High strength ultra-lightweight ceramic proppants prepared by double resin-coating process with fly ash
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Ceramic proppants is crucial in hydraulic fracturing for increasing oil and gas reservoirs. In this study, the ceramic particlesand resin-impregnated ceramic particles were prepared with fly ash, and then ultra-lightweight ceramic particles (proppants)were obtained by double resin-coating process. Crystalline phase and microstructure of the ceramic particles were investigatedby X-ray diffraction (XRD) and scanning electron microscopy (SEM), respectively. Effects of silicon carbide and epoxy resinconcentrations on the phase, apparent density, and breakage ratio of the ceramic particles were all studied systematically. Withincreasing silicon carbide contents, the corundum phase transform to mullite phase, decreasing the apparent density andincreasing the breakage ratios. The double resin-coated ceramic proppants featured smoother surface and less pores than theresin-impregnated samples, accompanying low apparent density (1.94 g/cm-3) and high strength (breakage ratio under 52 MPa,1.69%) when silicon carbide was 3.0 wt.% and epoxy resin concentrations was 55 wt.%. The results suggest the particles bythe effective double resin-coating process possess promising candidates for fracturing proppants in practical applications.
Abstract
Ceramic proppants is crucial in hydraulic fracturing for increasing oil and gas reservoirs. In this study, the ceramic particlesand resin-impregnated ceramic particles were prepared with fly ash, and then ultra-lightweight ceramic particles (proppants)were obtained by double resin-coating process. Crystalline phase and microstructure of the ceramic particles were investigatedby X-ray diffraction (XRD) and scanning electron microscopy (SEM), respectively. Effects of silicon carbide and epoxy resinconcentrations on the phase, apparent density, and breakage ratio of the ceramic particles were all studied systematically. Withincreasing silicon carbide contents, the corundum phase transform to mullite phase, decreasing the apparent density andincreasing the breakage ratios. The double resin-coated ceramic proppants featured smoother surface and less pores than theresin-impregnated samples, accompanying low apparent density (1.94 g/cm-3) and high strength (breakage ratio under 52 MPa,1.69%) when silicon carbide was 3.0 wt.% and epoxy resin concentrations was 55 wt.%. The results suggest the particles bythe effective double resin-coating process possess promising candidates for fracturing proppants in practical applications.
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