LOW BULK DENSITY PROPPANT AND METHODS FOR PRODUCING THE SAME
First Claim
Patent Images
1. A method for forming a low bulk density proppant comprising:
- forming substantially round and spherical green pellets from raw materials comprising water;
calcined, partially calcined, or uncalcined kaolin clay; and
at least one material selected from the group consisting of calcined diatomaceous earth and burned kaolin clay; and
sintering the pellets to form a proppant having a bulk density of less than about 1.60 g/cc;
wherein the proppant has a short term permeability greater than that of a proppant having a bulk density of less than about 1.60 g/cc made from pellets consisting of water and calcined, partially calcined or uncalcined kaolin clay.
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Abstract
Materials and Methods for making low bulk density proppant capable of providing permeability at subterranean pressures. The low bulk density proppant is made from kaolin clay and at least one of calcined diatomaceous earth and burned kaolin clay.
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Citations
21 Claims
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1. A method for forming a low bulk density proppant comprising:
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forming substantially round and spherical green pellets from raw materials comprising water;
calcined, partially calcined, or uncalcined kaolin clay; and
at least one material selected from the group consisting of calcined diatomaceous earth and burned kaolin clay; and
sintering the pellets to form a proppant having a bulk density of less than about 1.60 g/cc;
wherein the proppant has a short term permeability greater than that of a proppant having a bulk density of less than about 1.60 g/cc made from pellets consisting of water and calcined, partially calcined or uncalcined kaolin clay. - View Dependent Claims (2, 3, 4)
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5. A method for producing a low bulk density proppant comprising:
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heating kaolin clay sufficient to produce a burned kaolin clay comprising at least 5 weight percent of mullite;
co-milling calcined, partially calcined, or uncalcined kaolin clay and the burned kaolin clay to form a co-milled mixture;
forming substantially round and spherical green pellets from the co-milled mixture and water; and
sintering the pellets to form a proppant having a bulk density of less than about 1.60 g/cc;
wherein the proppant has a short term permeability greater than that of proppant having a bulk density of less than about 1.60 g/cc made from pellets consisting of water and calcined, partially calcined or uncalcined kaolin clay. - View Dependent Claims (6, 7)
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8. A method for producing a low bulk density proppant comprising:
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co-milling calcined, partially calcined, or uncalcined kaolin clay and calcined diatomaceous earth to form a co-milled mixture;
forming substantially round and spherical green pellets from the co-milled mixture and water; and
sintering the pellets to form a proppant having a bulk density of less than about 1.60 g/cc;
wherein the proppant has a short term permeability greater than that of a proppant having a bulk density of less than about 1.60 g/cc made from pellets consisting of water and calcined, partially calcined or uncalcined kaolin.
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9. A method for propping fractures in subterranean formations comprising:
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mixing a fluid and a proppant comprising a plurality of sintered substantially round and spherical particles made from calcined, partially calcined, or uncalcined kaolin clay and at least one material selected from the group consisting of calcined diatomaceous earth and burned kaolin clay, and having a bulk density of less than about 1.60 g/cc and a 4 Kpsi short term permeability greater than 187 Darcies; and
introducing the mixture into a fracture in a subterranean formation. - View Dependent Claims (10)
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11. A proppant comprising:
calcined, partially calcined, or uncalcined kaolin clay and at least one material selected from the group consisting of calcined diatomaceous earth and burned kaolin clay, wherein the proppant comprises a sintered substantially round and spherical particle having a bulk density of less than about 1.60 g/cc and a 4 Kpsi short term permeability greater than 187 Darcies. - View Dependent Claims (12)
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13. A plurality of pellets made from a mixture comprising:
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calcined, partially calcined, or uncalcined kaolin clay and at least one material selected from the group consisting of calcined diatomaceous earth and burned kaolin clay, wherein a proppant produced from the pellets has a bulk density of less than about 1.60 g/cc. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21)
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Specification