Microwave-sintered mullite structural ceramics based on low-grade bauxite applied for fracturing proppants

IF 3.5 3区 工程技术 Q3 ENERGY & FUELS Energy Science & Engineering Pub Date : 2024-07-23 DOI:10.1002/ese3.1783
Xiaogang Li, Junya Xiong, Zhaozhong Yang, Jinyi Zhu, Weizhe Li
{"title":"Microwave-sintered mullite structural ceramics based on low-grade bauxite applied for fracturing proppants","authors":"Xiaogang Li,&nbsp;Junya Xiong,&nbsp;Zhaozhong Yang,&nbsp;Jinyi Zhu,&nbsp;Weizhe Li","doi":"10.1002/ese3.1783","DOIUrl":null,"url":null,"abstract":"<p>This study aimed to assess the feasibility of manufacturing fracturing proppants by microwave sintering and using low-grade bauxite as raw material. The effects of microwave hotspot SiC and sintering additive MnO<sub>2</sub> content on the performance of the mullite-based structural materials were studied, respectively. The optimum sintering condition was determined by single-factor experiments. The sintering process and mechanism were explored based on the analysis of physicochemical properties, phase transitions, and microstructure. The results showed that (1) mullite ceramic composites could be successfully prepared only with SiC added and with poor interparticle bonding microstructure. (2) With the addition of MnO<sub>2</sub> and CaO, the granular-shaped mullite crystals transformed into rod-like mullite crystals, forming a net structure. (3) As the input power increased, the overfast sintering rate would reduce proppants' mechanical properties, and it was also necessary to select a reasonable sintering time to avoid overburning. (4) When the mass ratio of MnO<sub>2</sub>:CaO:SiC:bauxite was 2:1.5:12:84.5 and under the sintering condition of 1000 W, 2 h, the performance (breakage ratio of 8.5% under 28 MPa closed pressure, apparent density of 2.58 g/cm<sup>3</sup>, turbidity of 52 FTU, and acid solubility of 6.77%) could meet the requirements of the Chinese Petroleum and Gas Industry Standard (SY/T 5108–2014). This study provides a powerful way for reducing the fracturing cost, which not only improves the low-grade bauxite utilization scale within the ceramic industry, but also expands the application of microwave sintering technology in mullite structural materials for the petroleum and gas industry.</p>","PeriodicalId":11673,"journal":{"name":"Energy Science & Engineering","volume":null,"pages":null},"PeriodicalIF":3.5000,"publicationDate":"2024-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1002/ese3.1783","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Energy Science & Engineering","FirstCategoryId":"5","ListUrlMain":"https://onlinelibrary.wiley.com/doi/10.1002/ese3.1783","RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q3","JCRName":"ENERGY & FUELS","Score":null,"Total":0}
引用次数: 0

Abstract

This study aimed to assess the feasibility of manufacturing fracturing proppants by microwave sintering and using low-grade bauxite as raw material. The effects of microwave hotspot SiC and sintering additive MnO2 content on the performance of the mullite-based structural materials were studied, respectively. The optimum sintering condition was determined by single-factor experiments. The sintering process and mechanism were explored based on the analysis of physicochemical properties, phase transitions, and microstructure. The results showed that (1) mullite ceramic composites could be successfully prepared only with SiC added and with poor interparticle bonding microstructure. (2) With the addition of MnO2 and CaO, the granular-shaped mullite crystals transformed into rod-like mullite crystals, forming a net structure. (3) As the input power increased, the overfast sintering rate would reduce proppants' mechanical properties, and it was also necessary to select a reasonable sintering time to avoid overburning. (4) When the mass ratio of MnO2:CaO:SiC:bauxite was 2:1.5:12:84.5 and under the sintering condition of 1000 W, 2 h, the performance (breakage ratio of 8.5% under 28 MPa closed pressure, apparent density of 2.58 g/cm3, turbidity of 52 FTU, and acid solubility of 6.77%) could meet the requirements of the Chinese Petroleum and Gas Industry Standard (SY/T 5108–2014). This study provides a powerful way for reducing the fracturing cost, which not only improves the low-grade bauxite utilization scale within the ceramic industry, but also expands the application of microwave sintering technology in mullite structural materials for the petroleum and gas industry.

Abstract Image

查看原文
分享 分享
微信好友 朋友圈 QQ好友 复制链接
本刊更多论文
应用于压裂支撑剂的基于低品位铝土矿的微波烧结莫来石结构陶瓷
本研究旨在评估利用微波烧结和低品位铝土矿作为原料制造压裂支撑剂的可行性。分别研究了微波热点SiC和烧结添加剂MnO2含量对莫来石基结构材料性能的影响。通过单因素实验确定了最佳烧结条件。在分析物理化学性质、相变和微观结构的基础上,探讨了烧结过程和机理。结果表明:(1) 只有添加 SiC 才能成功制备莫来石陶瓷复合材料,且颗粒间结合微观结构较差。(2) 随着 MnO2 和 CaO 的加入,粒状莫来石晶体转变为棒状莫来石晶体,形成网状结构。(3) 随着输入功率的增加,过快的烧结速率会降低支撑剂的机械性能,同时还需要选择合理的烧结时间以避免过烧。(4)当 MnO2:CaO:SiC:bauxite 的质量比为 2:1.5:12:84.5 时,在 1000 W、2 h 的烧结条件下,其性能(28 MPa 闭压下的破碎率为 8.5%,表观密度为 2.58 g/cm3,浊度为 52 FTU,酸溶解度为 6.77%)可满足中国石油天然气行业标准(SY/T 5108-2014)的要求。该研究为降低压裂成本提供了有力途径,不仅提高了陶瓷行业低品位铝土矿的利用规模,还拓展了微波烧结技术在石油天然气行业莫来石结构材料中的应用。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
求助全文
约1分钟内获得全文 去求助
来源期刊
Energy Science & Engineering
Energy Science & Engineering Engineering-Safety, Risk, Reliability and Quality
CiteScore
6.80
自引率
7.90%
发文量
298
审稿时长
11 weeks
期刊介绍: Energy Science & Engineering is a peer reviewed, open access journal dedicated to fundamental and applied research on energy and supply and use. Published as a co-operative venture of Wiley and SCI (Society of Chemical Industry), the journal offers authors a fast route to publication and the ability to share their research with the widest possible audience of scientists, professionals and other interested people across the globe. Securing an affordable and low carbon energy supply is a critical challenge of the 21st century and the solutions will require collaboration between scientists and engineers worldwide. This new journal aims to facilitate collaboration and spark innovation in energy research and development. Due to the importance of this topic to society and economic development the journal will give priority to quality research papers that are accessible to a broad readership and discuss sustainable, state-of-the art approaches to shaping the future of energy. This multidisciplinary journal will appeal to all researchers and professionals working in any area of energy in academia, industry or government, including scientists, engineers, consultants, policy-makers, government officials, economists and corporate organisations.
期刊最新文献
Issue Information Similar simulation test of the mechanical properties of layered composite rock mass A novel approach to classify lithology of reservoir formations using GrowNet and Deep-Insight with physic-based feature augmentation Combined genetic algorithm and response surface methodology-based bi-optimization of a vertical-axis wind turbine numerically simulated using CFD Experimental study on the utilization of Fly ash solid waste in tunnel shotcrete materials
×
引用
GB/T 7714-2015
复制
MLA
复制
APA
复制
导出至
BibTeX EndNote RefMan NoteFirst NoteExpress
×
×
提示
您的信息不完整,为了账户安全,请先补充。
现在去补充
×
提示
您因"违规操作"
具体请查看互助需知
我知道了
×
提示
现在去查看 取消
×
提示
确定
0
微信
客服QQ
Book学术公众号 扫码关注我们
反馈
×
意见反馈
请填写您的意见或建议
请填写您的手机或邮箱
已复制链接
已复制链接
快去分享给好友吧!
我知道了
×
扫码分享
扫码分享
Book学术官方微信
Book学术文献互助
Book学术文献互助群
群 号:481959085
Book学术
文献互助 智能选刊 最新文献 互助须知 联系我们:info@booksci.cn
Book学术提供免费学术资源搜索服务,方便国内外学者检索中英文文献。致力于提供最便捷和优质的服务体验。
Copyright © 2023 Book学术 All rights reserved.
ghs 京公网安备 11010802042870号 京ICP备2023020795号-1