Influence of Sintering Temperature on the Microstructure and Property of Low-cost Ceramic Proppants Prepared by Adding Purple Sands

Abstract

High-strength corundum-mullite based ceramic proppants have been fabricated from 2nd bauxite (62.3wt%Al2O3) and purple sands, which were used as main raw materials by solid sintering method, combined with the additive of feldspar and pyrolusite powder. The phase analysis was studied by X-ray diffraction (XRD) and the morphology of specimen was observed by the scanning electron microscopy (SEM). The result showed that the additive of feldspar was beneficial to the formation of internal liquid phase of sample with the sintering temperature increasing, which reduced the pores and promoted the densification of sample. Meanwhile the proper liquid phase resulted in the growth of mullite and promoted the close integration of mullite and corundum, forming the network structure of needle-like mullite. Ultimately the proppants exhibited the optimal performance at 1450 °C with bulk density of 1.59 g/cm3, apparent density of 3.11 g/cm3 and the lowest breakage ratio of 3.76% under 52 MPa pressure.