Preparation and characterization of quartz ceramic proppant replacing natural quartz sand by solid waste silica fume

Abstract

The improper disposal of industrial wastes will cause environmental pollution and economic losses due to the loss of active ingredients. Solid waste silica fume and pyrolusite powder were used to synthesize quartz ceramic proppant by pelleting and sintering to replace natural quartz sand for unconventional oil and gas exploitation. The effects of pyrolusite powder content and sintering temperature on the apparent density, breakage ratio, and acid solubility of the proppant were thoroughly studied. The phase composition and microstructure of the proppant were characterized by X-ray diffraction and scanning electron microscopy, respectively. The results revealed that the main crystal phase of the proppant prepared without pyrolusite was cristobalite, while that with pyrolusite was cristobalite and quartz, and the content of quartz phase increased gradually with increasing the pyrolusite content. The addition of pyrolusite remarkably increased the density and improved the performance of the proppant due to the resulting glass phase at high temperatures and the presence of andradite. As adding 20% pyrolusite, the apparent density of the proppant sintered at 900°C was 2.26 g/cm³, while the breakage ratio under 28 MPa closed pressure and acid solubility reached the minimum, 9.89% and 5.3%, respectively, meeting the industrial standard requirements.