WO2014172954A1 - 一种粉煤灰及废陶瓷制石油压裂支撑剂及其制备方法 - Google Patents

一种粉煤灰及废陶瓷制石油压裂支撑剂及其制备方法 Download PDF

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WO2014172954A1
WO2014172954A1 PCT/CN2013/076382 CN2013076382W WO2014172954A1 WO 2014172954 A1 WO2014172954 A1 WO 2014172954A1 CN 2013076382 W CN2013076382 W CN 2013076382W WO 2014172954 A1 WO2014172954 A1 WO 2014172954A1
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fly ash
fracturing proppant
waste
petroleum fracturing
waste ceramics
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PCT/CN2013/076382
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English (en)
French (fr)
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张胜杰
张林群
王英军
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鹤壁天瑞石油支撑剂有限公司
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Priority to CA2878623A priority Critical patent/CA2878623C/en
Priority to US14/413,351 priority patent/US9611423B2/en
Publication of WO2014172954A1 publication Critical patent/WO2014172954A1/zh

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    • 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
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    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
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    • 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
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    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/62204—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products using waste materials or refuse
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/62695—Granulation or pelletising
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    • 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
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3262—Manganese oxides, manganates, rhenium oxides or oxide-forming salts thereof, e.g. MnO
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    • 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
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3427—Silicates other than clay, e.g. water glass
    • C04B2235/3463—Alumino-silicates other than clay, e.g. mullite
    • C04B2235/3472—Alkali metal alumino-silicates other than clay, e.g. spodumene, alkali feldspars such as albite or orthoclase, micas such as muscovite, zeolites such as natrolite
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    • C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
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    • 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 belongs to the technical field of petroleum fracturing proppants, and particularly relates to a petroleum fracturing proppant for fly ash and waste ceramics and a preparation method thereof. Background technique
  • fracturing In oil and gas oilfield exploitation, fracturing is widely used to increase oil well production, prolong the high-yield life of oil wells, and exploit difficult resources.
  • the proppant In order to prevent the closure of underground pressure cracks, retain the oil and gas channels, and maintain the conductivity, the proppant must be used to fill the cracks. Due to the different depth of the oil layer, the oily viscosity is different, and the properties of the proppant such as strength, apparent density and particle size are also different.
  • the fracturing support is divided into three categories: high density, high strength, medium density high strength and low density high strength. In recent years, there has been a demand for ultra low density of proppant.
  • the common particle size of fracturing proppants on the market is 16 ⁇ 30 mesh (1180 ⁇ 600 ⁇ ), 20 ⁇ 40 mesh (850 ⁇ 425 ⁇ ), 30 ⁇ 50 mesh (600 ⁇ 300 ⁇ ), 40 ⁇ 60 mesh (425 ⁇ 250 ⁇ ) Mesh and 40 ⁇ 70 mesh (425 ⁇ 212 ⁇ ) mesh and other specifications, however, regardless of the variety and specifications, the petroleum fracturing proppant should have a low apparent density under the premise of sufficient crush resistance. It is beneficial to reduce the fracturing cost, ensure the saturation of the pressure crack filling and increase the oil well production.
  • the production of petroleum fracturing proppants is generally based on high alumina bauxite, supplemented by one or several metal oxides as mineralizers, such as manganese oxide, calcium oxide, iron oxide, magnesium oxide, zircon and the like.
  • the raw materials are pulverized, mixed, spheronized, and sintered to obtain a fracturing proppant.
  • the fracturing proppant disclosed in Chinese Patent No. 93111983.9 the main material is 70% ⁇ 90% of the cooked bauxite after being calcined and pulverized, and then the multi-component oxide and the soft clay are used to co-mill and Plus The water or organic solvent is mixed and then loosened, spheronized, sieved, sintered, polished and sieved again to obtain a fracturing proppant.
  • the fracturing proppant disclosed in Chinese Patent Application No. 02157202.X is prepared by: 90% ⁇ 94% high grade raw bauxite, plus 6% ⁇ 10% manganese oxide ore powder, after 1330 °C ⁇ It is fired at a high temperature of 1350 °C.
  • 02157202.X is currently widely used in the production of proppant, but the fracturing proppant provided by this patent relies on special bauxite or first-grade bauxite and Mn0 2 with a content of more than 50%. High-quality resources such as manganese ore are prepared at higher temperatures. Therefore, high energy consumption and high resource consumption during the preparation process limit the further development of fracturing proppants. Summary of the invention
  • the technical problem to be solved by the present invention is to provide a petroleum fracturing proppant made of fly ash and waste ceramics and a preparation method thereof, and the invention adopts low-cost fly ash and waste ceramic as raw materials, and is low.
  • the petroleum fracturing proppant prepared at the temperature has a small apparent density, strong crushing resistance, low cost, and reduced energy consumption.
  • the invention provides a petroleum fracturing proppant made of fly ash and waste ceramic, which is prepared from the following components:
  • the main material is fly ash and waste ceramic
  • auxiliary materials are potassium feldspar powder and manganese ore powder;
  • the sum of the main ingredient and the auxiliary material is 100%.
  • the waste ceramic is a low aluminum waste ceramic.
  • the mass ratio of the fly ash to the waste ceramic is (4 ⁇ 6): (2 ⁇ 3).
  • the mass ratio of the potassium feldspar powder to the manganese ore powder is (2 ⁇ 5): 1.
  • Mn0 2 in the manganese ore powder accounts for 0 wt% to 5 wt% of the fly ash and waste ceramic petroleum fracturing proppant.
  • the invention also provides a preparation method of fly ash and waste ceramic petroleum fracturing proppant, comprising the following steps:
  • the mixture is fired to obtain a fly ash and a waste ceramic petroleum fracturing proppant.
  • the waste ceramic is a low aluminum waste ceramic.
  • the mixture has a particle size of from 3,350 to 106 ⁇ m.
  • the step A) is specifically:
  • the fly ash, the waste ceramics, the potassium feldspar powder and the manganese ore powder are mixed, placed in a forced mixer for homogenization and refining treatment, and after granulation, sieved to obtain a mixture.
  • the firing time is 4-8 hours.
  • the invention prepares a fly ash and waste ceramic petroleum fracturing proppant by using fly ash, waste ceramics, potassium feldspar powder and manganese ore powder as raw materials, and the invention adopts low cost pulverized coal.
  • Ash and waste ceramics are used as raw materials.
  • A1 2 0 3 in fly ash and waste ceramics form mullite, and the surplus SiO 2 in the raw materials is converted into low-viscosity minerals such as phosphorus quartz, which reduces the appearance of the product. density.
  • a liquid phase containing 30% to 40% of the total volume of the raw materials is formed in the raw materials mixed at a high temperature, and the liquid phase formed is not only the liquid phase but also the liquid phase formed.
  • the surface tension is large, the wetting performance is good, and the material is denser, thus increasing the strength of the petroleum fracturing proppant.
  • the liquid phase has a strong dissolving ability for A1 2 0 3 and SiO 2 in the raw material at 1100 ° C, and when the A1 2 0 3 and SiO 2 in the raw material are dissolved to a certain concentration, they react with each other to form a needle shape.
  • the mullite is crystallized and then continuously dissolved and crystallized to change the mullite from a solid phase reaction to a liquid phase reaction, which greatly accelerates the reaction rate and lowers the temperature required for the reaction.
  • the surplus Si0 2 is converted into a double-headed pseudo-phosphorus quartz crystal, so that the finished product has higher strength.
  • the invention provides a petroleum fracturing proppant made of fly ash and waste ceramic, which is prepared from the following components:
  • the main material is fly ash and waste ceramic
  • the sum of the main ingredient and the auxiliary material is 100%.
  • the present invention uses fly ash and waste ceramic as the main material of the petroleum fracturing proppant, and the type of the waste ceramic is not particularly limited in the present invention, and is preferably a low aluminum waste ceramic, industrially, a low aluminum waste ceramic and powder.
  • the amount of coal ash is large and the cost is low. Therefore, the rational use of low-aluminum waste ceramics and fly ash is of great significance for energy saving, environmental protection and resource conservation.
  • the total amount of the raw materials of the fly ash and the waste ceramic is preferably 40% by weight to 90% by weight, more preferably 50% by weight to 80% by weight, and most preferably 60% by weight to 70% by weight.
  • the mass ratio of the fly ash and the waste ceramic is preferably (4 ⁇ 6): (2-3), and ⁇ is preferably (4 ⁇ 5 ⁇ 5 ⁇ 5): (2.2-2.8) ⁇
  • potassium feldspar powder and manganese ore powder are used as auxiliary materials for petroleum fracturing proppant, wherein potassium feldspar powder and manganese ore powder form a composite mineralizer, potassium feldspar powder is the main mineralizer, and strontium in potassium feldspar powder 20 0 acts as a mineralization; the manganese ore powder is an auxiliary mineralizer and a coloring agent, and Mn0 2 in the manganese ore powder accounts for 0 wt% to 5 wt% of the fly ash and waste ceramic petroleum fracturing proppant, It is preferably from 1% by weight to 4% by weight, most preferably from 2% by weight to 3% by weight.
  • the manganese ore powder and the potassium feldspar powder are preferably added in an amount of from 1% by weight to 40% by weight, more preferably from 10% by weight to 30% by weight, most preferably from 15% by weight to 25% by weight, based on the total amount of the raw materials.
  • the mass ratio of the potassium feldspar powder to the manganese ore powder is preferably (2-5): 1 , more preferably (2 ⁇ 5 ⁇ 4 ⁇ 5): 1 , and most preferably (3 ⁇ 4): 1.
  • the present invention in a liquid phase in potassium feldspar powder and manganese powder ⁇ 2 0 Mn0 2 is formed of a composite mineralizer, the mixed raw material at a high temperature on the total volume of material of 30% to 40% of the liquid phase is formed, generated Not only the surface tension is large, the wetting performance is good, the material is denser, and therefore, the strength of the petroleum fracturing proppant is increased.
  • the volumetric density of the petroleum fracturing proppant provided by the invention is ⁇ 1.50 ⁇ / «11 3 , apparent density
  • the bulk density is ⁇ 1.40 g/cm 3 and the apparent density is ⁇ 2.40 g/cm 3 .
  • the invention also provides a preparation method of fly ash and waste ceramic petroleum fracturing proppant, comprising the following steps:
  • the mixture is fired to obtain a fly ash and a waste ceramic petroleum fracturing proppant.
  • the invention firstly mixes fly ash, waste ceramics, potassium feldspar powder and manganese ore powder for homogenization and refinement treatment, and there is no particular limitation on the manner of the homogenization refining treatment, and the specific method is:
  • the invention carries out the homogenization and refinement treatment of the raw materials, makes the particle size distribution of the raw materials more uniform, the chemical reaction is more smooth, and the chemical reaction is carried out more fully, so that the grain of the petroleum fracturing proppant is finer and the petroleum pressure is increased.
  • the strength of the split proppant is increased.
  • the total amount of the raw materials of the fly ash and the waste ceramic is preferably 40% by weight to 90% by weight, more preferably 50% by weight to 80% by weight, and most preferably 60% by weight to 70% by weight.
  • the mass ratio of the fly ash to the waste ceramic is preferably (4-6): (2 ⁇ 3), more preferably (4.5-5.5): (2 ⁇ 2 ⁇ 2 ⁇ 8).
  • Mn0 2 in the manganese ore fine powder accounts for 0 wt% to 5 wt% of the waste fly ash and the ceramic petroleum fracturing proppant.
  • the manganese ore powder and the potassium feldspar powder are preferably added in an amount of from 1% by weight to 40% by weight, more preferably from 10% by weight to 30% by weight, most preferably from 15% by weight to 25% by weight, based on the total amount of the raw materials.
  • the mass ratio of the potassium feldspar powder to the manganese ore powder is preferably (2 ⁇ 5): 1, more preferably (2.5 ⁇ 4.5): 1 , most preferably (3 ⁇ 4): 1.
  • the fly ash, the waste ceramics, the potassium feldspar powder and the manganese ore powder are placed in a forced mixer for homogenization and refining treatment, and after granulation, they are sieved to obtain a mixture.
  • the granulation method of the present invention is not particularly limited, and the granulation method well known to those skilled in the art may be used; the manner of sieving in the present invention is not particularly limited, and the sieving method well known to those skilled in the art is can.
  • the particle size of the mixture obtained after sieving has different specifications, preferably 3350 ⁇ 106 ⁇ , more preferably 850 ⁇ 425 ⁇ , 600 ⁇ 300 ⁇ , 425 ⁇ 250 ⁇ , 425 ⁇ 212 ⁇ or 212 ⁇ 106 ⁇ .
  • the waste ceramic used in the present invention is preferably a low aluminum waste ceramic.
  • the mixture is fired to obtain a fly ash and a waste ceramic petroleum fracturing proppant.
  • the burning place of the present invention is not particularly limited, and is preferably 1100 to 1200 ° C, more preferably 1110 to 1150 ° C in a rotary kiln, and the firing time is preferably 4 to 8 h, It is preferably 5 to 7 hours.
  • the fly ash and the waste ceramic petroleum fracturing proppant are obtained, and the weight ratio of the chemical components in the fly ash and the waste ceramic petroleum fracturing proppant reaches: A1 2 0 3 : 40% ⁇ 48%, Si0 2 : 38% to 45%, K 2 0: 2% to 4%.
  • the invention prepares a fly ash and waste ceramic petroleum fracturing proppant by using fly ash, waste ceramics, potassium feldspar powder and manganese ore powder as raw materials, and the invention uses low cost fly ash and waste ceramic as raw materials.
  • ⁇ 1 2 0 3 in fly ash and waste ceramics produces mullite, which is surplus in raw materials.
  • the Si0 2 is converted into a low-viscosity mineral such as phosphorus quartz, which reduces the apparent density of the product.
  • a liquid phase containing 30% to 40% of the total volume of the raw materials is formed in the raw materials mixed at a high temperature, and the liquid phase formed is not only the liquid phase but also the liquid phase formed.
  • the surface tension is large, the wetting performance is good, and the material is denser, thus increasing the strength of the petroleum fracturing proppant.
  • the liquid phase has a strong dissolving ability for ⁇ 1 2 0 3 and SiO 2 in the raw material at 1100 ° C, and when the A1 2 0 3 and SiO 2 in the raw material are dissolved to a certain concentration, they react with each other to form a needle shape.
  • the mullite is crystallized and then continuously dissolved and crystallized to change the mullite from a solid phase reaction to a liquid phase reaction, which greatly accelerates the reaction rate and lowers the temperature required for the reaction.
  • the surplus Si0 2 is converted into a double-headed pseudo-phosphorus quartz crystal, so that the finished product has higher strength.
  • the results show that the volume density of the fly ash and waste ceramic petroleum fracturing proppant provided by the present invention is ⁇ 1.50 g/cm 3 , the apparent density is ⁇ 2.60 g/cm 3 , and the breaking rate is ⁇ 8 under the closing pressure of 86 MPa. %.
  • 60Kg Hebi Wanhe Power Plant dust removal waste ash, 20 Kg Hebi City Ceramic Industrial Park Xinzhongyuan Ceramics Factory's low aluminum waste ceramics, 15 Kg K-feldspar powder and 5 Kg manganese ore powder are mixed and homogenized and refined by forced mixer After processing, and then granulating, the mixture having a particle size of 900-600 ⁇ m is obtained by sieving, and the mixture is fired at a pressure of 1100 ° C to 1150 ° C for 4 hours under a normal pressure in a 2.5 m x 45 m rotary kiln, and the sieve is cooled. After the separation, the fly ash and the waste ceramic petroleum fracturing proppant with the mesh number of 20 ⁇ 40 mesh (850 ⁇ 425 ⁇ ) can be obtained.
  • the volume density of the fly ash and waste ceramic petroleum fracturing proppant was determined to be 1.42 g/cm 3 , the apparent density was 2.47 g/cm 3 , and the breaking rate was ⁇ 8% at a closing pressure of 86 Mpa.
  • 60Kg Hebi Wanhe Power Plant dust removal waste ash 20 Kg Hebi City Ceramic Industrial Park Xinzhongyuan Ceramics Factory's low aluminum waste ceramics, 15 Kg K-feldspar powder and 5 Kg manganese ore powder are mixed and homogenized and refined by forced mixer After processing, and then granulating, the mixture having a particle size of 710-425 ⁇ m is obtained by sieving, and the mixture is fired at a pressure of 1100 ° C to 1150 ° C for 4 hours under a normal pressure using a 2.5 m x 45 m rotary kiln for 4 hours. After the separation, a fly ash with a mesh number of 30-50 mesh (600 ⁇ 300 ⁇ ) and a petroleum ceramic fracturing proppant can be obtained.
  • the low-aluminum waste ceramics of the source ceramics plant, 15 Kg of potassium feldspar powder and 5 Kg of manganese ore powder are mixed and subjected to homogenization and refining processing by a forced mixer, and then granulated and sieved to obtain a mixture having a particle diameter of 500 to 425 ⁇ m.
  • the mixture is fired at a pressure of 1100 ° C to 1150 ° C for 4 hours under a normal pressure with a 2.5 m x 45 m rotary kiln. After cooling and sieving, a pulverized coal having a mesh number of 40 to 60 mesh (425 to 250 ⁇ m) can be obtained. Petroleum fracturing proppant made of ash and waste ceramics.
  • the volume density of the fly ash and waste ceramic petroleum fracturing proppant was determined to be 1.47 g/cm 3 , the apparent density was 2.53 g/cm 3 , and the breaking rate was ⁇ 8% at a closing pressure of 86 MPa.
  • the fly ash and the waste ceramic petroleum fracturing proppant were measured to have a bulk density of 1.49 g/cm 3 and an apparent density of 2.55 g/cm 3 , and the breaking rate was ⁇ 8% at a closing pressure of 86 MPa.
  • 60Kg Hebi Wanhe Power Plant dust removal waste ash 20 Kg Hebi City Ceramic Industrial Park Xinzhongyuan Ceramics Factory's low aluminum waste ceramics, 15 Kg K-feldspar powder and 5 Kg manganese ore powder are mixed and homogenized and refined by forced mixer After processing, and then granulating, the mixture having a particle size of 500-355 ⁇ m is obtained by sieving, and the mixture is fired at a pressure of 1100 ° C to 1150 ° C for 4 hours under a normal pressure in a 2.5 m x 45 m rotary kiln, and the sieve is cooled. After the separation, fly ash with a mesh number of 40-70 mesh (425-212 ⁇ ) and a petroleum ceramic fracturing proppant can be obtained.
  • the bulk density of the fly ash and waste ceramic petroleum fracturing proppant was determined to be 1.49 g/cm 3 , the apparent density was 2.56 g/cm 3 , and the breaking rate was ⁇ 8% at a closing pressure of 86 MPa.
  • the bulk density of the fly ash and waste ceramic petroleum fracturing proppant was determined to be 1.49 g/cm 3 , the apparent density was 2.56 g/cm 3 , and the breaking rate was ⁇ 8% at a closing pressure of 86 MPa.

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  • Compositions Of Oxide Ceramics (AREA)

Abstract

本发明提供了一种粉煤灰及废陶瓷制石油压裂支撑剂，由以下组分制备而成：40wt%~90wt%的主料，所述主料为粉煤灰和废陶瓷；1wt%~40wt% 的辅料，所述辅料为钾长石粉和锰矿粉；主料和辅料之和为100%。本发明采用低成本的粉煤灰和废陶瓷为原料，在较低的温度下制备得到的石油压裂支撑剂视密度小、抗破碎能力强，并且成本低，减少了能源消耗。

Description

一种粉煤灰及废陶瓷制石油压裂支撑剂及其制备方法
本申请要求于 2013 年 04 月 25 日提交中国专利局、 申请号为 201310148377.7、 发明名称为 "一种粉煤灰及废陶瓷制石油压裂支撑剂及 其制备方法"的中国专利申请的优先权，其全部内容通过引用结合在本申 请中。 技术领域
本发明属于石油压裂支撑剂技术领域,具体涉及一种粉煤灰及废陶瓷 制石油压裂支撑剂及其制备方法。 背景技术
在油田油气开采中， 为提高油井产量， 延长油井高产寿命， 开采难动 用资源而广泛采用压裂工艺。 为防止地下压裂缝的闭合， 保留油气通道， 保持导流能力， 必须使用支撑剂填充裂缝。 由于油层深度不同， 油质黏度 不同， 对支撑剂的性能如强度， 视密度， 粒度大小要求也不相同。 压裂支 撑剂按照体积密度分为高密高强， 中密高强和低密高强三大类，近年来又 出现了对支撑剂超低密度的需求。 目前市场上压裂支撑剂的常用粒度有 16~30目（ 1180~600μηι )、 20~40目（850~425μηι)、 30~50目（600~300μηι )、 40~60目 （425~250μηι )目和 40~70目 （425~212μηι )目等多种规格， 但是， 无论何种品种和规格， 石油压裂支撑剂要在具有足够的抗破碎能力前提 下， 具有较低的视密度， 以利于降低压裂成本， 保证对压裂缝填充的饱和 度， 提高油井产量。
目前石油压裂支撑剂生产普遍以高铝矾土为主要原料，辅以一种或几 种金属氧化物做矿化剂，如氧化锰、氧化钙、氧化铁、氧化镁、锆英石等。 申请号为 02112746.8的中国专利公开的压裂支撑剂， 主要原料为 45wt%~55wt%的熟铝矾土、 10wt%~30wt%的高岭土和 20wt%~35wt%的宜 兴产红泥。 将上述原料粉碎、 混料、 成球、 烧结， 得到压裂支撑剂。 申请 号为 93111983.9的中国专利公开的压裂支撑剂，主料为 70%~90%的熟铝矾 土经焙烧和粉碎后 ,再加入多组分氧化物与软质粘土组成的辅料共磨和加 水或有机溶剂混碾， 然后经松解、 成球、 筛分、 烧结、 抛光和再次筛分， 得到压裂支撑剂。 申请号为 02157202.X的中国专利公开的压裂支撑剂，其 制备方法为： 90%~94%的高品位生铝矾土，外加 6%~10%的氧化锰矿石粉， 经 1330°C~1350°C高温烧成。 申请号为 02157202.X的中国专利是目前支撑 剂生产创业普遍采用的配方，但是该专利提供的压裂支撑剂依靠特级铝矾 土或一级铝矾土和 Mn02, 含量在 50%以上的锰矿石等优质资源在较高的 温度下制备而成， 因此， 制备过程中高能耗， 高资源消耗限制了压裂支撑 剂的进一步的发展。 发明内容
有鉴于此，本发明要解决的技术问题在于提供一种粉煤灰及废陶瓷制 石油压裂支撑剂及其制备方法，本发明采用低成本的粉煤灰和废陶瓷为原 料，在较低的温度下制备得到的石油压裂支撑剂视密度小、抗破碎能力强， 并且成本低， 减少了能源消耗。
本发明提供了一种粉煤灰及废陶瓷制石油压裂支撑剂，由以下组分制 备而成：
40wt%~90wt%的主料， 所述主料为粉煤灰和废陶瓷；
lwt%~40wt%的辅料， 所述辅料为钾长石粉和锰矿粉；
主料和辅料之和为 100%。
优选的， 所述废陶瓷为低铝废陶瓷。
优选的， 所述粉煤灰与废陶瓷的质量比为 （4~6 )： ( 2~3 )。
优选的， 所述钾长石粉与锰矿粉的质量比为 （2~5 )： 1。
优选的，所述锰矿粉中 Mn02占所述粉煤灰及废陶瓷制石油压裂支撑 剂的 0wt%~5wt%。
本发明还提供了一种粉煤灰及废陶瓷制石油压裂支撑剂的制备方法， 包括以下步骤：
A )将粉煤灰、废陶瓷、钾长石粉和锰矿粉混合， 进行均化细化处理， 经过制粒后筛分， 得到混合物；
B )将所述混合物烧制， 得到粉煤灰及废陶瓷制石油压裂支撑剂。 优选的， 所述废陶瓷为低铝废陶瓷。
优选的， 所述混合物的粒径为 3350~106μηι。
优选的， 所述步骤 A )具体为：
将粉煤灰、废陶瓷， 钾长石粉和锰矿粉混合， 置于强制混合机中进行 均化细化处理后， 经过制粒后筛分， 得到混合物。
优选的， 所述烧制的时间为 4~8h。
与现有技术相比， 本发明以粉煤灰、废陶瓷、钾长石粉和锰矿粉为原 料制备了一种粉煤灰及废陶瓷制石油压裂支撑剂，本发明以成本低的粉煤 灰和废陶瓷为原料， 在制备过程中， 粉煤灰和废陶瓷中的 A1203生成莫来 石， 原料中富余的 Si02转化为磷石英等低视密矿物， 降低了产品的视密 度。 利用钾长石粉中的 K20和锰矿粉中的 Mn02形成的复合矿化剂， 使 在高温下混合的原料中形成占原料总体积 30%~40%的液相， 生成的液相 不但表面张力大， 浸润性能好， 使物料更致密， 因此， 增大了石油压裂支 撑剂的强度。 而且该液相在 1100°C对原料中的 A1203和 Si02就具有了很 强的溶解能力， 当原料中的 A1203和 Si02溶解到一定浓度时， 相互反应 生成针状莫来石析晶而出，然后不断溶解和析晶，使莫来石化从固相反应 变为液相反应，这就大大加快了反应速度和降低了反应所需的温度。在莫 来石液化的同时， 由于矿化剂的作用， 富余的 Si02转变为双头予状磷石 英晶体， 使成品具有较高的强度。
结果表明，本发明所提供的粉煤灰及废陶瓷制石油压裂支撑剂的体积 密度≤1.50 g/cm3, 视密度≤2.60g/cm3, 在 86MPa的闭合压力下， 破碎率 ≤8%。 具体实施方式
本发明提供了一种粉煤灰及废陶瓷制石油压裂支撑剂，由以下组分制 备而成：
80wt%~90wt%的主料， 所述主料为粉煤灰和废陶瓷；
10wt%~20wt%的辅料， 所述辅料钾长石粉和锰矿粉；
主料和辅料之和为 100%。 本发明以粉煤灰及废陶瓷作为石油压裂支撑剂的主料，本发明对所述 废陶瓷的种类并无特殊限制， 优选为低铝废陶瓷， 在工业上，低铝废陶瓷 和粉煤灰的废弃量较大， 成本低， 因此， 将低铝废陶瓷和粉煤灰合理利用 具有节能环保、 节约资源的重要意义。 其中， 粉煤灰和废陶瓷的占原料总 量优选为 40wt%~90wt% , 更优选为 50wt%~80wt% , 最优选为 60wt%~70wt%。其中，所述粉煤灰及废陶瓷的质量比优选为（ 4~6 ): ( 2-3 ), 吏优选为 ( 4·5~5·5 ): ( 2.2-2.8 )ο
在本发明中，以钾长石粉和锰矿粉作为石油压裂支撑剂的辅料，其中， 钾长石粉与锰矿粉形成复合矿化剂，钾长石粉为主要矿化剂，钾长石粉中 的 Κ20起到矿化作用； 所述锰矿粉为辅助矿化剂和染色剂， 锰矿粉中的 Mn02占所述粉煤灰及废陶瓷制石油压裂支撑剂的 0wt%~5wt%, 更优选 为 lwt%~4wt%, 最优选为 2wt%~3wt%。所述锰矿粉和钾长石粉的添加量 占原料总量的质量范围优选为 lwt%~40wt%, 更优选为 10wt%~30wt%, 最优选为 15wt%~25wt%。 其中， 所述钾长石粉与锰矿粉的质量比优选为 ( 2-5 ): 1 , 更优选为 （2·5~4·5 ): 1 , 最优选为 （ 3~4 ): 1。
本发明以钾长石粉中的 Κ20和锰矿粉中的 Mn02形成复合矿化剂， 使在高温下混合的原料中形成占原料总体积 30%~40%的液相， 生成的液 相不但表面张力大， 浸润性能好， 使物料更致密， 因此， 增大了石油压裂 支撑剂的强度。
本发明所提供的石油压裂支撑剂的体积密度≤1.50§/«113 , 视密度
≤2.60g/cm3。 优选的， 所述体积密度≤1.40g/cm3, 视密度≤2.40g/cm3。
本发明还提供了一种粉煤灰及废陶瓷制石油压裂支撑剂的制备方法， 包括以下步骤：
A )将粉煤灰、废陶瓷、钾长石粉和锰矿粉混合， 进行均化细化处理， 经过制粒后筛分， 得到混合物；
B )将所述混合物烧制， 得到粉煤灰及废陶瓷制石油压裂支撑剂。 本发明首先将粉煤灰、废陶瓷、钾长石粉和锰矿粉混合， 进行均化细 化处理， 对所述均化细化处理的方式并无特殊限制， 具体方法为：
将粉煤灰、废陶瓷、钾长石粉和锰矿粉置于强制混合机中进行均化细 化处理。 本发明将原料进行均化细化处理，使原料粒度分布更加均勾，化 学反应更加顺利，并且化学反应进行的更加充分，使得到的石油压裂支撑 剂的晶粒更细小， 提高了石油压裂支撑剂的强度。
其中， 粉煤灰和废陶瓷的占原料总量优选为 40wt%~90wt%, 更优选 为 50wt%~80wt%, 最优选为 60wt%~70wt%。 其中， 所述粉煤灰及废陶瓷 的质量比优选为 （4~6 )： ( 2~3 ), 更优选为 ( 4.5-5.5 ): ( 2·2~2·8 )。 锰矿 粉中的 Mn02占所述废粉煤灰及陶瓷制石油压裂支撑剂的 0wt%~5wt%。 所述锰矿粉和钾长石粉的添加量占原料总量的质量范围优选为 lwt%~40wt%, 更优选为 10wt%~30wt%, 最优选为 15wt%~25wt%。其中， 所述钾长石粉与锰矿粉的质量比优选为 （2~5 )： 1 , 更优选为 （2.5~4.5 )： 1 , 最优选为 ( 3~4 )： 1。
将粉煤灰、废陶瓷、钾长石粉和锰矿粉置于强制混合机中进行均化细 化处理后， 经过制粒后筛分，得到混合物。 本发明对所述制粒的方式并无 特殊限制，本领域技术人员熟知的制粒方式即可；本发明对所述筛分的方 式并无特殊限制， 本领域技术人员熟知的筛分方式即可。 其中， 筛分后得 到的混合物的粒径有不同的规格， 优选为 3350~106μηι , 更优选为 850~425μηι、 600~300μηι、 425~250μηι、 425~212μηι或 212~106μηι。 本发 明所使用的废陶瓷优选为低铝废陶瓷。
本发明将所述混合物进行烧制，即可得到粉煤灰及废陶瓷制石油压裂 支撑剂。本发明对所述烧制的场所并无特殊限制，优选在回转窑中进行烧 为 1100~1200°C , 更优选为 1110~1150°C , 所述烧制的时间优选为 4~8h, 更优选为 5~7h。
烧制结束后得到粉煤灰及废陶瓷制石油压裂支撑剂，所述粉煤灰及废 陶瓷制石油压裂支撑剂中化学成分重量比例达到： A1203: 40%~48%, Si02: 38%~45%, K20: 2%~4%。
本发明以粉煤灰、废陶瓷、钾长石粉和锰矿粉为原料制备了一种粉煤 灰及废陶瓷制石油压裂支撑剂， 本发明以成本低的粉煤灰和废陶瓷为原 料， 在制备过程中， 粉煤灰和废陶瓷中的 Α1203生成莫来石， 原料中富余 的 Si02转化为磷石英等低视密矿物， 降低了产品的视密度。 利用钾长石 粉中的 K20和锰矿粉中的 Mn02形成的复合矿化剂， 使在高温下混合的 原料中形成占原料总体积 30%~40%的液相，生成的液相不但表面张力大， 浸润性能好， 使物料更致密， 因此， 增大了石油压裂支撑剂的强度。 而且 该液相在 1100°C对原料中的 Α1203和 Si02就具有了很强的溶解能力， 当 原料中的 A1203和 Si02溶解到一定浓度时， 相互反应生成针状莫来石析 晶而出， 然后不断溶解和析晶， 使莫来石化从固相反应变为液相反应， 这 就大大加快了反应速度和降低了反应所需的温度。 在莫来石液化的同时， 由于矿化剂的作用， 富余的 Si02转变为双头予状磷石英晶体， 使成品具 有较高的强度。
结果表明，本发明所提供的粉煤灰及废陶瓷制石油压裂支撑剂的体积 密度≤1.50g/cm3,视密度≤2.60g/cm3,在 86MPa的闭合压力下，破碎率≤8%。
为了进一步理解本发明，下面结合实施例对本发明提供的粉煤灰及废 陶瓷制石油压裂支撑剂及其制备方法进行说明，本发明的保护范围不受以 下实施例的限制。 实施例 1
将 60Kg鹤壁万和电厂的除尘废灰， 20 Kg鹤壁市陶瓷工业园区新中 源陶瓷厂的低铝废陶瓷， 15 Kg钾长石粉和 5 Kg锰矿粉混合后经强制混 合机进行均化细化加工， 而后制粒， 经筛分取得粒径为 900~600μηι的混 合物， 将所述混合物在常压下用 2.5米 x45米回转窑经 1100°C~1150°C烧 制 4个小时， 冷却筛分后即可得到目数为 20~40目（850~425μηι)的粉煤灰 及废陶瓷制石油压裂支撑剂。
测定所述粉煤灰及废陶瓷制石油压裂支撑剂的体积密度为 1.42g/cm3, 视密度为 2.47g/cm3, 在 86Mpa闭合压力下， 破碎率≤8%。 实施例
将 50Kg鹤壁万和电厂的除尘废灰， 30 Kg鹤壁市陶瓷工业园区金鸡 山陶瓷厂的低铝废陶瓷， 15 Kg钾长石粉和 5 Kg锰矿粉混合后经强制混 合机进行均化细化加工， 而后制粒， 经筛分取得粒径为 900~600μηι的混 合物， 将所述混合物在常压下用 2.5米 x45米回转窑经 1100°C~1150°C烧 制 4个小时， 冷却筛分后即可得到目数为 20~40目（850~425μηι)的粉煤灰 及废陶瓷制石油压裂支撑剂。
测定所述粉煤灰及废陶瓷制石油压裂支撑剂的体积密度为
1.45g/cm3, 视密度为 2.50 g/cm3, 在 86Mpa闭合压力下， 破碎率≤8%。 实施例 3
将 60Kg鹤壁万和电厂的除尘废灰， 20 Kg鹤壁市陶瓷工业园区新中 源陶瓷厂的低铝废陶瓷， 15 Kg钾长石粉和 5 Kg锰矿粉混合后经强制混 合机进行均化细化加工， 而后制粒， 经筛分取得粒径为 710~425μηι的混 合物， 将所述混合物在常压下用 2.5米 x45米回转窑经 1100°C~1150°C烧 制 4个小时， 冷却筛分后即可得到目数为 30-50目 ( 600~300μηι )的粉煤 灰及废陶瓷制石油压裂支撑剂。
测定所述粉煤灰及废陶瓷制石油压裂支撑剂的体积密度为
1.45g/cm3, 视密度为 2.52g/cm3, 在 86Mpa闭合压力下， 破碎率≤8%。 实施例 4
将 50Kg鹤壁万和电厂的除尘废灰， 30 Kg鹤壁市陶瓷工业园区金鸡 山陶瓷厂的低铝废陶瓷， 15 Kg钾长石粉和 5 Kg锰矿粉混合后经强制混 合机进行均化细化加工， 而后制粒， 经筛分取得粒径为 710~425μηι的混 合物， 将所述混合物在常压下用 2.5米 x45米回转窑经 1100°C~1150°C烧 制 4个小时， 冷却筛分后即可得到目数为 30-50目 ( 600~300μηι )的粉煤 灰及废陶瓷制石油压裂支撑剂。
测定所述粉煤灰及废陶瓷制石油压裂支撑剂的体积密度为
1.48g/cm3, 视密度为 2.53 g/cm3, 在 86Mpa闭合压力下， 破碎率≤8%。 实施例 5
将 60Kg鹤壁万和电厂的除尘废灰， 20 Kg鹤壁市陶瓷工业园区新中 源陶瓷厂的低铝废陶瓷， 15 Kg钾长石粉和 5 Kg锰矿粉混合后经强制混 合机进行均化细化加工， 而后制粒， 经筛分取得粒径为 500~425μηι的混 合物， 将所述混合物在常压下用 2.5米 x45米回转窑经 1100°C~1150°C烧 制 4个小时， 冷却筛分后即可得到目数为 40~60目 （425~250μηι )的粉煤 灰及废陶瓷制石油压裂支撑剂。
测定所述粉煤灰及废陶瓷制石油压裂支撑剂的体积密度为 1.47g/cm3, 视密度为 2.53g/cm3, 在 86Mpa闭合压力下， 破碎率≤8%。 实施例 6
将 50Kg鹤壁万和电厂的除尘废灰， 30 Kg鹤壁市陶瓷工业园区金鸡 山陶瓷厂的低铝废陶瓷， 15 Kg钾长石粉和 5 Kg锰矿粉混合后经强制混 合机进行均化细化加工， 而后制粒， 经筛分取得粒径为 500~425μηι的混 合物， 将所述混合物在常压下用 2.5米 x45米回转窑经 1100°C~1150°C烧 制 4个小时， 冷却筛分后即可得到目数为 40-60目 ( 425~250μηι )的粉煤 灰及废陶瓷制石油压裂支撑剂。
测定所述粉煤灰及废陶瓷制石油压裂支撑剂的体积密度为 1.49g/cm3, 视密度为 2.55 g/cm3, 在 86Mpa闭合压力下， 破碎率≤8%。 实施例 7
将 60Kg鹤壁万和电厂的除尘废灰， 20 Kg鹤壁市陶瓷工业园区新中 源陶瓷厂的低铝废陶瓷， 15 Kg钾长石粉和 5 Kg锰矿粉混合后经强制混 合机进行均化细化加工， 而后制粒， 经筛分取得粒径为 500~355μηι的混 合物， 将所述混合物在常压下用 2.5米 x45米回转窑经 1100°C~1150°C烧 制 4个小时， 冷却筛分后即可得到目数为 40-70目 ( 425-212μηι )的粉煤 灰及废陶瓷制石油压裂支撑剂。
测定所述粉煤灰及废陶瓷制石油压裂支撑剂的体积密度为 1.49g/cm3, 视密度为 2.56g/cm3, 在 86Mpa闭合压力下， 破碎率≤8%。 将 50Kg鹤壁万和电厂的除尘废灰， 30 Kg鹤壁市陶瓷工业园区金鸡 山陶瓷厂的低铝废陶瓷， 15 Kg钾长石粉和 5 Kg锰矿粉混合后经强制混 合机进行均化细化加工， 而后制粒， 经筛分取得粒径为 500~355μηι的混 合物， 将所述混合物在常压下用 2.5米 x45米回转窑经 1100°C~1150°C烧 制 4个小时， 冷却筛分后即可得到目数为 40-70目 ( 425-212μηι )的粉煤 灰及废陶瓷制石油压裂支撑剂。
测定所述粉煤灰及废陶瓷制石油压裂支撑剂的体积密度为 1.49g/cm3, 视密度为 2.56g/cm3, 在 86Mpa闭合压力下， 破碎率≤8%。 以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的 普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进 和润饰， 这些改进和润饰也应视为本发明的保护范围。

Claims

权 利 要 求
1、 一种粉煤灰及废陶瓷制石油压裂支撑剂， 由以下组分制备而成： 40wt%~90wt%的主料， 所述主料为粉煤灰和废陶瓷；
lwt%~40wt%的辅料， 所述辅料为钾长石粉和锰矿粉；
主料和辅料之和为 100%。
2、 根据权利要求 1所述的石油压裂支撑剂， 其特征在于， 所述废陶 瓷为低铝废陶瓷。
3、 根据权利要求 1所述的石油压裂支撑剂、 其特征在于， 所述粉煤 灰与废陶瓷的质量比为 （4~6 )： ( 2~3 )。
4、 根据权利要求 1所述的石油压裂支撑剂， 其特征在于， 所述钾长 石粉与锰矿粉的质量比为 （2~5 )： 1。
5、 根据权利要求 1所述的石油压裂支撑剂， 其特征在于， 所述锰矿 粉中 Mn02占所述粉煤灰及废陶瓷制石油压裂支撑剂的 0wt%~5wt%。
6、 一种粉煤灰及废陶瓷制石油压裂支撑剂的制备方法， 包括以下步 骤：
A )将粉煤灰、废陶瓷、钾长石粉和锰矿粉混合， 进行均化细化处理， 经过制粒后筛分， 得到混合物；
B )将所述混合物烧制， 得到粉煤灰及废陶瓷制石油压裂支撑剂。
7、 根据权利要求 6所述的制备方法， 其特征在于， 所述废陶瓷为低 铝废陶瓷。
8、 根据权利要求 6所述的制备方法， 其特征在于， 所述混合物的粒 径为 3350~106μηι。
9、 根据权利要求 6所述的制备方法， 其特征在于， 所述步骤 Α )具 体为：
将粉煤灰、废陶瓷， 钾长石粉和锰矿粉混合， 置于强制混合机中进行 均化细化处理， 经过制粒后筛分， 得到混合物。
10、根据权利要求 6所述的制备方法， 其特征在于， 所述烧制的时间 为 4~8h。
+
PCT/CN2013/076382 2013-04-25 2013-05-29 一种粉煤灰及废陶瓷制石油压裂支撑剂及其制备方法 WO2014172954A1 (zh)

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