Source: http://www.google.es/patents/US7825053
Timestamp: 2013-05-22 14:27:44
Document Index: 29141354

Matched Legal Cases: ['Application No. 60', 'Application No. 200800008', 'Application No. 200700583', 'Application No. 200701830', 'Application No. 200700583', 'Application No. 200700296', 'Application No. 200700583', 'Application No. 2', 'Application No. 200680038963', 'Application No. 200580030252', 'Application No. 200680027748', 'Application No. 200580030660', 'Application No. 200680014974']

Patente US7825053 - Sintered spherical pellets - Google PatentesB�squeda Im�genes Maps Play YouTube Noticias Gmail Drive M�s » B�squeda avanzada de patentes | Historial web | Iniciar sesi�n B�squeda avanzada de patentesPatentesSintered, spherical composite pellets or particles comprising alumina fines, at least one of clay and bauxite and optionally a sintering aid, are described, along with a process for their manufacture. The use of such pellets in hydraulic fracturing of subterranean formations and in grinding is also ...http://www.google.es/patents/US7825053?utm_source=gb-gplus-sharePatente US7825053 - Sintered spherical pellets N�mero de publicaci�nUS7825053 B2Tipo de publicaci�nConcesi�n N�mero de solicitud12/692,779 Fecha de publicaci�n2 Nov 2010 Fecha de presentaci�n25 Ene 2010 Fecha de prioridad14 Sep 2004Tambi�n publicado comoCN101023243AEP1799962A2US7678723US20060081371US20080220996US20100126728WO2006032008A2WO2006032008A3 InventoresSteve CanovaRobert DuenckelMark EdmundsBenjamin EldredBrett Allen Wilson Cesionario originalCarbo Ceramics Inc. Clasificaci�n de EE.UU.501/127507/269501/144166/280.2501/131501/130166/308.1501/128501/141 Clasificaci�n internacionalC09K8/80E21B43/267C04B35/10C04B35/18 Clasificaci�n cooperativaC04B2235/3262C04B2235/3821C04B2235/3445C04B2235/3206C04B2235/727C04B2235/3427C04B2235/3409C04B2235/3201C04B35/117C04B35/62695C04B2235/3203C04B2235/3804C04B2235/3418C04B2235/5436C04B2235/3272C04B2235/528C09K8/80C04B35/636C04B2235/72C04B2235/5296C04B2235/3217C04B2235/77C04B2235/38C04B35/111C04B2235/3232C04B2235/3208C04B2235/349C04B35/62635C04B2235/3463C04B2235/3284C04B2235/386 Clasificaci�n europeaC04B 35/626A10KC04B 35/111C09K 8/80C04B 35/636C04B 35/626A24C04B 35/117ReferenciasCitas de patentes (198)Otras citas (121)Enlaces externosUSPTO Cesi�n de USPTO EspacenetSintered spherical pelletsUS 7825053 B2 Resumen Sintered, spherical composite pellets or particles comprising alumina fines, at least one of clay and bauxite and optionally a sintering aid, are described, along with a process for their manufacture. The use of such pellets in hydraulic fracturing of subterranean formations and in grinding is also described.
CROSS-REFERENCE TO RELATED APPLICATIONS This patent application is a divisional of U.S. patent application Ser. No. 12/123,189, filed May 19, 2008, now U.S. Pat. No. 7,678,723 which claims benefit of U.S. patent application Ser. No. 11/226,476, filed Sep. 14, 2005, now abandoned, which claims benefit of provisional Application No. 60/609,778, filed on Sep. 14, 2004, which are incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION The present invention relates to oil and gas well proppants and, more particularly, to proppants with excellent crush resistance in a broad range of applications in which one of the starting raw materials used to produce the proppant is alumina fines.
DETAILED DESCRIPTION In accord with the present invention, spherical pellets or particles, having alumina fines as one of the starting raw materials, are produced. The spherical particles are useful as oil and gas proppants as well as grinding media. The spherical particles may be fired at a sintering temperature for a period of time sufficient to enable recovery of sintered, spherical pellets having an apparent specific gravity of between 2.70 and 3.75 and a bulk density of from about 1.35 to about 2.15 g/cm3. The proppants of the present embodiments range from intermediate to exceptionally high strength and are effective at closure stresses of up to about 15,000 psi. Thus, the proppants of the present embodiments are generally applicable for moderate to very deep oil and gas wells where closure stresses may be extreme.
A suitable alumina fines material for use in the compositions for producing the proppant of the present embodiments is the alumina fines dust collector by-product of alumina purification using the Bayer process. According to the Bayer process, the aluminum component of bauxite ore is dissolved in sodium hydroxide, impurities are removed from the solution and alumina trihydrate is precipitated from the solution and then calcined to aluminum oxide. A Bayer Process plant is essentially a device for heating and cooling a large recirculating stream of caustic soda solution. Bauxite is added at the high temperature point, red mud is separated at an intermediate temperature, and alumina is precipitated at the low temperature point in the cycle. The alumina fines that are useful for the preparation of the proppant pellets according to the present embodiments are a by-product this process. A suitable alumina fines product has an alumina content of about 99 percent by weight, a loss on ignition of about 13%-22%, an average particle size of about 12 microns and about 86% or more of the particle size distribution is less than 45 microns. The term �loss on ignition� refers to a process, well known to those of ordinary skill in the art, in which samples are dried at about 100� C. to drive off free moisture and then heated to about 1000� C. to drive off chemically bound water and other compounds.
The term �apparent specific gravity,� as used herein, is a number without units, but is defined to be numerically equal to the weight in grams per cubic centimeter of volume, excluding void space or open porosity in determining the volume. The apparent specific gravity values given herein were determined by water displacement.
The term �bulk density�, as used herein, is defined to mean the weight per unit volume, including in the volume considered the void spaces between the particles.
As noted above, the compositions for producing the proppant of the present embodiments may also include sintering aids such as iron oxide or zinc oxide. The iron oxide may be added to the composition as hematite iron oxide (Fe2O3) or other fauns of iron oxide, such as FeO and Fe3O4, and thus the term �iron oxide� as used herein means all fauns of iron oxide and may be generically represented as FexOy. A suitable iron oxide material is pigment grade iron oxide which is commercially available from Densimix, Inc. A suitable zinc oxide material is commercially available from U.S. Zinc.
The term �spherical� and related forms, as used herein, is defined to mean an average ratio of minimum diameter to maximum diameter of about 0.80 or greater, or having an average sphericity value of about 0.8 or greater compared to a Krumbein and Sloss chart. The sintered proppant pellets of the present embodiment have an average sphericity of about 0.8 or greater when visually compared with the Krumbein and Sloss chart. The proppant pellets of certain of the present embodiments have a roundness of about 0.9 and a sphericity of about 0.9.
EXAMPLE 1 A 58/42 ratio mixture of alumina fines and calcined kaolin clay was prepared by first grinding the mixture so that 99.4% of the mixture had a particle size of less than 325 mesh. Next, about 3200 grams of the 58/42 ratio mixture was charged to an R02 Eirich mixer.
The mixer was operated on high speed rotor and 1050 grams of water containing 24 grams of starch as a binding agent was added. Pelletizing was continued at high speed rotor for 4.5 minutes. Next, the speed of the mixer was reduced to �slow� rotor and 200 grams of polishing dust having the same 58/42 ratio composition of alumina fines and calcined kaolin clay was added. The pellets were polished under slow rotor for a total of 1.5 minutes.
The pellets were then dried and screened to −16 mesh/+30 mesh prior to firing at temperatures ranging from 2850 to 3000� F. The resulting pellets had a bulk density of 1.34 gm/cm3.
The crush strength of the pellets was tested in accordance with the API procedure for determining resistance to crushing noted above and at an induced pressure of 4,000 psi the pellets had a crush percentage of 2.1. The best strength was obtained at firing temperatures of 3000� F. which was the maximum temperature capability of the laboratory furnace. The data indicate that firing the pellets from this blend at higher temperatures would generate pellets with optimum strength.
EXAMPLE 2 About 3200 grams of a 64/28/8 ratio mixture of alumina fines, calcined kaolin clay, and iron oxide having a particle size of 98.6%<325 mesh were added to an R02 Eirich mixer.
The pellets were then dried and screened to −16 mesh/+30 mesh prior to firing at about 2,750� F. The resulting pellets had an apparent specific gravity of about 3.30, a bulk density of 1.84 gm/cm3 and a sphericity of greater than 0.8, as determined using the Krumbein and Sloss chart.
EXAMPLE 3 About 4.5 kilograms of a 36/63/1 ratio mixture of alumina fines, bauxite, and zinc oxide having a particle size of 99.9%<325 mesh were added to an R02 Eirich mixer.
The pellets were then dried and screened to −16 mesh/+30 mesh prior to firing at about 2,840� F. The resulting pellets had an apparent specific gravity of about 3.65, a bulk density of 1.99 gm/cm3 and a sphericity of greater than 0.8, as determined using the Krumbein and Sloss chart.
EXAMPLE 4 About 3.6 kilograms of a 20/80 ratio mixture of alumina fines and bauxite having a particle size of 99.9%<325 mesh were added to an R02 Eirich mixer.
The pellets were then dried and screened to −16 mesh/+30 mesh prior to firing at about 2,750� F. The resulting pellets had an apparent specific gravity of about 3.63, a bulk density of 1.98 gm/cm3 and a sphericity of greater than 0.8, as determined using the Krumbein and Sloss chart.
A viscous fluid, frequently referred to as �pad�, is injected into the well at a rate and pressure to initiate and propagate a fracture in the subterranean formation. The fracturing fluid may be an oil base, water base, acid, emulsion, foam, or any other fluid. Injection of the fracturing fluid is continued until a fracture of sufficient geometry is obtained to permit placement of the propping pellets. Thereafter, pellets as hereinbefore described are placed in the fracture by injecting into the fracture a fluid into which the pellets have previously been introduced and suspended. The propping distribution is usually, but not necessarily, a multi-layer pack. Following placement of the pellets, the well is shut-in for a time sufficient to permit the pressure in the fracture to bleed off into the formation. This causes the fracture to close and apply pressure on the propping pellets which resist further closure of the fracture.
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KGProcess for manufacturing alpha-Al2O3 microcrystalline sintered bodies and their useFR2486930A1 T�tulo no disponibleGB578424A T�tulo no disponibleGB715354A T�tulo no disponibleGB715882A T�tulo no disponibleGB886342A T�tulo no disponibleGB992237A T�tulo no disponibleGB1033143A T�tulo no disponibleGB1411135A T�tulo no disponibleGB1421531A T�tulo no disponibleGB2037727A T�tulo no disponibleGB2079261A T�tulo no disponibleGB2092561A T�tulo no disponibleMX161299A T�tulo no disponiblePH18450A T�tulo no disponibleRU2014281C1 T�tulo no disponibleRU2079471C1 T�tulo no disponibleRU2083528C1 T�tulo no disponibleRU2090537C1 T�tulo no disponibleRU2098387C1 T�tulo no disponibleRU2098618C1 T�tulo no disponibleRU2107674C1 T�tulo no disponibleRU2112189C1 T�tulo no disponibleRU2112761C1 T�tulo no disponibleRU2121988C1 T�tulo no disponibleRU2129985C1 T�tulo no disponibleRU2129987C1 T�tulo no disponibleRU2133716C1 T�tulo no disponibleRU2140874C1 T�tulo no disponibleRU2140875C1 T�tulo no disponibleRU2147564C1 T�tulo no disponibleRU2147565C1 T�tulo no disponibleRU2147717C1 T�tulo no disponibleRU2150442C1 T�tulo no disponibleRU2151124C1 T�tulo no disponibleRU2151125C1 T�tulo no disponibleRU2151987C1 T�tulo no disponibleRU2154042C1 T�tulo no disponibleRU2155735C1 T�tulo no disponibleRU2163227C1 T�tulo no disponibleRU2166079C1 T�tulo no disponibleRU2168484C2 T�tulo no disponibleRU2178924C1 T�tulo no disponibleRU2180397C1 T�tulo no disponibleRU2183370C1 T�tulo no disponibleRU2183739C2 T�tulo no disponibleRU2191167C1 T�tulo no disponibleRU2191169C1 T�tulo no disponibleRU2191436C1 T�tulo no disponibleRU2192053C1 T�tulo no disponibleRU99107936A T�tulo no disponibleOtras citasReferencia1"rock." 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