Effect of thermochemical activation of clay raw materials on phase formation, microstructure and properties of aluminosilicate proppants

Phase formation, structure and properties of light-weight aluminosilicate proppants based on clay-diabase and clay-granite binary mixes

Thermal behavior of samarium oxide – Ball clay mixtures for high macroscopic neutron capture cross section ceramic materials

Important aspects of increasing the competitiveness of domestic metallurgy and mechanical engineering are increasing the durability of thermal units and involving non-traditional, cheaper energy resources in production. One of these resources is carbon waste from the aluminum industry - electrode scrap and waste from the carbon lining of electrolyzers. The problem of their use as substitutes for solid fuels (coke coal) in the metallurgical, engineering and energy industries is fluorine- and alkali-containing salts that impregnate them, destroying the traditional lining of thermal units. The development of effective refractories resistant to fluorine- and alkali-containing corrodants (melts and gases) makes it possible to increase the competitiveness and efficiency of thermal units both through the use of cheaper energy carriers and by increasing the duration of their campaign. An important aspect is the simultaneous disposal of hazardous industrial waste and the reduction of the environmental burden on the ecosphere of the Republic of Kazakhstan. The basis for the development of new refractory materials resistant to fluorine- and alkali-containing corrodants is the analysis of the existing raw material base of the Republic of Kazakhstan and the choice of materials that make it possible to obtain aluminosilicate refractories with increased chemical resistance. In the work, the phase and chemical composition of refractory clays and kaolins of the Republic of Kazakhstan were studied, their rheological and thermophysical properties were investigated. Selected raw materials for the development of technology for the production of dense aluminosilicate refractory products.

Study of refractory raw materials of the Republic of Kazakhstan

Ceramic proppants are preferred in hydraulic fracturing because of their high strength, good sphericity, and excellent acid corrosion resistance. Bauxite is the main raw material of ceramic proppants, but with the increasing depletion of bauxite resources, substitutes for bauxite need to be sought. Coal gangue is a solid waste that is rich in SiO2 and Al2O3, making it a potential substitute for the preparation of ceramic proppants. The use of coal gangue to prepare ceramic proppants can reduce the cost of ceramic proppants and benefit environmental protection. Studies on using coal gangue to prepare ceramic proppants have been conducted and achieved progress, but further improvement can still be obtained. Here, the basic principle, progress, and prospects of coal gangue ceramic proppants are reviewed. First, coal gangue ceramic proppants are divided into two categories, namely, proppants prepared using coal gangue as an auxiliary material and proppants prepared using coal gangue as the main material. Second, the progress of research of coal gangue ceramic proppants is summarized from the perspective of additives, and the influence of different kinds of additives on the sintering temperature and performance of proppants is discussed. Lastly, the future prospects of coal gangue ceramic proppants are presented. 

Basic principle, progress, and prospects of coal gangue ceramic proppants

The sintering-strengthening effect of the additions of the highly ferrous bauxite (with Fe2O3 content of 20-25 % in the calcined state) in the compositions with refractory clays was established. It was found that in the temperature range 1350-1500°C the additions of bauxite in amounts of 10-40% have a fluxing effect due to the iron oxide introduced with bauxite in compositions with clay. An increasing the bauxite additive in the amount of 50-70% ensures its strengthening effect by increasing the total content of the mullite of the prismatic habit in the firing products of composites with clay. Preliminary clay and bauxite calcination at 900 °C and an increase in the content of bauxite additive up to 50-70% in compositions with clay allow to produce aluminosilicate proppants with a bulk density of 1.62-1.65 g/cm3 and compressive strength up to 52 MPa.

https://iopscience.iop.org/article/10.1088/1757-899X/286/1/012012/pdf

Alumosilicate ceramic proppants based on natural refractory raw materials

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Alumosilicate ceramic proppants based on natural refractory raw materials