Disclosure of Invention
The invention provides a ceramsite proppant prepared from blast furnace tapping channel waste and a preparation process thereof. The ceramsite proppant meets the service performance required by the industrial standard, and simultaneously takes the refractory material waste for the blast furnace tapping channel as the raw material after use, so that the problems of resource shortage, environmental pollution and sustainable development are solved, and the preparation process is low in cost and simple in process.
In order to realize the task, the invention adopts the following technical scheme:
a ceramsite proppant prepared from blast furnace tapping channel waste is prepared by pretreating tapping channel waste, clay, shale and/or a sintering aid, mixing with other raw materials, granulating, screening and sintering.
Further, the raw materials comprise iron tapping channel waste materials: 30% -60%, clay: 10% -40%, shale: 20% -50%, sintering aid: 0-10 percent of the total weight percentage of the iron tapping channel waste, the clay, the shale and the sintering additive is 100 percent.
Preferably, the material is prepared from the following raw materials in percentage by mass, the iron runner waste material is 45 percent in percentage by mass, the clay is 20 percent in percentage by mass, the shale is 30 percent in percentage by mass, and the sintering aid is 5 percent in percentage by mass, wherein the sintering aid is manganese ore powder.
Specifically, the volume density of the ceramsite proppant is less than or equal to 1.7g/cm3Apparent density is less than or equal to 3g/cm3The breaking rate is less than or equal to 9 percent under the stress condition of 69MPa, the roundness and the sphericity are more than or equal to 0.8, the acid solubility is less than or equal to 5 weight percent, and the turbidity is less than or equal to 100 FTU.
The preparation process of the ceramsite proppant prepared from the blast furnace tapping channel waste comprises the following steps:
the method comprises the following steps: pretreating the iron tap channel waste, and respectively grinding the pretreated iron tap channel waste, clay, shale and sintering aid;
step two: weighing the pretreated tapping channel waste, clay, shale and sintering aid according to the following mass fractions respectively, and mixing; then adding a bonding agent into the granulator to mix the raw materials into balls;
step three: respectively drying, screening and sintering the spherulites to obtain the composite material; and then, carrying out secondary screening on the sintered sample and testing the performance to finally obtain the ceramsite proppant meeting the standard.
The scrap of the iron tapping channel: 30% -60%, clay: 10% -40%, shale: 20% -50%, sintering aid: 0-10 percent of the total weight percentage of the iron tapping channel waste, the clay, the shale and the sintering additive is 100 percent.
Specifically, the step of pretreating the tapping channel waste sequentially comprises the steps of sorting, knocking and cutting to remove a deteriorated layer, crushing an original brick layer, and mixing, grinding and homogenizing.
Further, the binding agent is a solution prepared from single components or composite components of polyvinyl alcohol, dextrin and carboxymethyl cellulose, and the total mass of the polyvinyl alcohol, the dextrin and the carboxymethyl cellulose in the solution accounts for 0-5% of the total mass of the solution.
Further, the sintering aid is a single component or a composite component of potassium feldspar, dolomite, calcite, manganese ore powder and iron oxide.
Specifically, the scrap of the tapping runner: 55%, clay: 15%, shale: 25%, sintering aid: 5 percent, the sum of the weight percentages of the iron tapping channel waste, the clay, the shale and the sintering additive is 100 percent;
the sintering aid is a mixed component of potassium feldspar and iron oxide, wherein the mass ratio of the potassium feldspar to the iron oxide is 2: 3.
Further, the drying temperature is 80-120 ℃, the sintering temperature is 1200-1500 ℃, and the heat preservation time is 1.0-4.0 h.
Compared with the prior art, the invention has the following advantages:
(1) the invention provides a ceramsite proppant which takes the waste of a used blast furnace iron tap channel as a raw material, realizes resource recycling and environmental protection, realizes waste utilization by using the raw material, improves the additional value of the waste of the iron tap channel and reduces the preparation cost; the performance of the prepared ceramsite proppant can meet the requirements of industrial standards, and the preparation process is low in cost.
(2) The method takes the blast furnace iron tapping channel waste as a raw material, the residual iron in the waste is taken as a fluxing agent, and an iron removal process is not needed in the treatment process of the iron tapping channel waste.
(3) The invention provides a preparation process of a ceramsite proppant, which is simple in process, economic and energy-saving.
Detailed Description
The present invention is described below with reference to specific examples, but the present invention is not limited to the following examples, and it should be understood by those skilled in the art that the invention can be implemented by making several simple deductions or substitutions to prepare satisfactory ceramsite proppant without departing from the spirit of the present invention, and all such alternatives are within the scope of the present invention. The amounts of the substances are given in mass% unless otherwise specified below.
The tapping runner waste in the present invention refers to a post-use blast furnace tapping runner refractory material produced in the steel smelting process and is a blast furnace tapping runner waste as a solid waste. The main phase being Al2O3-SiC-C. All the reagents are available in blast furnaces of steel plants, and the rest are commercially available.
The ceramsite proppant provided by the invention is prepared by taking the iron tap channel waste, clay, shale and/or sintering aid as raw materials, mixing, granulating and sintering.
The raw materials comprise iron tap channel waste materials: 30% -60%, clay: 10% -40%, shale: 20% -50%, sintering aid: 0-10 percent of the total weight percentage of the iron tapping channel waste, the clay, the shale and the sintering additive is 100 percent.
The preparation process of the ceramsite proppant prepared from the blast furnace tapping channel waste comprises the following steps:
the method comprises the following steps: pretreating the iron tap channel waste, and respectively grinding the pretreated iron tap channel waste, clay, shale and sintering aid;
step two: weighing the pretreated tapping channel waste, clay, shale and sintering aid according to the following mass fractions respectively, and mixing; then adding a bonding agent into the granulator to mix the raw materials into balls;
step three: respectively drying, screening and sintering the spherulites to obtain the composite material;
the scrap of the iron tapping channel: 30% -60%, clay: 10% -40%, shale: 20% -50%, sintering aid: 0-10 percent of the total weight percentage of the iron tapping channel waste, the clay, the shale and the sintering additive is 100 percent.
The binding agent is a solution prepared from single components or composite components of polyvinyl alcohol, dextrin and carboxymethyl cellulose, and the total mass of the polyvinyl alcohol, the dextrin and the carboxymethyl cellulose in the solution accounts for 0-5% of the total mass of the solution.
The sintering aid is a single component or a composite component of potassium feldspar, dolomite, calcite, manganese ore powder and iron oxide.
Example 1
The embodiment provides a ceramsite proppant prepared from blast furnace tapping channel waste, and the ceramsite proppant is prepared by pretreating the tapping channel waste by using the tapping channel waste, clay, shale and/or a sintering aid as raw materials, mixing the pretreated tapping channel waste with other raw materials, granulating, screening and sintering.
The raw material tapping channel waste of the ceramsite proppant in this example: 45%, clay: 20%, shale: 30%, sintering aid: 5 percent, and the sum of the mass percentages of the iron tapping channel waste, the clay, the shale and the sintering additive is 100 percent. The sintering aid is single manganese ore powder.
The embodiment also discloses a preparation process of the ceramsite proppant prepared from the blast furnace tapping channel waste, which comprises the following steps:
the method comprises the following steps: crushing the iron tap channel waste and the shale, and respectively grinding the iron tap channel waste, the clay, the shale and the sintering aid; all the raw materials are ground and then sieved by a 200-mesh sieve, namely the granularity of the powder is less than 0.074 mm.
Wherein, the iron tap channel waste material is firstly recycled: sorting and classifying the iron tap channel waste materials, knocking and cutting to remove the deteriorated layer, crushing the original brick layer, and mixing, grinding and homogenizing to obtain the refractory material reclaimed material.
Step two: weighing the iron tap channel waste, the clay, the shale and the sintering aid according to the mass fractions, and mixing; then adding a bonding agent into the granulator to mix the raw materials into balls;
the preparation method specifically comprises the steps of mixing weighed raw materials in a ball mill, then putting the uniformly mixed powder into a sugar-coating granulator, wherein the total quality of polyvinyl alcohol, dextrin and carboxymethyl cellulose in a binding agent solution accounts for 0% of the solution in percentage by mass. I.e. water alone as binder, without the addition of other components. Mixing the powder into balls;
step three: respectively drying, screening and sintering the spherulites to obtain the composite material;
the method comprises the following steps: drying the spherical particles, and performing primary screening on the dried spherical particles by using a standard screen; and finally sintering in a high-temperature furnace. The drying temperature of the ceramsite green body is 80 ℃, the sintering temperature is 1400 ℃, and the heat preservation time is 3 hours.
And in the screening detection, the performance of the sintered ceramsite is detected after secondary screening, and finally the ceramsite proppant with the performance meeting the SY/T5108-2014 industrial standard is obtained.
The sintered ceramsite proppant has the volume density of 1.61g/cm3Apparent density 2.62g/cm3The fracture rate is 5.9 percent under the stress condition of 69MPa, the roundness and the sphericity are 0.8, the acid solubility is 3.5wt percent, the turbidity is 90FTU, the performance of the material meets the requirement of the industry standard, and the material can be used for fracturing operation.
Example 2:
the same as example 1, but different from example 1, the ceramsite proppant is prepared from the following raw materials in percentage by mass: 50%, clay: 20%, shale: 30%, sintering aid: 0 percent, and the sum of the mass percentages of the iron tapping channel waste, the clay, the shale and the sintering additive is 100 percent.
The single component of the polyvinyl alcohol solution is used as a binding agent, and the concentration of the binding agent polyvinyl alcohol is 1 percent by mass.
The drying temperature of the ceramsite green body is 80 ℃, the sintering temperature is 1450 ℃, and the heat preservation time is 3 hours.
The sintered ceramsite proppant has the volume density of 1.56g/cm3Apparent density of 2.65g/cm3The fracture rate is 6.4 percent under the stress condition of 69MPa, the roundness and the sphericity are 0.8, the acid solubility is 3.9wt percent, the turbidity is 85FTU, the performance of the material meets the requirement of the industry standard, and the material can be used for fracturing operation.
Example 3
The same as example 1, but different from example 1, the ceramsite proppant is prepared from the following raw materials in percentage by mass: 55%, clay: 15%, shale: 25%, sintering aid: 5 percent, and the sum of the mass percentages of the iron tapping channel waste, the clay, the shale and the sintering additive is 100 percent. The sintering aid is a potassium feldspar and iron oxide composite component, wherein the mass ratio of the potassium feldspar to the iron oxide is 2: 3.
The drying temperature of the ceramsite green body is 90 ℃, the sintering temperature is 1400 ℃, and the heat preservation time is 3 hours.
The bonding agent is prepared from dextrin serving as a single component and serving as a bonding agent, and the dextrin in the bonding agent solution accounts for 3% of the total mass of the solution in percentage by mass.
The sintered ceramsite proppant has the volume density of 1.58g/cm3Apparent density 2.63g/cm3The breaking rate is 6.1 percent under the stress condition of 69MPa, the roundness and the sphericity are 0.8, the acid solubility is 3.7wt percent, the turbidity is 90FTU, the performance of the material meets the requirement of the industrial standard, and the material can be used for fracturing operation.
Example 4
The same as example 1, but different from example 1, the ceramsite proppant is prepared from the following raw materials in percentage by mass: 60%, clay: 10%, shale: 20%, sintering aid: 10 percent, and the sum of the weight percentages of the iron tapping channel waste, the clay, the shale and the sintering additive is 100 percent. The sintering aid is a dolomite and calcite composite component, wherein the mass ratio of the dolomite to the calcite is 1: 1.
The drying temperature of the ceramsite green body is 90 ℃, the sintering temperature is 1350 ℃, and the heat preservation time is 3 hours.
The binding agent is prepared from carboxymethyl cellulose as a single component by mass percent to prepare a solution as the binding agent, and the carboxymethyl cellulose in the binding agent solution accounts for 5 percent of the total quality of the solution by mass percent.
The sintered ceramsite proppant has the volume density of 1.60g/cm3Apparent density of 2.64g/cm3The fracture rate is 6.0 percent under the stress condition of 69MPa, the roundness and the sphericity are 0.8 percent, the acid solubility is 3.8 percent, the turbidity is 80FTU, the performance of the material meets the requirement of the industry standard, and the material can be used for fracturing operation.