Ceramic particles formed from perforated membranes

Patent metadata

Field	Value
Publication number	US-2016272880-A1
Application number	US-201415033695-A
Country	US
Kind code	A1
Filing date	Nov 14, 2014
Priority date	Nov 19, 2013
Publication date	Sep 22, 2016
Grant date	—

Abstract

Methods and apparatus for forming proppant particles which include providing an aqueous slurry of ceramic forming raw materials, flowing the slurry through a perforated membrane, which may be energized, to form slurry bodies, receiving the slurry bodies in a collecting hopper, and drying the slurry bodies to form particles. In some aspects, the slurry is energized as it flows through the perforated membrane.

First claim

What is claimed is:

1 . A method comprising:
providing an aqueous slurry of ceramic forming raw materials; flowing the slurry through at least one perforated membrane to form slurry bodies; receiving the slurry bodies in a collecting hopper; and drying the slurry bodies to form particles.

2 . The method of claim 1 wherein the aqueous slurry comprises bauxite containing less than eighty percent alumina.

3 . The method of claim 1 wherein the aqueous slurry comprises a rheology modifying agent.

4 . The method of claim 1 wherein the slurry bodies flow through the perforated membrane by extrusion.

5 . The method of claim 1 wherein the slurry further comprises a reactant and a dispersant.

6 . The method of claim 5 wherein the dispersant is a surfactant.

7 . The method of claim 6 wherein the surfactant at least partially influences slurry body shape, size, or combination thereof.

8 . The method of claim 1 wherein the perforated membrane comprises a substantially planar surface.

9 . The method of claim 1 wherein collecting hopper is a bathless container.

10 . The method of claim 1 wherein the particles formed are proppant particles.

11 . The method of claim 1 further comprising a sintering step.

12 . The method of claim 11 wherein the particles are sintered at a temperature in the range of from about 1400° C. to about 1650° C.

13 . The method of claim 1 wherein the aqueous slurry has a solids content of from about 60% by weight to about 88% by weight.

14 . The method of claim 1 wherein the aqueous slurry further comprises at least one ingredient influencing the rheology properties of the slurry.

15 . The method of claim 14 wherein the ingredient is attapulgite.

16 . The method of claim 1 wherein the aqueous slurry comprises about greater than or equal to 46% by weight alumina, about less than or equal to 18% by weight silica and about less than or equal to 10% by weight zirconia or derivatized zirconia oxides.

17 . The method of claim 1 wherein the aqueous slurry further comprises at least one of glass, flyash or soda ash.

18 . The method of claim 1 wherein the aqueous slurry further comprises graphite coated iron particles, graphite coated magnetic powder, or combination thereof.

19 . The method of claim 1 wherein the reactant is a polysaccharide.

20 . The method of claim 19 wherein the polysaccharide is an alginate.

21 . The method of claim 1 wherein the coagulation agent is calcium chloride.

22 . The method of claim 1 wherein the slurry is energized as it flows through the perforated membrane.

23 . The method of claim 1 further comprising receiving the slurry bodies in a bath, wherein the bath comprises a foam disposed thereon.

24 . The method of claim 1 wherein the at least one perforated membrane is a plurality of perforated membranes.

25 . A method comprising:
providing an aqueous slurry of ceramic forming raw materials, the slurry further comprising a reactant and a dispersant; flowing the slurry through a perforated membrane while energizing the slurry to form slurry bodies; passing the slurry bodies through a mist in a chamber, the mist comprising a coagulation agent to react with the reactant in the slurry bodies; receiving the slurry bodies in a collecting hopper; and drying the slurry bodies to form particles.

26 . A method of hydraulic fracturing a subterranean formation penetrated by a wellbore, the formation having a fracturing stress, the method comprising:
pumping a fracturing fluid into the wellbore at a pressure above the fracturing stress of the formation; and adding proppant particles to the fracturing fluid and delivering the proppant particles and the fluid into the wellbore
wherein the proppant particles are prepared by providing an aqueous slurry of ceramic forming raw materials, flowing the slurry through a perforated membrane to form slurry bodies, receiving the slurry bodies in a collecting hopper, and drying the slurry bodies to form the proppant particles.

27 . A system comprising:
a storage tank for providing a slurry of particle forming raw materials; a perforated membrane for forming slurry bodies from the aqueous slurry; a misting chamber disposed adjacent the perforated membrane; and, a collecting hopper disposed adjacent the misting chamber;
wherein the storage tank is fluidly connected with perforated membrane.

Assignees

• Schlumberger Technology Corp

Inventors

• Barthelmess Thomas Philip
• Roettle Joachim

Classifications

• C04B35/64

  Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F}) · CPC title

• B01J2219/2423

  Separation means, e.g. membrane inside the reactor · CPC title

• C04B35/628

  Coating the powders {or the macroscopic reinforcing agents} · CPC title

• E21B43/267

  reinforcing fractures by propping · CPC title

• C09K8/80 Primary

  Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open · CPC title