Light weight proppant with improved strength and methods of making same

1. A method for producing a proppant comprising

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

i. at least one metal oxide or precursor thereof that is capable of forming whiskers in said proppant and as part of said proppant, wherein a microstructure of the whiskers includes anisotropic crystals elongated along a C-axis,

ii. at least one amorphous material containing at least one entrapped vaporizable material,

iii. preformed whiskers, wherein the preformed whiskers are present in the green body material in an amount less than 2 wt % based on a weight, wherein the preformed whiskers are present as a non-continuous phase of the green body material;

iv. at least one whisker promoter, optionally in the absence of fluorine or fluorine compounds; and

v. a fluxing agent:

b. reactive sintering said green body under reactive sintering conditions to form a sintered body comprising whiskers and at least one amorphous phase, wherein the whiskers are non-uniformly distributed.

2. 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.

3. The method of claim 1 , wherein said amorphous material comprises perlite, stober silica, pumice, andesite, scoria, volcanic glasses, or any combination thereof.

4. The method of claim 3 , wherein said vaporizable material comprises water (H 2 O) carbon dioxide (CO 2 ), sulfur dioxide (SO 2 ), hydrogen sulfide (H 2 S), nitrogen, argon, helium, neon, methane, carbon monoxide (CO), hydrogen, oxygen, hydrogen chloride (HCl), hydrogen fluoride (HF), hydrogen bromide (HBr), nitrogen oxide (NOx), sulfur hexafluoride (SF 6 ), carbonyl sulfide (COS), volcanic gases, or any combination thereof.

5. The method of claim 1 , wherein said amorphous material has a lower specific gravity than other said green body materials.

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

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

8. The method of claim 1 , said green body material comprising

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

ii. the at least one amorphous material containing at least one entrapped vaporizable material, and

iii. the preformed whiskers, and

iv. the at least one whisker promoter, optionally in the absence of fluorine or fluorine compounds;

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

9. The method of claim 8 , wherein the median particle size, d a50 , of said alumina or alumina precursor is from about 0.01 μm to about 100 μm, wherein d a50 is a median particle size where 50% of the particles of the distribution have a smaller particle size.

10. The method of claim 8 , wherein the median particle size, d s50 , of said siliceous material is from about 0.01 μm to about 100 μm, wherein d s50 is a median particle size where 50% of the particles of the distribution have a smaller particle size.

11. The method of claim 8 , wherein the median particle size, d a50 , of said amorphous material containing at least one entrapped vaporizable material is from about 0.01 μm to about 100 μm, wherein d a50 is a median particle size where 50% of the particles of the distribution have a smaller particle size.

12. The method of claim 8 , wherein said alumina or alumina precursor has a particle size distribution, d as , from about 0.5 to about 15, wherein, d as ={(d a90 −d a10 )/d a50 } wherein d a10 is a particle size wherein 10% of the particles have a smaller particle size, d a50 is a median particle size wherein 50% of the particles have a smaller particle size, and d a90 is a particle size wherein 90% of the particle volume has a smaller particle size.

13. The method of claim 8 , wherein said siliceous material has a particle size distribution, d ss , from about 0.5 to about 15, wherein, d ss ={(d s90 −d s10 )/d s50 } wherein d s10 is a particle size wherein 10% of the particles have a smaller particle size, d s50 is a median particle size wherein 50% of the particles have a smaller particle size, and d s90 is a particle size wherein 90% of the particle volume has a smaller particle size.

14. The method of claim 1 , wherein the fluxing agent is selected from the group consisting of nepheline syenite, feldspar, synthetic clay, natural clay and combinations thereof.

15. The method of claim 6 , wherein the template comprises a different composition than the green body material.