Self-toughened high-strength proppant and methods of making same

1. A method for producing a proppant comprising

a. forming a green body on a template from a green body material comprising

i. at least one metal oxide or precursor thereof that forms whiskers in said proppant and as part of said proppant, and

ii. preformed whiskers, wherein the preformed whiskers are not in contact with each other, and

iii. at least two whisker promoters, optionally in the absence of fluorine or fluorine compounds, wherein the whisker promoters are disposed within the template;

reactive sintering said green body under reactive sintering conditions to form a sintered body comprising in-situ whiskers and at least one amorphous phase, wherein the in-situ whiskers comprise anisotropic crystals elongated along a C-axis.

2. The method of claim 1 , wherein said sintered body further comprises at least one non-whisker containing crystalline phase.

3. The method of claim 2 , wherein said non-whisker containing crystalline phase comprises crystalline alumina.

4. The method of claim 3 , wherein said crystalline alumina is in particulate form.

5. The method of claim 1 , wherein said at least one metal oxide comprises a first metal oxide and a second metal oxide, wherein said first metal oxide and said second metal oxide are different from each other.

6. The method of claim 1 , wherein said at least one metal oxide comprises a first metal oxide and a second metal oxide, wherein said first metal oxide and said second metal oxide are different from each other with respect to metal that forms the oxide, and wherein said template is porous or non-porous.

7. The method of claim 1 , wherein said method further comprises forming said green body around a template so as to completely encapsulate said template.

8. The method of claim 6 , wherein said template is a hollow sphere.

9. The method of claim 6 , wherein said reactive sintering at least partially convert said template to a template comprising in-situ whiskers and at least one amorphous phase.

10. The method of claim 9 , wherein concentration of in-situ whiskers in said template is different from concentration of in-situ whiskers in said sintered body that is on said template.

11. The method of claim 1 , wherein said in-situ whiskers comprise mineral or metal oxide in-situ whiskers.

12. A proppant comprising a shell, a template, a sintered body, wherein said sintered body, the shell, and the template comprises in-situ whiskers disposed within said sintered body, the shell, the template, and at least one amorphous phase, wherein the in-situ whiskers comprise anisotropic crystals elongated along a C-axis, wherein concentrations of the in-situ whiskers in the shell and the template are different.

13. The proppant of claim 12 , said proppant further comprising at least one non-whisker containing crystalline phase.

14. The proppant of claim 13 , wherein said non-whisker containing crystalline phase comprises at least one crystalline particulate phase.

15. The proppant of claim 13 , wherein the proppant has the following characteristics:

mullite phase: 5 wt % to 40 wt %

overall crystalline phase: 10 wt % to 75 wt %

overall amorphous phase: 5 wt % to 50 wt %

quartz phase: 0% to 5%

cristobalite phase: 0 wt % to 5 wt %;

all based on the wt % of said proppant.

16. The proppant of claim 12 , wherein said in-situ whiskers are present as an in-situ whisker phase that is a continuous phase.

17. The proppant of claim 12 , wherein said in-situ whiskers are present as an in-situ whisker phase that is a non-continuous phase.

18. The proppant of claim 12 , wherein said in-situ whiskers are uniformly distributed throughout said sintered body.

19. The proppant of claim 12 , wherein in-situ whiskers are present in said sintered body in a three-dimensional non-woven structure.

20. The proppant of claim 12 , wherein said in-situ whiskers have a phase connectivity of 3.

21. The proppant of claim 12 , wherein said in-situ whiskers have a phase connectivity of 2.

22. The proppant of claim 12 , wherein said in-situ whiskers are metal oxide or mineral derived in-situ whiskers.

23. The proppant of claim 12 , wherein said sintered body encapsulates said template.

24. The proppant of claim 23 , wherein said template is a hollow sphere.

25. The proppant of claim 23 , wherein said template comprises in-situ whiskers and at least one amorphous phase.

26. The proppant of claim 25 , wherein said template further comprises at least one non-whisker containing crystalline phase.

27. The proppant of claim 23 , wherein said template comprise in-situ whiskers and at least one amorphous phase wherein concentration of in-situ whiskers in said template is different from concentration of in-situ whiskers in said sintered body that is on said template.

28. The proppant of claim 23 , wherein said template comprise in-situ whiskers and at least one amorphous phase wherein concentration of in-situ whiskers in said template is lower than concentration of in-situ whiskers in said sintered body that is on said template.

29. The proppant of claim 25 , wherein said in-situ whiskers in said template and in said sintered body comprise mineral or metal oxide derived whiskers.

30. The proppant of claim 12 , wherein said proppant has at least one of the following characteristics:

a. an overall diameter of from about 90 microns to about 2,000 microns;

b. a Krumbein sphericity of at least about 0.5 and a roundness of at least about 0.5;

c. a crush strength of about 10 MPa or greater;

d. a specific gravity of from about 1.0 to about 3.0;

e. a porosity of from about 6% to about 40%;

f. at least 90% of proppant pores having a pore size of from about 0.1 μm to about 10 μm, and

g. at least 80% of proppant pores are not in contact with each other.

31. A method to prop open subterranean formation fractures comprising introducing a proppant formulation comprising the proppant of claim 12 into a subterranean formation.

32. A method of treating a subterranean producing zone penetrated by a well bore comprising the steps of:

a. preparing or providing a treating fluid that comprises a fluid, energized fluid, foam, or a gas carrier having the proppant of claim 12 suspended therein, and

b. pumping said treating fluid into said subterranean producing zone whereby said particles are deposited therein.

33. The method of claim 32 , wherein said treating fluid is a fracturing fluid and said particles are deposited in fractures formed in said subterranean producing zone, or wherein said treating fluid is a gravel packing fluid and said particles are deposited in said well bore adjacent to said subterranean producing zone.

34. A method for producing a glass-ceramic composite comprising

a. crushing a siliceous material to a particle size of from about 0.2 microns to about 5.0 microns;

b. forming a green body on a template from a green body material comprising

i. alumina and/or at least one alumina precursor and the crushed siliceous material in a ratio to form mullite whiskers in said glass-ceramic composite, and

ii. a minor amount of mullite whiskers, wherein the mullite whiskers comprise anisotropic crystals elongated along a C-axis, wherein the mullite whiskers are discrete and separate whiskers aligned in one dimension; and

iii. at least two whisker promoters in the absence of fluorine or fluorine compounds, wherein the whisker promoters are disposed within the template;

c. sintering said green body under sintering conditions to form in situ said glass-ceramic composite comprising at least one mullite whisker phase and at least one amorphous phase.

35. The method of claim 34 , wherein said siliceous material comprises cenospheres, fly ash or any combination thereof.

36. The method of claim 35 , wherein said cenospheres are present in an amount based on weight % of cenosphere to alumina of from 30 wt % cenosphere: 70 wt % alumina to 55 wt % cenosphere: 45 wt % alumina.

37. The method of claim 34 , wherein at least one of said whisker promoters comprises B 2 O 3 and/or at least one transition metal oxide, and said transition metal oxide comprises Fe 2 O 3 , TiO 2 , CoO, NiO, or any combination thereof, and said whisker promoter comprises from about 1% by weight to about 2% by weight of said green body mixture.

38. The method of claim 34 , wherein said sintering is performed in the presence of a gas, and said gas comprises from about 100 ppm to about 100%.

39. The method of claim 34 , wherein the green body material further comprises at least one sintering promoter comprising a sintering aid, a glassy phase formation agent, a grain growth inhibitor, a ceramic strengthening agent, a crystallization control agent, or phase formation control agent, or any combination thereof, and wherein said sintering promoter comprises zirconium, iron, magnesium, alumina, bismuth, lanthanum, silicon, calcium, cerium, yttrium, a silicate, a borate or any combination thereof, or a compound containing zirconium, iron, magnesium, alumina, bismuth, lanthanum, silicon, calcium, cerium, yttrium, a silicate, a borate or any combination thereof.

40. The method of claim 34 , wherein said green body material further comprises a binder, wherein said binder comprises a wax, a starch, polyvinyl alcohol, a sodium silicate solution, a low molecular weight functionalized polymer or any combination thereof.

41. The method of claim 34 , wherein said green body material further comprises a dispersant, wherein said dispersant comprises a surfactant.

42. The method of claim 34 , wherein said mullite whiskers in said glass-ceramic composite have diameters from about 0.05 μm to about 2 μm, aspect ratios from about 10 to about 50, and lengths from about 1 μm to about 50 μm.

43. The method of claim 34 , wherein the phases of said glass-ceramic composite comprises 3-3 connectivity for the mullite whisker phase and the amorphous phase.

44. The method of claim 34 , wherein the phases of said glass-ceramic composite comprises 3-3-0 connectivity for the mullite whisker phase, the amorphous phase and the unreacted alumina or alumna precursor.

45. The method of claim 34 , wherein the phases of said glass-ceramic composite comprises 3-3-0 connectivity for the mullite whisker phase, the amorphous phase and the unreacted siliceous material.

46. The method of claim 34 , wherein the phases of said glass-ceramic composite comprises 3-3-0-0 connectivity for the mullite whisker phase, the amorphous phase, the unreacted siliceous material and the unreacted alumina or alumna precursor.

47. The method of claim 34 , wherein said amorphous phase consists of at least one ceramic comprising alumina, silica, or any combination thereof.

48. The method of claim 34 , wherein said template is hollow.

49. The method of claim 48 , wherein said hollow template comprises a cenosphere, a micro glass sphere, a synthetic cenosphere, a polymer bead or any combination thereof.

50. A glass-ceramic composite material comprising a sintered body having at least one mullite whisker phase and at least one amorphous phase, wherein the mullite whisker phase comprises in-situ whiskers disposed within the sintered body, wherein the in-situ whiskers comprise anisotropic crystals elongated along a C-axis, wherein the in-situ whiskers are present in an amount from about 10 wt % to about 50 wt % based on a weight of the glass-ceramic composite material.

51. A method for producing a proppant comprising

a. forming a green body on a template from a green body material comprising

i. at least one metal oxide or precursor thereof that forms whiskers in said proppant and as part of said proppant, and

ii. optionally preformed whiskers, and

iii. at least two whisker promoters, optionally in the absence of fluorine or fluorine compounds, wherein the whisker promoters are disposed within the template; and

iv. at least one carbide or metal carbide,

b. reactive sintering said green body under reactive sintering conditions to form a sintered body comprising in-situ whiskers and at least one amorphous phase, wherein the in-situ whiskers comprise anisotropic crystals elongated along a C-axis, wherein the in-situ whiskers are present in an amount from about 10 wt % to about 50 wt % based on a weight of the proppant.

52. The method of claim 51 , wherein said carbide is SiC.

53. A proppant comprising a sintered body, wherein said sintered body comprises in-situ whiskers disposed within the sintered body, at least one glassy phase, and at least one amorphous phase, wherein the in-situ whiskers comprise anisotropic crystals elongated along a C-axis, wherein the in-situ whiskers are present in an amount from about 10 wt % to about 50 wt % based on a weight of the proppant.

54. The proppant of claim 53 , wherein said sintered body further comprises at least one non-whisker containing crystalline phase.

55. The proppant of claim 53 , wherein said sintered body further comprises at least one carbide or metal carbide.

56. The proppant of claim 55 , wherein said at least one carbide is SiC.

57. The proppant of claim 55 , wherein said at least one carbide or metal carbide is present in an amount of from 1% by weight to 25% by weight, based on the weight of the proppant.

58. The proppant of claim 53 , further comprising at least one carbide or metal carbide in particulate form, and at least one non-whisker containing crystalline particulate phase.

59. The proppant of claim 58 , wherein said at least one non-whisker containing crystalline particulate phase is alumina.

60. The proppant of claim 53 , wherein said in-situ whiskers are present as an in-situ whisker phase that is a continuous phase.

61. The proppant of claim 53 , wherein said in-situ whiskers are present as an in-situ whisker phase that is a non-continuous phase.

62. The proppant of claim 53 , wherein said in-situ whiskers are uniformly distributed throughout said sintered body.

63. The proppant of claim 53 , wherein in-situ whiskers are present in said sintered body in a three-dimensional non-woven structure.

64. The glass-ceramic composite material of claim 50 , further comprising pre-formed whiskers.

65. The glass-ceramic composite material of claim 64 , wherein said pre-formed whiskers have a different morphology from the in-situ whiskers.

66. The proppant of claim 12 , further comprising pre-formed whiskers.

67. The proppant of claim 66 , wherein said in-situ whiskers have a different morphology from the pre-formed whiskers.