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CN101880524A - 一种超轻密度陶粒支撑剂及其制备方法 - Google Patents

一种超轻密度陶粒支撑剂及其制备方法 Download PDF

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CN101880524A
CN101880524A CN2010101573464A CN201010157346A CN101880524A CN 101880524 A CN101880524 A CN 101880524A CN 2010101573464 A CN2010101573464 A CN 2010101573464A CN 201010157346 A CN201010157346 A CN 201010157346A CN 101880524 A CN101880524 A CN 101880524A
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extremely
low density
propping agent
preparation
ceramsite propping
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吴文忠
林生明
黄致捷
罗红雨
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AMERICAN ROYBO Co Ltd
JUNJIE PORCELAIN CO Ltd NINGDE
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AMERICAN ROYBO Co Ltd
JUNJIE PORCELAIN CO Ltd NINGDE
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Priority to CN2010101573464A priority Critical patent/CN101880524A/zh
Priority to MX2012000801A priority patent/MX2012000801A/es
Priority to CA2751907A priority patent/CA2751907C/en
Priority to RU2011153515/03A priority patent/RU2540695C2/ru
Priority to RU2014148285/03A priority patent/RU2014148285A/ru
Priority to BR112012000296A priority patent/BR112012000296A2/pt
Priority to PCT/US2010/042980 priority patent/WO2011014410A1/en
Priority to US13/386,143 priority patent/US8727003B2/en
Priority to EP10804904.0A priority patent/EP2459846A4/en
Priority to AU2010276638A priority patent/AU2010276638B2/en
Publication of CN101880524A publication Critical patent/CN101880524A/zh
Priority to US14/247,578 priority patent/US9399727B2/en
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Abstract

本发明公开一种超轻密度陶粒支撑剂及其制备方法，其特征是以瓷土、高岭土或焦宝石等为主要原料，以粘土为粘结剂，配以熔剂性辅料和强度添加剂加工生产的；其制备方法主要包括：粉料的湿法制备、半成品成球工艺、烧成工艺三个部分，本发明采取的技术方案与现有技术相比具有原料来源广泛，生产工艺简单、生产成本低等特点，采用本发明生产的陶粒支撑剂的体积密度小于1.50g/cm3，适用于新、老油气井水力中浅井压裂施工，能有效降低水力压裂施工过程中陶粒支撑剂对动力泵和管线磨损，减少支撑剂用量，降低压裂施工成本等。

Description

一种超轻密度陶粒支撑剂及其制备方法
【技术领域】
本发明涉及一种油、气井压裂工艺用的陶粒支撑剂及其制备方法，特别是涉及一种超轻密度陶粒支撑剂及其制备方法。
【背景技术】
陶粒支撑剂是石油、天然气低渗透油气井开采压裂施工的关键材料。产品应用于油气井压裂施工时，将其填充到低渗透矿床的岩层裂隙中，进行高闭合压裂处理，使含油气岩层裂开，起到支撑裂隙不因应力释放而闭合，从而保持油气的高导流能力，不但能增加油气产量，而且能延长油气井服务年限。
根据中国石油天然气行业标准备SY/T5108-2006《压裂支撑剂性能指标及测试方法》，我国的陶粒支撑剂的生产企业多采用铝矾土或高铝材料作为主要原料，陶粒支撑剂按体积密度和抗破碎能力分为低密度、中密度和高密度三个系列，其对应的抗闭合压力分别为52MP、69MPa和86MPa，以上支撑剂的体积密度都在1.58g/cm3以上，然而在油气田水力压裂作业中，理想的陶粒支撑剂：1、体积密度小，压裂液的携沙能力就好，便于泵入地下；2、化学惰性好，能抵抗抗地层下油、酸、盐、水的侵蚀，高温下同样稳定；3、强度高，能支撑相应地层压力，不会压碎；4、圆度好，能使支撑剂颗粒具有较好的空隙。
由于目前生产的陶粒支撑剂主要采用铝矾土或高铝材料作为主要原料，这种铝矾土陶粒支撑剂不仅生产成本高、价格高，而且，产品的体积密度都在1.58g/cm3以上，导致在水力压裂施工过程中，易磨损泵和管路，能耗消耗大，施工费用高。
【发明内容】
本发明所要解决的技术问题之一在于提供一种体积密度小于1.58g/cm3的超低密度陶粒支撑剂，在水力压裂施工过程中，不易磨损泵和管路，能耗消耗小，施工费用较低。
本发明所要解决的技术问题之二在于一种体积密度小于1.58g/cm3的超低密度陶粒支撑剂的制备方法。
本发明采用以下两种技术方案解决上述技术问题之一：
技术方案一：一种超低密度陶粒支撑剂，包括瓷土、高岭土、粘结剂、熔剂性辅料；各种原料的质量百分比为：瓷土5-85％、高岭土5-80％，粘土5-30％，熔剂性辅料2-20％。
还包括强度添加剂，其占总量的质量百分比为0.1-10％。
所述强度添加剂是钛精矿、锆英砂、锻烧氧化铝的一种或多种复合料。
所述的熔剂性辅料是长石、瓷石、锂辉石、滑石、瓷砂的一种或多种复合料。
技术方案二：
一种超低密度陶粒支撑剂，包括瓷土、焦宝石、粘结剂、熔剂性辅料；各种原料的质量百分比为：瓷土5-85％、焦宝石5-80％，粘土5-30％，熔剂性辅料2-20％。
还包括强度添加剂，其占总量的质量百分比为0.1-10％。
所述强度添加剂是钛精矿、锆英砂、锻烧氧化铝的一种或多种复合料。
所述的熔剂性辅料是长石、瓷石、锂辉石、滑石、瓷砂的一种或多种复合料。
本发明采用以下技术方案解决上述技术问题之二：
一种超低密度陶粒支撑剂的制备方法，包括如下步骤：粉料的湿法制备、半成品成球工艺、烧成工艺三个部分。
所述粉料的湿法制备包括如下步骤：按照配方的要求将各种原料分别进行预粉碎，再经配比称量、球磨、过筛、除铁、压滤、挤成条状、烘干、打粉工序，制备得到可供成球的粉料。
所述粉料的湿法制备包括如下步骤：按照配方的要求将各种原料分别进行预粉碎，再经配比称量、球磨；将球磨后的泥浆通过喷雾干燥器制备含水率为6-12％的颗粒料，再通过打粉，制备得到可供成球的粉料。
所述半成品成球工艺包括如下步骤：将制得的粉料加入成球机，同时喷洒雾化水滚动成球，制得圆球度达到0.9以上的坯球，再经回转干燥窑烘干、滚动回转筛筛分，得到半成品球。
所述烧成工艺包括如下步骤：将制得的半成品球用回转烧成窑、或隧道窑、或辊道窑作为烧成设备，烧成温度为1200-1320℃。烧成时间2-16小时。
本发明的优点在于：(1)首次将瓷土、高岭土或焦宝石作为主要原料，取代铝矾土原料，用于陶粒支撑剂的生产，具有原料来源广泛，生产成本低等特点；(2)采用球磨机湿法生产工艺加工粉料，代替现有技术中雷蒙磨干料粉磨制粉工艺，减少了生产过程中粉尘产生，具有生产工艺简单、劳动强度低等特点；(3)最重要的是，采用本发明生产的陶粒支撑剂与现有技术生产的中低密度支撑剂相比具有体积密度低的特点，适用于新、老油气井水力中浅井压裂施工，能有效降低水力压裂施工过程中陶粒支撑剂对动力泵和管线磨损，减少支撑剂用量，降低压裂施工成本等。
【具体实施方式】
实施例1：
(1)选择瓷土、高岭土、粘土、长石、滑石作为生产原料，各原料按质量百分比为：
瓷土：48.0％
高岭土：22.0％
粘土：18.0％
长石粉：11.0％
滑石粉：1.0％
其中长石粉和滑石粉也可以由瓷石、锂辉石、瓷砂的一种或多种复合料来取代。
(2)将各种原料分别进行预粉碎，再按配比准确称量，加入球磨机内进行加工20个小时以上，料球水的比例为1∶1.5∶0.8，出料细度控制在320目筛余小于0.5％，然后把泥浆放入泥浆池中，依次进行过筛、除铁、压滤、挤成条状、烘干、打粉等工序，制备得到可供成球的粉料。
也可将球磨后的泥浆通过喷雾干燥器制备含水率为6-12％颗粒料，再通过打粉，制备得到可供成球的粉料。
(3)将制得的粉料加入成球机，同时喷洒雾化水滚动成球，制得圆球度达到0.9以上的坯球，再经回转干燥窑烘干、滚动回转筛筛分，得到半成品球。
(4)将制得的半成品球用辊道窑烧成，烧成温度为1280℃。烧成时间6.0小时；经冷却筛选后即得本发明产品。
筛取一定量的粒径范围0.425-0.212mm(40/70目)的本发明产品，按GB/T4734-1996《陶瓷材料及制品化学分析方法》检测标准，本实施例的超低密度陶粒支撑剂的化学成份组成如下：
Al2O3：23.52％
SiO2：71.62％
K2O+Na2O：2.82％
MgO+CaO：0.38％
Fe2O3：1.49％
TiO2：0.10％
根据SY/T5108-2006推荐方法，测得本实施例的40/70陶粒支撑剂产品，其主要性能批标如下：
  粒径规格   体积密度(g/cm3)   视密度(g/cm3)   破碎率(52Mpa)   酸溶解度   浊度
  0.425----0.212mm(40/70目)   1.35   2.44   6.50％   6.0   24
本实施例产品质量适用于于新、老油气井水力浅井压裂施工。
实施例2：
(1)选择瓷土、焦宝石、粘土、滑石、钛精矿作为生产原料，各原料按质量百分比为：
瓷土：23.0％
焦宝石：58.0％
粘土：12.0％
滑石粉：2％
钛精矿：5.0％
其中滑石粉也可以由长石、瓷石、锂辉石、瓷砂的一种或多种复合料来取代。
其中钛精矿也可由锆英砂、锻烧氧化铝的一种或多种复合料。
(2)粉料的湿法制备方法同实施例1第(2)点。
(3)半成品成球工艺同实施例1第(3)点。
(4)将制得的半成品球用回转窑烧成，烧成温度为1320℃。烧成时间2.5小时；经冷却筛选后即得本发明产品。
筛取一定量的粒径范围0.425-0.212mm(40/70目)的本发明产品，按GB/T4734-1996《陶瓷材料及制品化学分析方法》检测标准，本实施例的超低密度陶粒支撑剂的化学成份组成如下：
Al2O3：34.24％
SiO2：71.62％
K2O+Na2O：1.92％
MgO+CaO：0.87％
Fe2O3：2.02％
TiO2：2.38％
根据SY/T5108-2006推荐方法，测得本实施例的40/70陶粒支撑剂产品，其主要性能批标如下：
粒径规格   体积密度(g/cm3)   视密度(g/cm3)   破碎率(52Mpa)   酸溶解度   浊度
  0.425----0.212mm(40/70目)   1.42   2.46   3.20％   6.0   39
本实施例产品质量适用于新、老油气井水力中浅井压裂施工。
实施例3：
本实施例制作方法均与实施例1相同，不同之处在于其原料百分比为：
瓷土：5.0％
高岭土：80.0％
粘土：5.0％
滑石粉：2.0％
钛精矿：8.0％
其中高岭土可由焦宝石来取代。
其中滑石粉也可以由长石、瓷石、锂辉石、瓷砂的一种或多种复合料来取代。
其中钛精矿也可以是锆英砂、锻烧氧化铝的一种或多种复合料。
实施例4：
本实施例制作方法均与实施例1相同，不同之处在于其原料百分比为：
瓷土：85.0％
高岭土：5.0％
粘土：5.0％
滑石粉：2.0％
钛精矿：3.0％
其中高岭土可由焦宝石来取代。
其中滑石粉也可以由长石、瓷石、锂辉石、瓷砂的一种或多种复合料来取代。
其中钛精矿也可以是锆英砂、锻烧氧化铝的一种或多种复合料。
实施例5：
本实施例制作方法均与实施例1相同，不同之处在于其原料百分比为：
瓷土：20.0％
高岭土：20.0％
粘土：30.0％
滑石粉：20.0％
钛精矿：10.0％
其中高岭土可由焦宝石来取代。
其中滑石粉也可以由长石、瓷石、锂辉石、瓷砂的一种或多种复合料来取代。
其中钛精矿也可以是锆英砂、锻烧氧化铝的一种或多种复合料。
实施例6：
本实施例制作方法均与实施例1相同，不同之处在于其原料百分比为：
瓷土：20.0％
高岭土：60.0％
粘土：10.0％
滑石粉：9.9％
钛精矿：0.1％
其中高岭土可由焦宝石来取代。
其中滑石粉也可以由长石、瓷石、锂辉石、瓷砂的一种或多种复合料来取代。
其中钛精矿也可以是锆英砂、锻烧氧化铝的一种或多种复合料。

Claims (13)

1.一种超低密度陶粒支撑剂，其特征在于：包括瓷土、高岭土、粘结剂、熔剂性辅料；各种原料的质量百分比为：瓷土5-85％、高岭土5-80％，粘土5-30％，熔剂性辅料2-20％。
2.如权利要求1所述的一种超低密度陶粒支撑剂，其特征在于：还包括强度添加剂，其占总量的质量百分比为0.1-10％。
3.如权利要求2所述的一种超低密度陶粒支撑剂，其特征在于：所述强度添加剂是钛精矿、锆英砂、锻烧氧化铝的一种或多种复合料。
4.如权利要求1至3中任一项所述的一种超低密度陶粒支撑剂，其特征在于：所述的熔剂性辅料是长石、瓷石、锂辉石、滑石、瓷砂的一种或多种复合料。
5.一种超低密度陶粒支撑剂，其特征在于：包括瓷土、焦宝石、粘结剂、熔剂性辅料；各种原料的质量百分比为：瓷土5-85％、焦宝石5-80％，粘土5-30％，熔剂性辅料2-20％。
6.如权利要求5所述的一种超低密度陶粒支撑剂，其特征在于：还包括强度添加剂，其占总量的质量百分比为0.1-10％。
7.如权利要求6所述的一种超低密度陶粒支撑剂，其特征在于：所述强度添加剂是钛精矿、锆英砂、锻烧氧化铝的一种或多种复合料。
8.如权利要求5至7中任一项所述的一种超低密度陶粒支撑剂，其特征在于：所述的熔剂性辅料是长石、瓷石、锂辉石、滑石、瓷砂一种或多种复合料。
9.一种超低密度陶粒支撑剂的制备方法，其特征在于：包括如下步骤：粉料的湿法制备、半成品成球工艺、烧成工艺三个部分。
10.如权利要求9所述的一种超低密度陶粒支撑剂的制备方法，其特征在于：所述粉料的湿法制备包括如下步骤：按照配方的要求将各种原料分别进行预粉碎，再经配比称量、球磨、过筛、除铁、压滤、挤成条状、烘干、打粉工序，制备得到可供成球的粉料。
11.如权利要求9所述的一种超低密度陶粒支撑剂的制备方法，其特征在于：所述粉料的湿法制备包括如下步骤：按照配方的要求将各种原料分别进行预粉碎，再经配比称量、球磨；将球磨后的泥浆通过喷雾干燥器制备含水率为6-12％的颗粒料，再通过打粉，制备得到可供成球的粉料。
12.如权利要求9所述的一种超低密度陶粒支撑剂的制备方法，其特征在于：所述半成品成球工艺包括如下步骤：将制得的粉料加入成球机，同时喷洒雾化水滚动成球，制得圆球度达到0.9以上的坯球，再经回转干燥窑烘干、滚动回转筛筛分，得到半成品球。
13.如权利要求9所述的一种超低密度陶粒支撑剂的制备方法，其特征在于：所述烧成工艺包括如下步骤：将制得的半成品球用回转烧成窑、或隧道窑、或辊道窑作为烧成设备，烧成温度为1200-1320℃。烧成时间2-16小时。
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