The influence of multi component powder characteristics on mechanical properties of ceramic proppants

The critical phase in production of specific ceramic materials for hydraulic fracturing in oil/gas production – proppants – is considered to be the formation of high green density spheres of defined diameter (0.4–1.25 mm) from the complex raw material mixture. The degree of sphericity and roundness, as well as the mechanical strength of proppants dependent on the physico–chemical characteristics of the starting powder (multi–component system) and on the procedure and parameters of sphere formation. Two systems, based on alumina and bauxite, both in combination with clay and feldspar, have been investigated as candidate mixtures for intermediate strength/intermediate density proppant (ISP) production. It has been shown that in obtaining the optimal properties of final system–proppant, good packing in green state is less important than the interaction of plastic and non–plastic components during sintering in the closed system. The physico–chemical properties of the liquid phase seem to play a dominant role in obtaining the desired microstructure and resulting mechanical properties.