method of manufacture
CN107963902A (zh) 2017-12-04 2018-04-27 昆明理工大学 一种高吸水性陶粒的制备方法
US20210363057A1 (en) * 2018-08-04 2021-11-25 Abbas Khan Novel method of producing improved lightweight ceramic sand and uses thereof
CN110294626A (zh) * 2019-07-17 2019-10-01 于克福 以赤泥等废弃物资源为原料的生态砂石骨料及其制备方法

Also Published As

Publication number Publication date
US11905463B2 (en) 2024-02-20
US20220411690A1 (en) 2022-12-29
WO2021151597A1 (fr) 2021-08-05
DE102020102489A1 (de) 2021-08-05
AU2020426186A1 (en) 2022-05-26
SA522433160B1 (ar) 2024-05-14
BR112022010631A2 (pt) 2022-08-16

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