Ceramic particles with controlled pore and/or microsphere placement and/or size and method of making same
The present invention relates to lightweight high strength microsphere containing ceramic particles having controlled microsphere placement and/or size and microsphere morphology, which produces an improved balance of specific gravity and crush strength such that they can be used in applications such as proppants to prop open subterranean formation fractions. Proppant formulations are further disclosed which use one or more microsphere containing ceramic particles of the present invention. Methods to prop open subterranean formation fractions are further disclosed. In addition, other uses for the microsphere containing ceramic particles of the present invention are further disclosed, as well as methods of making the microsphere containing ceramic particles.
1. A method for producing proppants, wherein said method comprises
filtering by membrane filtration one or more of the starting materials that form said proppant, and then forming a green body from said starting materials that have been filtered by membrane filtration and then sintering said green body to said proppant, wherein said proppant has a specific gravity of from about 1.8 to about 2.25, a microsphere and/or pore total volume of from about 1% to about 10%, a crush strength of from about 10 MPa to about 300 MPa, and a four point bending strength of about 50 MPa to about 400 MPa.
2. The method of claim 1 , wherein said membrane filtration is a cross flow membrane separation.
3. The method of claim 1 , wherein said membrane filtration is a dead end filtration.