CN117264623A - Ceramsite propping agent based on waste FCC catalyst and preparation method and application thereof - Google Patents

Abstract

The invention provides a ceramsite proppant based on a waste FCC catalyst, and a preparation method and application thereof, and belongs to the technical field of ceramsite proppants. The invention uses waste FCC catalyst as main raw material, its main component is Al ₂ O ₃ And SiO ₂ The method comprises the steps of carrying out a first treatment on the surface of the The invention adds silica which contains rich SiO ₂ Can improve the SiO of the ceramsite ₂ Content ratio of SiO ₂ The cristobalite sintered to generate slight expansion, thereby reducing the apparent density of the ceramsite propping agent; according to the invention, illite powder is added, so that the illite has adhesive propertyWherein the illite contains K ₂ O，K ₂ SiO with O as a soluble part of alkaline earth oxides ₂ And Al ₂ O ₃ Promote matrix sintering, generate mullite and cristobalite, increase product strength and reduce breakage rate.

Description

A kind of ceramsite proppant based on waste FCC catalyst and its preparation method and application

Technical field

The present invention relates to the technical field of ceramsite proppant, and in particular to a ceramsite proppant based on spent FCC catalyst and its preparation method and application.

Background technique

Ceramsite proppant has better sphericity, anti-fragmentation ability and flow conductivity than quartz sand, and is widely used in deep oil and gas wells. However, the density of ceramsite is higher than that of quartz sand, which places higher requirements on pumping conditions and fracturing fluid performance, making construction more difficult. In contrast, low-density proppant is easy to carry, can greatly reduce the viscosity of fracturing fluid, reduces damage to fracturing equipment, and effectively reduces construction difficulty and oil production costs. Therefore, the development of low-density proppant has become the direction of proppant research. At present, there are patents for the preparation technology of ultra-low density ceramsite proppant in my country. Most of them use bauxite as the main raw material, add a small amount of mineralizers such as potassium feldspar, dolomite, and manganese powder, and are fired at high temperature in a rotary kiln. .

Fluid catalytic cracking technology (FCC, Fluid Catalytic Cracking) is the most important core technology in my country's petroleum refining industry, and its development momentum is very rapid. FCC catalyst is one of the most important raw materials in the industrial process of petroleum products. Its annual usage is far greater than the consumption of other types of refining catalysts. It accounts for 86% of the catalyst usage in the petroleum refining industry. above. The harmless treatment of spent FCC catalysts has always been a big challenge.

The existing technology uses waste FCC catalysts as part of the raw materials to prepare fracturing proppant and ceramsite. For example, Chinese patent CN110564400A discloses a fracturing proppant that uses oil-based drill cuttings thermal analysis residue to sinter and its preparation method. The raw materials include : 20 to 50 parts of oil-based drill cuttings thermal analysis residue; 28 to 60 parts of bauxite; 24 parts or less of FCC waste catalyst and not 0; etc. This patented spent FCC catalyst has a maximum usage of 24% and still requires the addition of bauxite.

Chinese patent CN114426429A discloses a filled sand mixture, ceramsite filled sand and its preparation method and application. The raw materials include: 10 to 45% of tailings after oily sludge treatment; 20 to 70% of FCC waste catalyst; 5 to 15% of clay. %; waste glass powder 5 to 25%; specific gravity regulator 1 to 3%. Although the amount of waste FCC added in this patent is relatively high, the strength of the prepared ceramsite is low, and it can only be used as filling sand for well workovers in oil production, without Oil fracturing proppant function.

Contents of the invention

In view of this, the purpose of the present invention is to provide a ceramsite proppant based on spent FCC catalyst and its preparation method and application. The ceramsite proppant based on the spent FCC catalyst provided by the present invention has low density and high strength, and the content of the spent FCC catalyst in the ceramsite proppant is high.

In order to achieve the above-mentioned object of the invention, the present invention provides the following technical solutions:

The invention provides a ceramsite proppant based on waste FCC catalyst, which is prepared from raw materials including the following mass percentages:

Waste FCC catalyst 38~55%;

Silica 20~31%;

Illite 17~35%.

Preferably, the content of Al ₂ O ₃ in the spent FCC catalyst is 45 to 52 wt%, and the content of SiO ₂ is 45 to 52 wt%.

Preferably, the content of K ₂ O in the illite is 6 to 10 wt%, the content of Al ₂ O ₃ is 20 to 35 wt%, and the content of SiO ₂ is 45 to 65 wt%.

Preferably, the content of SiO ₂ in the silica is ≥90wt%.

Preferably, the silica is block material or powder, and the particle size of the silica block material is ≤1 cm;

The particle size of the silica powder is 100-200 mesh;

The particle size of the illite is 100-200 mesh.

Preferably, the bulk density of the ceramsite proppant is ≤1.52g/cm ³ , the apparent density is ≤2.75g/cm ³ , the roundness and sphericity are ≥0.9, the turbidity is ≤50FTU, and the crushing rate is ≤8 under a closing pressure of 69MPa. %.

The invention provides a method for preparing the above-mentioned ceramsite proppant based on waste FCC catalyst, which includes the following steps:

Mix the spent FCC catalyst, silica and illite, and grind them to obtain mixed powder;

The mixed powder is sequentially dried, granulated and sieved to obtain ceramic green balls;

The ceramsite green ball is sintered to obtain a ceramsite proppant based on the waste FCC catalyst.

Preferably, the particle size of the mixed powder is ≥600 mesh; the particle size of the ceramic green ball is 35-65 mesh.

Preferably, the sintering temperature is 1180-1250°C, and the holding time is 0.8-2h.

The present invention provides the application of the above-mentioned ceramsite proppant based on waste FCC catalyst in oil and gas field fracturing.

The invention provides a ceramsite proppant based on spent FCC catalyst, which is prepared from raw materials containing the following mass percentages: spent FCC catalyst 30-50%; silica 20-31%; illite 20-31%. The present invention uses waste FCC catalyst and silica as raw materials, and illite as a burning aid and binder. These components are all product aggregates, and they are the raw materials for forming mullite crystals. The present invention uses waste FCC catalyst as the main raw material, the main components of which are Al ₂ O ₃ and SiO ₂ ; by adding silica, which is rich in SiO ₂ , the present invention can increase the content ratio of SiO ₂ in the ceramsite, and SiO ₂ sintering The cristobalite will expand slightly, thereby reducing the apparent density of the ceramsite proppant; in the present invention, by adding illite powder, the illite has bonding properties, in which illite contains K ₂ O, and K ₂ O serves as the soluble part of the alkaline earth metal oxide SiO ₂ and Al ₂ O ₃ promote the sintering of the matrix and generate mullite and cristobalite, which increases the strength of the product while reducing the breakage rate.

At the same time, the addition of illite is beneficial to the formation of ceramic proppant green balls. In the present invention, after the waste FCC catalyst, silica and illite are sintered, a mixed crystal of mullite and cristobalite with low density and high strength is generated. The generated mixed crystal is surrounded by a glass phase, and the entire ceramsite has low density and high strength. specialty. According to the enterprise standard Q/SH15000104-2016 of Sinopec Southwest Oil and Gas Branch and the enterprise standard Q/SH31400072-2015 of Jianghan Oilfield Branch, the properties of the fracturing proppant prepared using the present invention are as follows: bulk density ≤ 1.52g/cm ³ and apparent density It is ≤2.75g/cm ³ , roundness and sphericity ≥0.9, turbidity less than 50FTU, crushing rate of 40/70 mesh products under 69MPa pressure ≤8%, conductivity ≥25μm ² /cm, acid solubility ≤5.0 . The lowest apparent density can reach 2.2g/cm ³ , which is far lower than the apparent density of current sintered bauxite proppant (2.6-3.5g/cm ³ ).

The present invention provides a method for preparing the above-mentioned ceramsite proppant based on waste FCC catalyst. This method is simple to operate and suitable for industrial mass production. Furthermore, some of the raw materials used in the present invention are solid wastes, which generate income from disposal fees and have good economic benefits; the raw materials used in the present invention have fewer types, are cheap and easy to obtain; and the proppant ceramsite obtained by the present invention has lower apparent density and volume. Density, thus having higher flow conductivity during use; compared with sintered pure alumina ceramsite, the preparation method provided by this method is lower cost, and the ceramsite proppant has high strength and low density, which is especially suitable for Fracturing production of deep oil and gas wells with high conductivity.

Description of the drawings

Figure 1 is a flow chart of the preparation process of ceramsite proppant based on waste FCC catalyst;

Figure 2 is a micrograph of the internal crystal of a ceramsite proppant based on spent FCC catalyst;

Figure 3 shows the XRD pattern of ceramsite proppant based on spent FCC catalyst.

Detailed ways

The invention provides a ceramsite proppant based on waste FCC catalyst, which is prepared from raw materials including the following mass percentages:

Waste FCC catalyst 38~55%;

Silica 20~31%;

Illite 17~35%.

In terms of mass percentage, the raw materials for preparing the ceramsite proppant based on the spent FCC catalyst provided by the present invention include 38 to 50% of the spent FCC catalyst, preferably 40 to 48%, and more preferably 42 to 45%. In the present invention, the content of Al ₂ O ₃ in the spent FCC catalyst is preferably 45 to 52 wt%, more preferably 48 to 50 wt%; the content of SiO ₂ is preferably 45 to 52 wt%, more preferably 48 to 50 wt%. .

In terms of mass percentage, the raw materials for preparing the ceramsite proppant based on spent FCC catalyst provided by the present invention include 20 to 31% silica, preferably 22 to 30%, and more preferably 25 to 28%. In the present invention, the content of SiO ₂ in the silica is preferably ≥90 wt%, and more preferably 92 to 95 wt%.

In the present invention, the silica is a block or powder, and the particle size of the silica block is ≤1 cm;

The particle size of the silica powder is preferably 100 to 200 mesh.

In terms of mass percentage, the raw materials for preparing the ceramsite proppant based on spent FCC catalyst provided by the present invention include 20 to 31% of illite, preferably 22 to 30%, and more preferably 25 to 28%. In the present invention, the content of K ₂ O in the illite is preferably 6 to 10 wt%, more preferably 8 to 9 wt%; the content of Al ₂ O ₃ is preferably 20 to 35 wt%, more preferably 25 to 30 wt%. ; The content of SiO ₂ is preferably 45 to 65 wt%, and more preferably 50 to 60 wt%. In the present invention, the illite is used as a sintering aid and a binder.

In the present invention, the illite is preferably powder, and the particle size of the illite powder is preferably 100 to 200 mesh. In the present invention, the preparation method of illite powder preferably includes the following steps:

Illite ore is crushed and ground to obtain illite powder.

The present invention has no special requirements for the specific operation methods of crushing and grinding, and crushing and grinding methods well known to those skilled in the art can be used.

The main component of the ceramsite proppant based on the waste FCC catalyst of the present invention is silica, in which the silica content is 55-65wt% and the alumina content is 25-35wt%.

According to the enterprise standard Q/SH15000104-2016 of Sinopec Southwest Oil and Gas Branch and the enterprise standard Q/SH31400072-2015 of Jianghan Oilfield Branch, the properties of the fracturing proppant prepared using the present invention are as follows: bulk density ≤ 1.52g/cm ³ and apparent density It is ≤2.75g/cm ³ , roundness and sphericity ≥0.9, turbidity ≤30FTU, crushing rate of 40/70 mesh products under 69MPa pressure ≤8%, conductivity ≥25μm ² /cm, acid solubility ≤5.0 . The lowest apparent density can reach 2.2g/cm ³ , which is far lower than the apparent density of current sintered bauxite proppant (2.6-3.5g/cm ³ ).

The invention provides a method for preparing the above-mentioned ceramsite proppant based on waste FCC catalyst, which includes the following steps:

Mix the spent FCC catalyst, silica and illite, and grind them to obtain mixed powder;

The mixed powder is sequentially dried, granulated and sieved to obtain ceramic green balls;

The ceramsite green ball is sintered to obtain a ceramsite proppant based on the waste FCC catalyst.

In the present invention, waste FCC catalyst, silica and illite are mixed and ground to obtain mixed powder. In the present invention, it is preferred to use an electronic batching machine for automatic batching and a mixer for the mixing.

The present invention preferably uses a wet grinder for said grinding. The present invention has no special requirements on the specific grinding operation. In the present invention, the particle size of the mixed powder is preferably ≥600 mesh.

After obtaining the mixed powder, the present invention sequentially dries, granulates and sieves the mixed powder to obtain ceramic green balls. In the present invention, the drying method is preferably air drying. In the present invention, the granulation molding is preferably carried out in a pelletizing machine.

In the present invention, the sieving is preferably 65 mesh and 35 mesh sieves.

After obtaining the ceramsite green ball, the present invention sinters the ceramsite green ball to obtain a ceramsite proppant based on waste FCC catalyst. In the present invention, the sintering is preferably performed in a rotary kiln. In the present invention, the sintering temperature is preferably 1180-1250°C, more preferably 1200-1240°C; the holding time is preferably 0.8-2h, more preferably 1-1.5h. In the present invention, the sintering is preferably performed in an air atmosphere. In the present invention, during the sintering process, mullite crystals are generated when the temperature reaches 800-1000°C, and mixed crystals of mullite and cristobalite with low density and high strength are finally generated when the temperature reaches 1180-1250°C. The resulting mixed crystal is surrounded by a glass phase, and the entire ceramsite has the characteristics of low density and high strength.

After the sintering, the present invention preferably performs classification screening on the obtained ceramsite proppant based on the spent FCC catalyst.

The present invention provides the application of the above-mentioned ceramsite proppant based on waste FCC catalyst in oil and gas field fracturing.

In the present invention, the preparation process flow chart of the ceramsite proppant for the spent FCC catalyst is shown in Figure 1.

The ceramic proppant based on spent FCC catalyst provided by the present invention and its preparation method and application will be described in detail below with reference to the examples, but they should not be understood as limiting the scope of the present invention.

Example 1

27 tons of silica ore with a silica content of 92%, after double-roller crushing and jaw crushing, is put into a ball mill and ground to obtain 200-mesh silica ore powder for later use; 28 tons of silica ore with an alumina content of 25% and silica content The illite ore is 60% and the potassium oxide content is 7%. After double-roller crushing and jaw crushing, it is put into a ball mill and ball milled to obtain 200-mesh illite ore powder for later use; then 45 tons of alumina content 52%, The waste FCC catalyst with a silica content of 42% is mixed with silica powder and illite powder, ground to more than 600 mesh in a wet mill, air-dried with an air dryer, and granulated into balls by adding water. The obtained proppant green balls are then separately Use 65 mesh and 35 mesh sieves to obtain semi-finished products of 35 to 65 mesh. The semi-finished products are transported to the rotary kiln and kept at 1180°C for 2 hours. Then they enter the water-cooled kiln and are cooled to normal temperature. The cooled proppant of 40 to 70 mesh is used Sieve through sieve classification to obtain a 40/70 mesh ceramsite proppant product based on spent FCC catalyst.

Tested according to Q/SH15000104-2016 and Q/SH31400072-2015 standards, the performance is as follows: bulk density is 1.46g/cm ³ , apparent density is 2.63g/cm ³ , roundness and sphericity are 0.93, turbidity is 45FTU, the product The crushing rate under 69MPa pressure is 6.1%.

The microscopic picture of the internal crystal of the ceramsite proppant based on the spent FCC catalyst is shown in Figure 2, and the XRD pattern is shown in Figure 3. As can be seen from Figure 3, the diffraction peak position of the ceramsite proppant based on the spent FCC catalyst obtained in the present invention is basically consistent with the mullite standard spectrum, and contains the diffraction peak position of cristobalite, indicating that the ceramsite proppant based on the spent FCC catalyst obtained in the present invention is basically consistent with the diffraction peak position of the mullite standard spectrum. The granular proppant contains mixed crystals of mullite and cristobalite.

Example 2

25 tons of silica ore with a silica content of 97%, after double-roller crushing and jaw crushing, is put into a ball mill and ground to obtain 200-mesh silica ore powder for later use; 25 tons of silica ore with an alumina content of 21% and silica content The illite ore is 62% and the potassium oxide content is 9%. After double-roller crushing and jaw crushing, it is put into a ball mill and ground to obtain 200-mesh illite ore powder for later use; then take 50 tons of alumina content of 52%, The waste FCC catalyst with a silica content of 42% is mixed with silica powder and illite powder, ground to more than 600 mesh with a jet mill, and granulated into balls by adding water. The obtained proppant green balls are then sieved with 65 mesh and 35 mesh sieves respectively. Semi-finished products of 35 to 65 mesh are obtained. The semi-finished product is transported to the rotary kiln and kept at 1200°C for 2 hours. Then it enters the water-cooled kiln and is cooled to normal temperature. The cooled proppant is graded and sieved using a 40-70 mesh sieve to obtain 40/ 70 mesh ceramsite proppant product based on spent FCC catalyst.

Tested according to Q/SH15000104-2016 and Q/SH31400072-2015 standards, the performance is as follows: bulk density is 1.48g/cm ³ , apparent density is 2.66g/cm ³ , roundness and sphericity are 0.94, turbidity is 49FTU, the product The crushing rate under 69MPa pressure is 6.7%.

Example 3

20 tons of silica ore with a silica content of 92%, after double-roller crushing and jaw crushing, is put into a ball mill and ground to obtain 200-mesh silica ore powder for later use; 31 tons of silica ore with an alumina content of 25% and silica content The illite ore is 57% and the potassium oxide content is 8%. After double-roller crushing and jaw crushing, it is put into a ball mill and ground to obtain 200-mesh illite ore powder for later use; then 49 tons of alumina content 50%, The waste FCC catalyst with a silica content of 46% is mixed with silica powder and illite powder, and is ground in a wet mill to more than 600 mesh. The material is air-dried using an air dryer, and water is added to granulate it into balls. The obtained proppant green balls are then separately Use 65 mesh and 35 mesh sieves to obtain semi-finished products of 35 to 65 mesh. The semi-finished products are transported to the rotary kiln and kept at 1210°C for 2 hours. Then they enter the water-cooled kiln and are cooled to normal temperature. The cooled proppant of 40 to 70 mesh is used Sieve through sieve classification to obtain a 40/70 mesh ceramsite proppant product based on spent FCC catalyst.

Tested according to Q/SH15000104-2016 and Q/SH31400072-2015 standards, the performance is as follows: bulk density is 1.49g/cm ³ , apparent density is 2.69g/cm ³ , roundness and sphericity are 0.92, turbidity is 37FTU, the product The crushing rate under 69MPa pressure is 5.8%.

Example 4

29 tons of silica ore with a silica content of 96%, after double-roller crushing and jaw crushing, was put into a ball mill and ground to obtain 200-mesh silica ore powder for later use; 26 tons of silica ore with an alumina content of 35% and silica content The illite ore is 48% and the potassium oxide content is 6%. After double-roller crushing and jaw crushing, it is put into a ball mill and ground to obtain 200-mesh illite ore powder for later use; then 45 tons of alumina content of 50%, The waste FCC catalyst with a silica content of 43% is mixed with silica powder and illite powder, ground to more than 600 mesh with a jet mill, air-dried with an air dryer, and granulated into balls by adding water. The obtained proppant green balls are then used separately. Screen the 35-65 mesh semi-finished products through 65-mesh and 35-mesh sieves. The semi-finished products are transported to the rotary kiln and kept at 1220°C for 2 hours. Then they enter the water-cooled kiln and are cooled to normal temperature. The cooled proppant is then sieved through 40-70 mesh sieves. After classification and sieving, a 40/70 mesh ceramsite proppant product based on waste FCC catalyst was obtained.

Tested according to Q/SH15000104-2016 and Q/SH31400072-2015 standards, the performance is as follows: bulk density is 1.49g/cm ³ , apparent density is 2.70g/cm ³ , roundness and sphericity are 0.91, turbidity is 43FTU, the product The crushing rate under 69MPa pressure is 5.3%.

Example 5

22 tons of silica ore with a silica content of 96%, after double-roller crushing and jaw crushing, is put into a ball mill and ground to obtain 200-mesh silica ore powder for later use; 28 tons of silica ore with an alumina content of 35% and silica content The illite ore is 48% and the potassium oxide content is 6%. After roller crushing and jaw crushing, it is put into a ball mill and ball milled to obtain 200-mesh illite ore powder for later use; then take 50 tons of alumina content of 50%, The waste FCC catalyst with a silica content of 43% is mixed with silica powder and illite powder, and is ground in a wet mill to more than 600 mesh. The material is air-dried using an air dryer, and water is added to granulate it into balls. The obtained proppant green balls are then separately Use 65-mesh and 35-mesh sieves to obtain semi-finished products of 35 to 65 mesh. The semi-finished products are transported to the rotary kiln and kept at 1190°C for 2 hours. Then they enter the water-cooled kiln and are cooled to normal temperature. The cooled proppant of 40 to 70 mesh is used Sieve through sieve classification to obtain a 40/70 mesh ceramsite proppant product based on spent FCC catalyst.

Tested according to Q/SH15000104-2016 and Q/SH31400072-2015 standards, the performance is as follows: bulk density is 1.50g/cm ³ , apparent density is 2.71g/cm ³ , roundness and sphericity are 0.92, turbidity is 39FTU, the product The crushing rate under 69MPa pressure is 5.1%.

Example 6

26 tons of silica ore with a silica content of 97%, after double-roller crushing and jaw crushing, was put into a ball mill and ground to obtain 200-mesh silica ore powder for later use; 29 tons of silica ore with an alumina content of 31% and silica content The illite ore is 50% and the potassium oxide content is 7%. After double-roller crushing and jaw crushing, it is put into a ball mill and ball milled to obtain 200-mesh illite ore powder for later use; then 45 tons of alumina content 50%, The waste FCC catalyst with a silica content of 46% is mixed with silica powder and illite powder, and is ground in a wet mill to more than 600 mesh. The material is air-dried using an air dryer, and water is added to granulate it into balls. The obtained proppant green balls are then separately Use 65 mesh and 35 mesh sieves to obtain semi-finished products of 35 to 65 mesh. The semi-finished products are transported to the rotary kiln and kept at 1230°C for 2 hours. Then they enter the water-cooled kiln and are cooled to normal temperature. The cooled proppant of 40 to 70 mesh is used Sieve through sieve classification to obtain a 40/70 mesh ceramsite proppant product based on spent FCC catalyst.

Tested according to Q/SH15000104-2016 and Q/SH31400072-2015 standards, the performance is as follows: bulk density is 1.48g/cm ³ , apparent density is 2.69g/cm ³ , roundness and sphericity are 0.95, turbidity is 41FTU, the product The crushing rate under 69MPa pressure is 7.1%.

Example 7

31 tons of silica ore with a silica content of 92%, after double-roller crushing and jaw crushing, was put into a ball mill and ground to obtain 200-mesh silica ore powder for later use; 29 tons of silica ore with an alumina content of 34% and silica content The illite ore is 53% and the potassium oxide content is 7%. After double-roller crushing and jaw crushing, it is put into a ball mill and ground to obtain 200-mesh illite ore powder for later use; then 40 tons of alumina content of 50%, The waste FCC catalyst with a silica content of 46% is mixed with silica powder and illite powder, and is ground in a wet mill to more than 600 mesh. The material is air-dried using an air dryer, and water is added to granulate it into balls. The obtained proppant green balls are then separately Use 65-mesh and 35-mesh sieves to obtain semi-finished products of 35 to 65 mesh. The semi-finished products are transported to the rotary kiln and kept at 1240°C for 2 hours. Then they enter the water-cooled kiln and are cooled to normal temperature. The cooled proppant of 40 to 70 mesh is used Sieve through sieve classification to obtain a 40/70 mesh ceramsite proppant product based on spent FCC catalyst.

Tested according to Q/SH15000104-2016 and Q/SH31400072-2015 standards, the performance is as follows: bulk density is 1.50g/cm ³ , apparent density is 2.72g/cm ³ , roundness and sphericity are 0.91, turbidity is 31FTU, the product The crushing rate under 69MPa pressure is 5.5%.

Comparative example 1

23 tons of silica ore with a silica content of 92%, after double-roller crushing and jaw crushing, was put into a ball mill and ground to obtain 100-mesh silica ore powder for later use; 17 tons of silica ore with an alumina content of 25% and silica content The illite ore is 65% and the potassium oxide content is 9%. After double-roller crushing and jaw crushing, it is put into a ball mill and ground to obtain 200-mesh illite ore powder for later use; then take 60 tons of illite ore with an alumina content of 52%, The waste FCC catalyst with a silica content of 42% is mixed with silica powder and illite powder, ground to more than 600 mesh in a wet mill, air-dried with an air dryer, and granulated into balls by adding water. The obtained proppant green balls are then separately Use 65-mesh and 35-mesh sieves to obtain semi-finished products of 35 to 65 mesh. The semi-finished products are transported to the rotary kiln and kept at 1240°C for 2 hours. Then they enter the water-cooled kiln and are cooled to normal temperature. The cooled proppant of 40 to 70 mesh is used Sieve through sieve classification to obtain a 40/70 mesh ceramsite proppant product based on spent FCC catalyst.

Tested according to Q/SH15000104-2016 and Q/SH31400072-2015 standards, the performance is as follows: bulk density is 1.41g/cm ³ , apparent density is 2.53g/cm ³ , roundness and sphericity are 0.91, turbidity is 31FTU, the product The crushing rate under 69MPa pressure is 15.5%. Its breakage rate does not meet the standard requirements.

Comparative example 2

31 tons of silica ore with a silica content of 92%, after double-roller crushing and jaw crushing, is put into a ball mill and ground to obtain 100-mesh silica ore powder for later use; 35 tons of silica ore with an alumina content of 25% and silica content The illite ore is 65% and the potassium oxide content is 9%. After double-roller crushing and jaw crushing, it is put into a ball mill and ground to obtain 200-mesh illite ore powder for later use; then 34 tons of alumina content 52%, The waste FCC catalyst with a silica content of 42% is mixed with silica powder and illite powder, ground to more than 600 mesh in a wet mill, air-dried with an air dryer, and granulated into balls by adding water. The obtained proppant green balls are then separately Use 65-mesh and 35-mesh sieves to obtain semi-finished products of 35 to 65 mesh. The semi-finished products are transported to the rotary kiln and kept at 1240°C for 2 hours. Then they enter the water-cooled kiln and are cooled to normal temperature. The cooled proppant of 40 to 70 mesh is used Sieve through sieve classification to obtain a 40/70 mesh ceramsite proppant product based on spent FCC catalyst.

Tested according to Q/SH15000104-2016 and Q/SH31400072-2015 standards, the performance is as follows: bulk density is 1.39g/cm ³ , apparent density is 2.51g/cm ³ , roundness and sphericity are 0.92, turbidity is 43FTU, the product The crushing rate under 69MPa pressure is 19.5%. Its breakage rate does not meet the standard requirements.

The above are only preferred embodiments of the present invention. It should be noted that those skilled in the art can make several improvements and modifications without departing from the principles of the present invention. These improvements and modifications can also be made. should be regarded as the protection scope of the present invention.

Claims (10)

1. A ceramsite proppant based on waste FCC catalyst, prepared from raw materials containing the following mass percentages: Waste FCC catalyst 38~55%; Silica 20~31%; Illite 17~35%. 2. Ceramsite proppant based on spent FCC catalyst according to claim 1, characterized in that the content of Al ₂ O ₃ in the spent FCC catalyst is 45 to 52 wt%, and the content of SiO ₂ is 45 to 52 wt%. . 3. The ceramsite proppant based on waste FCC catalyst according to claim 1 or 2, characterized in that the content of K ₂ O in the illite is 6 to 10 wt%, and the content of Al ₂ O ₃ is 20 to 20 wt%. 35wt%, the content of _SiO2 is 45~65wt%. 4. The ceramsite proppant based on waste FCC catalyst according to claim 1 or 2, characterized in that the content of _SiO2 in the silica is ≥90wt%. 5. Ceramsite proppant based on spent FCC catalyst according to claim 1, characterized in that, The silica is block material or powder, and the particle size of the silica block material is ≤1cm; The particle size of the silica powder is 100-200 mesh; The particle size of the illite is 100-200 mesh. 6. The ceramsite proppant based on waste FCC catalyst according to claim 1, characterized in that the volume density of the ceramsite proppant is ≤ 1.52g/cm ³ , the apparent density is ≤ 2.75g/cm ³ , and the roundness is And sphericity ≥ 0.9, turbidity ≤ 50FTU, breakage rate ≤ 8% under 69MPa closing pressure. 7. The preparation method of ceramsite proppant based on spent FCC catalyst according to any one of claims 1 to 6, comprising the following steps: Mix the spent FCC catalyst, silica and illite, and grind them to obtain mixed powder; The mixed powder is sequentially dried, granulated and sieved to obtain ceramic green balls; The ceramsite green ball is sintered to obtain a ceramsite proppant based on the waste FCC catalyst. 8. The preparation method according to claim 7, characterized in that the particle size of the mixed powder is ≥600 mesh; the particle size of the ceramic green ball is 35-65 mesh. 9. The preparation method according to claim 7, characterized in that the sintering temperature is 1180-1250°C, and the holding time is 0.8-2h. 10. The ceramsite proppant based on the spent FCC catalyst described in any one of claims 1 to 6 or the ceramsite proppant based on the spent FCC catalyst prepared by the preparation method described in any one of claims 7 to 9 is used for fracturing in oil and gas fields. applications in.