Red Mud Fly Ash Proppant Production Process
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Solution Overview
Problem
Existing processes for producing proppants are costly and inefficient, using valuable raw materials and resulting products are not environmentally friendly or suitable for use as proppants due to high density and low strength.
Innovation Solution
A process involving the production of a mixture of red mud and fly ash with controlled moisture content, followed by granulation and sintering, which eliminates the need for additional energy-consuming drying steps and neutralization, producing a free-flowing sintered material with enhanced strength and environmental compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If red mud is used as a raw material for producing proppants, then production cost is reduced and environmental hazard is decreased, but the resulting ceramic materials have insufficient strength and density for proppant use
Solution Approach 1:
The patent combines red mud with fly ash to create a composite material system. This composite approach allows the incorporation of red mud (which reduces cost and environmental hazard) while fly ash contributes to enhancing the mechanical strength and density properties required for proppant application, thus resolving the contradiction between cost-effectiveness and structural performance
Solution Approach 2:
The patent systematically varies composition ratios, moisture content (7-30 wt.%), and sintering parameters to optimize the balance between using red mud for cost reduction and achieving sufficient proppant strength. By controlling these parameters, the process enables the use of red mud without compromising the mechanical requirements for proppant functionality
2Strength
If traditional proppant production processes are used, then proppant strength is achieved, but production cost increases and environmental friendliness decreases
Solution Approach 1:
The patent converts the environmental hazard of red mud (a hazardous waste product from aluminum production) into a beneficial raw material for proppant manufacturing. By incorporating red mud into the proppant formulation, the process simultaneously reduces environmental pollution and produces functional proppants, transforming a harmful waste stream into a valuable resource
Solution Approach 2:
Instead of discarding red mud as hazardous waste, the patent recovers and utilizes it as a feedstock for proppant production. This recovery approach eliminates the environmental hazard associated with red mud disposal while creating a useful product, thereby resolving the contradiction between environmental protection and proppant performance
3Productivity
If red mud with high moisture content is used, then additional drying steps are eliminated, but mixture quality control becomes more difficult
Solution Approach 1:
The patent defines a specific moisture content range (7-30 wt.%) for the red mud-fly ash mixture that enables direct granulation without prior drying. This parameter optimization allows the process to handle variable red mud moisture contents while maintaining consistent mixture quality and granulation performance, thus resolving the contradiction between process efficiency and quality control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process results in a cost-effective, environmentally friendly proppant with high strength and suitable properties for use in oil and gas production, while also providing a method for disposing of hazardous red mud.
Implementation Method 1
producing a granular product from the mixture
Implementation Method 2
sintering the granular product
Data Source
AI summary
The invention relates to a process for producing proppants, including the following steps: providing red mud, providing fly ash, producing a mixture from the red mud and the fly ash so that the mixture has a first moisture content in the range of 7 to 30 wt. %, producing a granular product from the mixture, and sintering the granular product.