Proppants and anti-flowback additives including kaolin clay
A method of making a sintered ceramic proppant may include providing a kaolin clay. The kaolin clay may include an Al 2 O 3 content no greater than about 46% by weight, and a K 2 O content no greater than 0.1% by weight. The kaolin clay may have a particle size distribution such that greater than 70% of the particles have an equivalent spherical diameter of less than 0.5 microns as measured by Sedigraph, and a shape factor less than about 18. The method may further include blunging the kaolin clay, agglomerating the kaolin clay, and sintering the agglomerated kaolin clay to produce a sintered ceramic proppant. The kaolin clay may have an A-bob Hercules viscosity of at least about 3,300 rpm at 18 kilodyne-cm and 70% solids.
1. A method of making a sintered ceramic proppant, the method comprising: providing a kaolin clay comprising an Al 2 O 3 content of not greater than about 46% by weight, and a K 2 O content no greater than 0.1% by weight, and having a particle size distribution of particles of the kaolin clay such that greater than 70% of the particles have an equivalent spherical diameter of less than 0.5 microns as measured by Sedigraph, and a shape factor less than about 18;
blunging the kaolin clay;
agglomerating the kaolin clay; and
sintering the agglomerated kaolin clay to produce a sintered ceramic proppant,
wherein the kaolin clay comprises a blend of a first kaolin clay comprising less than about 0.1% by weight K 2 O and a second kaolin clay comprising greater than about 0.1% by weight K 2 O, and
wherein the blend comprises at least about 10% by weight of the first kaolin clay.
2. 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.
3. The method of claim 2 , wherein the kaolin clay has an Al 2 O 3 content ranging from about 43% by weight to about 45% by weight.
4. The method of claim 1 , wherein the blend comprises at least about 25% by weight of the first kaolin clay.
5. The method of claim 1 , wherein the particle size distribution of the kaolin clay is such that greater than 93% of the particles have an equivalent spherical diameter of less than 2 microns as measured by Sedigraph.
6. 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 1 micron as measured by Sedigraph.
7. The method of claim 1 , wherein the particle size distribution of the kaolin clay is such that greater than 40% of the particles have an equivalent spherical diameter of less than 0.25 microns as measured by Sedigraph.
8. 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.
9. The method of claim 1 , wherein the kaolin clay comprises a K 2 O content ranging from about 0.01% by weight to about 0.06% by weight.
10. The method of claim 1 , wherein the shape factor is less than about 15.
11. The method of claim 1 , wherein the shape factor ranges from about 2 to about 15.
12. The method of claim 1 , wherein the shape factor ranges from about 5 to about 8.
13. The method of claim 1 , wherein the kaolin clay particles have a BET surface area of greater than about 15 m.sup.2/g.
14. The method of claim 1 , wherein the kaolin clay particles have a BET surface area of greater than about 35 m.sup.2/g.
15. The method of claim 1 , wherein the kaolin clay particles have a BET surface area ranging from about 15 m.sup.2/g to about 35 m.sup.2/g.
16. The method of claim 1 , wherein the sintered ceramic proppant has a specific gravity greater than about 2.65.
17. The method of claim 1 , wherein the sintered ceramic proppant has a bulk density greater than about 1.44 g/cm.sup.3.
18. The method of claim 1 , wherein the sintered ceramic proppant has a bulk density ranging from about 1.45 g/cm.sup.3 to about 1.50 g/cm.sup.3.
19. The method of claim 1 , wherein the crush strength measured under ISO 13503-2 of the sintered ceramic proppant at 10,000 psi is less than about 6% fines by weight.
20. The method of claim 1 , wherein the kaolin clay has an A-bob Hercules viscosity of at least about 3,300 rpm at 18 kilodyne-cm and 70% solids.
21. A method of making a sintered ceramic proppant, the method comprising:
providing a kaolin clay comprising an Al 2 O 3 content not greater than about 46% by weight, and a K 2 O content no greater than 0.1% by weight, and having a particle size distribution of particles of the kaolin clay such that greater than 70% of the particles have an equivalent spherical diameter of less than 0.5 microns as measured by Sedigraph, and an A-bob Hercules viscosity of at least about 3,300 rpm at 18 kilodyne-cm and 70% solids;
blunging the kaolin clay;
agglomerating the kaolin clay; and
sintering the agglomerated kaolin clay to produce a sintered ceramic proppant,
wherein the kaolin clay comprises a blend of a first kaolin clay comprising less than about 0.1% by weight K 2 O and a second kaolin clay comprising greater than about 0.1% by weight K 7 O, and
wherein the blend comprises at least about 10% by weight of the first kaolin clay.