High strength proppants

A sintered ceramic particle made from a ceramic material having a true density greater than 3.5 g/cc and a composition having no more than 30 weight percent silicon oxide and at least 15 weight percent iron oxide, based on the combined weight of the oxides of aluminum, iron and silicon, is disclosed. A proces that utilizes an externally applied compressive force to make a ceramic particle is also disclosed.

Ceramic particles and process for making the same

A proppant for use in fracturing geological formations is made from bauxitic ores and a calcium containing compound. The proppant has a calcium containing crystalline phase.

Ceramic particle and process for making the same

A ceramic particle with at least two microstructural phases is disclosed. The two microstructural phases comprises an amorphous phase representing 30 volume percent and 70 volume percent of the particle, and a first substantially crystalline phase comprising a plurality of predominately crystalline regions distributed through the amorphous phase. A process for making the ceramic particle is also disclosed.

CERAMIC PARTICLES AND METHODS FOR MAKING THE SAME

Disclosed is a population of ceramic particles that includes a plurality of individual, free flowing particles. The plurality has a total weight and particle size distribution. The effective width of the distribution is the difference between the distribution's dand dparticle sizes. The distribution's effective width exceeds 100 microns and includes three abutting and non-overlapping regions that include a first region, a second region, and a third region. The first region abuts the second region and the second region abuts the third region. The width of the second region is at least 25% of the effective width. The weight of particles in the second region does not exceed 15% of the plurality of particle's total weight. The weight of particles in the first region and the third region each exceed the weight of particles in the second region. Methods of making the populations of ceramic particles are also disclosed. 1. A population of ceramic particles , comprising:{'sub': 95', '5, 'a. a plurality of individual, free flowing ceramic particles, said plurality of particles having a total weight and particle size distribution including dand dparticle sizes;'}{'sub': 95', '5, "b. said distribution has an effective width which is the difference between the distribution's dand dparticle sizes, said distribution's effective width exceeds 100 microns and comprises three abutting and non-overlapping regions including a first region, a second region, and a third region wherein the first region abuts the second region and the second region abuts the third region; and wherein the width of said second region is at least 25% of the effective width; and"}c. wherein the weight of particles in said second region does not exceed 15% of the plurality of particle's total weight and the weight of particles in said first region and said third region each exceed the weight of particles in said second region.2. The population of wherein the ratio of d:dexceeds 0.22.3. The population of ...

CERAMIC PARTICLE AND PROCESS FOR MAKING THE SAME

A ceramic particle with at least two microstructural phases comprising an amorphous phase, representing between 30 volume percent and 70 volume percent of the particle, and a first substantially crystalline phase comprising a plurality of predominately crystalline regions distributed through the amorphous phase is disclosed. A process for making the ceramic particle is also disclosed. 1. A sintered ceramic particle , comprising: at least two microstructural phases comprising an amorphous phase , representing between 30 volume percent and 70 volume percent of said particle , and a first substantially crystalline phase comprising a plurality of predominately crystalline regions distributed through said amorphous phase.2. The sintered ceramic particle of wherein said amorphous phase forms a continuous matrix through said particle and said crystalline regions collectively form a discontinuous phase.3. The sintered ceramic particle of wherein said amorphous phase has a coefficient of thermal expansion claim 2 , said first substantially crystalline phase has a coefficient of thermal expansion and said first substantially crystalline phase's coefficient of thermal expansion is no less than said amorphous phase's coefficient of thermal expansion.4. The sintered ceramic particle of wherein said first substantially crystalline phase's coefficient of thermal expansion is at least 5% greater than said amorphous phase's coefficient of thermal expansion.5. The sintered ceramic particle of wherein said first substantially crystalline phase's coefficient of thermal expansion is at least 10% greater than said amorphous phase's coefficient of thermal expansion.6. The sintered ceramic particle of wherein said amorphous phase abuts at least one of said predominately crystalline regions at an interface and said interface exhibits stress.7. The sintered ceramic particle of wherein said particle exhibits compressive stress at said interface.8. The sintered ceramic particle of claim I ...

CERAMIC PARTICLES AND PROCESS FOR MAKING THE SAME

A proppant for use in fracturing geological formations is made from bauxitic ores and a calcium containing compound. The proppant has a calcium containing crystalline phase. 1. A proppant for use in fracturing geological formations , said proppant comprising:{'sub': 2', '3', '2, 'a. between 25 and 75 weight percent AlO, between 0 and 70 weight percent SiO, at least 3 weight percent CaO, wherein all percentages are determined by x-ray fluorescence; and'}b. at least 5 weight percent of a calcium containing crystalline phase as determined by x-ray diffraction with an internal standard.2. The proppant of having a specific gravity less than 15 g/cc.3. The proppant of wherein said calcium containing crystalline phase is anorthite.4. The proppant of wherein said proppant comprises less than 70 weight percent AlO.5. The proppant of wherein said proppant comprises less than 65 weight percent AlO.6. The proppant of wherein said proppant comprises less than 60 weight percent AlO.7. The proppant of wherein said proppant comprises less than 55 weight percent AlO.8. The proppant of wherein said proppant comprises less than 50 weight percent AlO.9. The proppant of wherein said proppant comprises between 0 and 40 weight percent FeO.10. The proppant of wherein said proppant comprises between 0 and 30 weight percent FeO.11. The proppant of wherein said proppant comprises between 0 and 20 weight percent FeO.12. The proppant of wherein said proppant comprises between 0 and 15 weight percent FeO.13. The proppant of wherein said proppant comprises at least 10 weight percent of said calcium containing crystalline phase.14. The proppant of wherein said proppant comprises at least 20 weight percent of said calcium containing crystalline phase.15. The proppant of wherein said proppant comprises at least 10 weight percent anorthite.16. The proppant of wherein said proppant comprises at least 20 weight percent anorthite.17. The proppant of wherein said proppant comprises at least 40 weight ...

PROCESS FOR MAKING A CERAMIC ARTICLE

Disclosed is a process for producing ceramic particles, such as proppants, that have at least 10 percent total porosity. The process includes forming a particle precursor that includes 5 percent to 30 percent of a first ceramic material and at least 40 percent of a second ceramic material. The sintering temperature of the first ceramic material may be lower than the sintering temperature of a second ceramic material. Heating the precursor to a maximum temperature above the sintering temperature of the first material and below the sintering temperature of the second material. Also disclosed is a ceramic article that has a particular combination of chemistry and alumina crystalline phase. 1. A process , for producing a ceramic particle , comprising the steps of: forming a particle precursor comprising more than 5 weight percent but less than 30 weight percent of a first ceramic material and at least 40 weight percent of a second ceramic material , said ceramic materials substantially uniformly distributed within said precursor; heating said precursor to a maximum temperature above the sintering temperature of said first ceramic material and below the sintering temperature of said second ceramic material , wherein said ceramic particle has at least 10 percent total porosity.2. The process of wherein said first ceramic material has a melting temperature lower than the sintering temperature of said second ceramic material and said heating step comprises heating said precursor above the melting temperature of the first ceramic material and below the sintering temperature of the second ceramic material.3. The process of wherein said second ceramic material's sintering temperature exceeds said first ceramic material's melting temperature by at least 50° C.4. The process of wherein said maximum temperature is at least 25° C. less than the sintering temperature of said second ceramic material.5. The process of wherein said particle precursor comprises between 10 and 20 weight ...

Ceramic particles and methods for making the same

Disclosed is a population of ceramic particles that includes a plurality of individual, free flowing particles. The plurality has a total weight and particle size distribution. The effective width of the distribution is the difference between the distribution's d 95 and d 5 particle sizes. The distribution's effective width exceeds 100 microns and includes three abutting and non-overlapping regions that include a first region, a second region, and a third region. The first region abuts the second region and the second region abuts the third region. The width of the second region is at least 25% of the effective width. The weight of particles in the second region does not exceed 15% of the plurality of particle's total weight. The weight of particles in the first region and the third region each exceed the weight of particles in the second region. Methods of making the populations of ceramic particles are also disclosed.

Ceramic particle comprising an alumina crystalline phase

Disclosed is a process for producing ceramic particles, such as proppants, that have at least 10 percent total porosity. The process includes forming a particle precursor that includes 5 percent to 30 percent of a first ceramic material and at least 40 percent of a second ceramic material. The sintering temperature of the first ceramic material may be lower than the sintering temperature of a second ceramic material. Heating the precursor to a maximum temperature above the sintering temperature of the first material and below the sintering temperature of the second material. Also disclosed is a ceramic article that has a particular combination of chemistry and alumina crystalline phase.

Ceramic article and process for making the same

Disclosed is a process for producing ceramic particles, such as proppants, that have at least 10 percent total porosity. The process includes forming a particle precursor that includes 5 percent to 30 percent of a first ceramic material and at least 40 percent of a second ceramic material. The sintering temperature of the first ceramic material may be lower than the sintering temperature of a second ceramic material. Heating the precursor to a maximum temperature above the sintering temperature of the first material and below the sintering temperature of the second material. Also disclosed is a ceramic article that has a particular combination of chemistry and alumina crystalline phase.

Ceramic particles and process for making the same

A proppant for use in fracturing geological formations is made from bauxitic ores and a calcium containing compound. The proppant has a calcium containing crystalline phase.

High strength proppants.

Se revela una partícula de cerámica sinterizada obtenida a partir de material cerámico que tiene una densidad verdadera mayor a 3,5 g/cc y una composición que tiene no más de 30 por ciento en peso de óxido de silicio y al menos 15 por ciento en peso de óxido de hierro, en base al peso combinado de los óxidos de aluminio, hierro y silicio. También se revela un proceso que utiliza una fuerza de compresión aplicada externamente para obtener partículas de cerámica.

Ceramic particle and process for making the same

A ceramic particle with at least two microstructural phases comprising an amorphous phase, representing between 30 volume percent and 70 volume percent of the particle, and a first substantially crystalline phase comprising a 5 plurality of predominately crystalline regions distributed through the amorphous phase is disclosed. A process for making the ceramic particle is also disclosed. FJA. - ,0507 1

Ceramic particles and methods for making the same.

Se divulga una población de partículas cerámicas que incluye diversas partículas individuales que fluyen libremente. La diversidad tiene una distribución del peso total y del tamaño de las partículas. El ancho efectivo de la distribución es la diferencia entre los tamaños de partículas d95 y d5 de la distribución. El ancho efectivo de la distribución excede los 100 micrones e incluye tres regiones contiguas y no superpues.tas que incluyen una primera región, una segunda región y una tercera región. La primera región colinda con la segunda región y la segunda región colinda con la tercera región. El ancho de la segunda región es al menos un 25% del ancho efectivo. El peso de las partículas en la segunda región no excede el 15% del peso total de las diversas partículas. El peso de las partículas en la primera región y en la tercera región excede cada una el peso de las partículas en la segunda región. También se divulgan métodos para fabricar las poblaciones de partículas cerámicas.

Ceramic article and process for making the same

High strength proppants

A sintered ceramic particle made from a ceramic material having a true density greater than 3.5 g/cc and a composition having no more than 30 weight percent silicon oxide and at least 15 weight percent iron oxide, based on the combined weight of the oxides of aluminum, iron and silicon, is disclosed. A process that utilizes an externally applied compressive force to make a ceramic particle is also disclosed

Ceramic particle and process for making the same.

Se describe una partícula cerámica con al menos dos fases microestructurales que comprenden una fase amorfa, que representa entre 30 por ciento en volumen y 70 por ciento en volumen de la partícula, y una primera fase sustancialmente cristalina que comprende una pluralidad de regiones predominantemente cristalinas distribuidas en la fase amorfa. Se describe también un proceso para la fabricación de la partícula cerámica.

Ceramic particles and process for making the same

A proppant for use in fracturing geological formations is made from bauxitic ores and a calcium containing compound. The proppant has a calcium containing crystalline phase.

Brazing technique

Methods for using high strngth ceramic elements

One embodiment of the present invention relates to spherical ceramic elements, such as proppants, for maintaining permeability in subterranean formations to facilitate extraction of oil and gas therefrom. The strength of the ceramic element may be enhanced by combining materials having different coefficients of thermal expansion. Methods of making the ceramic elements are also disclosed.