Composition and process for pelletizing carbon-based materials for proppant and industrial applications
A method for producing an electrically-conductive pellet includes reducing a size of a first material. The method also includes wetting the first material to produce a first slurry. The method also includes introducing the first slurry into a fluidizer to produce a first pellet. The method also includes reducing a size of a second material. The second material is an electrically-conductive material. The method also includes wetting the second material to produce a second slurry. The method also includes applying the second slurry to the first pellet.
1. An electrically-conductive pellet, comprising:
a core made from a first material comprising alumina, silica, kaolin, bauxite, or a combination thereof;
a shell layer that at least partially surrounds the core, wherein the shell layer is made from a second material that is electrically-conductive; and
an intermediate layer comprising a combination of the first material and the second material;
wherein the electrically-conductive pellet has:
an average cross-sectional length from about 200 μm to about 4000 μm,
a bulk density from about 0.3 g/cm 3 to about 2.0 g/cm 3 , and
an electrical conductivity from about 100 S/m to about 3000 S/m.
2. The electrically-conductive pellet of claim 1 , wherein the shell layer comprises petroleum coke, metal, graphite, or a combination thereof.
3. The electrically-conductive pellet of claim 1 , wherein the intermediate layer is positioned at least partially between the core and the shell layer.
4. The electrically-conductive pellet of claim 1 , wherein:
the core makes up from about 30% to about 80% of the electrically-conductive pellet,
the intermediate layer makes up from about 10% to about 40% of the electrically-conductive pellet, and
the shell layer makes up from about 10% to about 60% of the electrically-conductive pellet.
5. The electrically-conductive pellet of claim 4 , further comprising a non-radioactive tracer in the core, the shell layer or both.
6. The electrically-conductive pellet of claim 1 , wherein the pellet has an electrical conductivity of about 100 S/m to about 4000 S/m.
7. A sintered, electrically-conductive pellet, comprising:
a core made from a first material comprising alumina, silica, kaolin, bauxite, or a combination thereof;
a shell layer that at least partially surrounds the core, wherein the shell layer is made from a second material that is electrically-conductive; and
an intermediate layer comprising a combination of the first material and the second material,
wherein the sintered, electrically-conductive pellet has:
an average cross-sectional length from about 200 μm to about 4000 μm,
a bulk density from about 0.3 g/cm 3 to about 2.0 g/cm 3 , and
an electrical conductivity from about 100 S/m to about 3000 S/m;
wherein the core and shell layer are sintered to provide the sintered, electrically-conductive pellet.
8. The sintered, electrically-conductive pellet of claim 7 , wherein the shell layer comprises petroleum coke, metal, graphite or a combination thereof.
9. The sintered, electrically-conductive pellet of claim 8 , wherein the intermediate layer is positioned at least partially between the core and the shell layer.
10. The sintered, electrically-conductive pellet of claim 7 , wherein: the core makes up from about 30% to about 80% of the sintered, electrically-conductive pellet,
the intermediate layer makes up from about 10% to about 40% of the sintered, electrically-conductive pellet,
and the shell layer makes up from about 10% to about 60% of the sintered, electrically-conductive pellet.
11. The sintered, electrically-conductive pellet of claim 10 , further comprising a non-radioactive tracer in the core, the shell layer, or both.
12. The sintered, electrically-conductive pellet of claim 10 , further comprising an electrical conductivity of from about 100 S/m to about 4000 S/m.
13. The sintered, electrically-conductive pellet of claim 10 , further comprising an electrical conductivity of from about 500 S/m to about 2000 S/m.