LOW DENSITY CERAMIC PROPPANT AND METHOD FOR PRODUCTION THEREOF

1 . A method of preparing a sintered ceramic proppant, the method comprising:

providing a ceramic precursor material comprising kaolin clay, 0.2%-2% by weight alkali silicate, and not more than 0.05% by weight polymeric anionic dispersant;

pelletizing the ceramic precursor; and

sintering the ceramic precursor pellets for form a sintered ceramic proppant having a specific gravity ranging from 2.40 to 2.57.

2 . The method of claim 1 , wherein the particle size distribution of the kaolin clay is such that greater than 85% of the particles have an equivalent spherical diameter of less than 2 microns as measured by Sedigraph.

3 . (canceled)

4 . The method of claim 1 , wherein the particle size distribution of the kaolin clay is such that greater than 20% of the particles have an equivalent spherical diameter of less than 0.25 microns as measured by Sedigraph.

5 . (canceled)

6 . The method of claim 1 , wherein the particle size distribution of the kaolin clay is such that greater than 30% of the particles have an equivalent spherical diameter of less than 0.25 microns as measured by Sedigraph.

7 . (canceled)

8 . The method of claim 1 , wherein the particle size distribution of the kaolin clay is such that not greater than 10% of the particles have an equivalent spherical diameter of greater than 10 microns as measured by Sedigraph.

9 . (canceled)

10 . (canceled)

11 . The method of claim 1 , wherein the kaolin clay has an Al 2 O 3 content ranging from about 42% by weight to about 46% by weight.

12 . The method of claim 1 , wherein the kaolin clay comprises a K 2 O content ranging from about 0.005% by weight to about 0.08% by weight.

13 . (canceled)

14 . The method of claim 1 , wherein the kaolin clay has a shape factor of less than about 15.

15 . The method of claim 1 , wherein the kaolin clay has a BET surface area of greater than about 15 m 2 /g.

16 . The method of claim 1 , wherein the slurry includes not more than 0.3% polymeric anionic dispersant.

17 . (canceled)

18 . (canceled)

19 . The method of claim 1 , wherein 0.5%-1% by weight of the alkali silicate is present in the slurry.

20 . The method of claim 1 , wherein the sintered ceramic proppant has a specific gravity greater than about 2.50.

21 . The method of claim 1 , wherein the sintered ceramic proppant has a specific gravity less than about 2.50.

22 . The method of claim 1 , wherein the sintered ceramic proppant has a bulk density ranging from about 1.25 g/cm 3 to about 1.45 g/cm 3 .

23 . (canceled)

24 . The method of claim 1 , wherein the crush strength measured under ISO 13503-2 of the sintered ceramic proppant at 7,500 psi is less than about 10% fines by weight.

25 . (canceled)

26 . The method of claim 1 , wherein the pelletizing is accomplished using a spray fluidizer.

27 . The method of claim 1 , wherein the pelletizing is accomplished using an Eirich mixer.

28 . The method of claim 1 , wherein the kaolin clay comprises a blend of a first kaolin clay having a particle size distribution such that greater than 90% of the particles have an equivalent spherical diameter of less than 2 microns as measured by Sedigraph and a second kaolin clay particle size distribution of the kaolin clay is such that from 82% to 94% of the particles have an equivalent spherical diameter of less than 2 microns as measured by Sedigraph.

29 . The method of claim 28 , wherein the first kaolin clay has a shape factor of less than about 15 and the second kaolin clay has a shape factor of greater than about 20.

30 . The method of claim 1 , wherein the ceramic proppant is sintered at a temperature ranging from about 1200 degrees C. to about 1400 degrees C.