Ceramic proppant (petroleum fracturing proppant) is a key material for oil and gas extraction, used to support the cracks formed after fracturing and improve the oil and gas diversion capacity. The production process is mainly divided into wet process and dry process.
Raw material pretreatment
Crushing: Raw materials such as bauxite and copper tailings are crushed to ≤ 3mm by jaw crushers and cone crushers.
Grinding: The ball mill or air flow crusher grinds the raw materials to below 3 μ m (wet process requires adding water to make slurry).
Granulation
Wet granulation (applicable to kaolin): spray drying tower (such as counter flow pressure spray drying tower) granulation to form 100-35 mesh solid spherical particles.
Dry granulation (suitable for bauxite): disc granulator or high-speed shear granulator, with the addition of adhesive (such as polyvinyl alcohol) to form.
calcination
Rotary kiln (1300-1450 ℃): to sinter and densify particles, and improve strength.
Two step sintering method (optimized process): first heat up to 1250-1350 ℃, then cool down to 1100-1200 ℃ to reduce energy consumption and improve yield.
Finished product processing
Cooling: The grate cooler or tube cooler cools down to ≤ 100 ℃.
Screening: vibrating screen classification (such as 40/70 mesh, 70/140 mesh).
Packaging: valve pockets or bulk transportation.
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