The Benefits of Using sourcing ceramic proppant factories

While the oil and natural gas industry has had its ups and downs, many speculate it is again poised for growth due to the current political climate. Subsequently, there is a renewed interest around proppants &#; the hard microspheres injected into well bores to &#;prop open&#; rock fissures allowing natural gas and oil to flow out. According to the Fredonia Group, North American proppant demand looks set to grow at an annual rate of 7.6% through .

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Frac sand, or silica sand, a naturally made, abundant quartz sand, is the most commonly used proppant due to its low cost and high availability. However, while frac sand offers an economic solution in most cases, some settings require a bit more ingenuity on behalf of the proppant.

Ceramic proppants &#; a man-made proppant, offer a tailored solution in more demanding drilling settings.

Benefits of Ceramic Proppants

While ceramic proppants cost more than their naturally-made counterparts, they do offer  advantages that make them the preferred choice in some settings, because they are capable of maximizing the yield from a given well. These advantages include:

Greater Crush Strength

As well bores get deeper, the pressure on proppants gets higher, and frac sand is not always up to the task.

Ceramic proppants can withstand a much greater crush strength than traditional frac sand products &#; up to 10,000 psi.¹ This allows drillers to access much deeper shale formations.

Higher Conductivity

Ceramic proppants also boast a number of characteristics that translate to better conductivity, or the effectiveness at which the petroleum product can flow around the proppants in the rock fissure.

Improved uniformity in size, shape, and overall sphericity allows natural gas or oil to more easily flow around ceramic proppants in the well bore.

Conductivity is further improved due to the stable thermal and chemical nature of ceramic proppants; there is much less risk for the proppant to thermally or chemically react with the shale formation causing an undesirable deposit to form, which would ultimately clog the fissure.¹

Tailored Solutions

Because they are manmade, the characteristics of ceramic proppants can be much more tightly controlled than with sand products. Proppants can be selected based on a variety of engineered characteristics to offer a more tailored solution to the specific needs of a well site.

Within the category of ceramic proppants, proppants are also available in three sub-categories, with higher density proppants able to withstand greater stress:

• Lightweight Ceramic
• Intermediate Density Ceramic
• High Density Ceramic

Ceramic Proppant Production

Ceramic proppants can be made from a variety of materials. While most are made from bauxite, kaolin (aka China Clay), or a blend of the two materials, a variety of other materials may be used, including magnesium silicate and fly ash. Various additives may also be included.

The manufacturing process of ceramic proppants can differ, but in general, proppants follow the process described below.

Crushing

Raw materials are crushed into powder form. Materials and additives may be mixed in to develop specialized formulations in order to maximize performance of the end product.

Pelletizing

The powdered raw material is then pelletized to create a uniform, round pellet/granule product. Proppant sizing is a critical factor in the performance of a proppant at a given well and as such, producers often provide a wide offering of mesh sizes. Proppants are typically between 8 and 140 mesh and it is not uncommon to use multiple sizes at a given well.¹

Drying

Once agglomerated, pellets are dried to reduce the moisture content of the material. This is typically carried out in a rotary dryer or other type of industrial drying system. Pellets are classified via screening.

Sintering

Perhaps the most important step in the process, on-size pellets are sintered in a rotary kiln to &#;cure&#; the pellets. This high temperature sintering, which occurs at around &#; º F, causes chemical and crystalline changes in the material, causing it to harden further, ultimately imparting the crush strength that will be required for high pressure drilling applications.

Cooling

The hot material exits the kiln and is fed to a rotary cooler. The cooler cools the hot product so it can move on to storage or transport.

Ceramic Proppant Development

When working with ceramic proppants, feasibility testing and process development are often an integral part of developing specialized proppants. Source materials are often tested first at batch scale to confirm feasibility, then at continuous pilot scale in rotary kilns designed to simulate production conditions, depending on the capabilities of the testing facility.

Testing not only confirms feasibility of the intended process with the unique source material, but it also provides the data necessary, such as time and temperature profiles, for process scale-up and the design of a commercial scale unit.

Conclusion

While ceramic proppants make up a small portion of the overall proppant market compared to frac sand, they are still a valuable tool in high stress settings. Their thermal and chemical stability, combined with a more uniform shape and size, and their high conductivity, make them a worthwhile alternative for more specialized applications.

FEECO provides feasibility testing and process development around the manufacture of ceramic proppants. In addition to our testing services, we engineer and manufacture custom rotary kilns to meet your proppant sintering needs, as well as rotary dryers and coolers for the proppant production process. For more information, contact us today!

1.F. Liang et al. A Comprehensive Review on Proppant Technologies. Petroleum 2 () 26 &#; 39. Web. Feb. .

Ceramic Proppant Market Analysis and Latest Trends

Ceramic proppant is a type of proppant used in hydraulic fracturing to keep fractures open and enable the flow of hydrocarbons out of the well. It is made from ceramic materials such as alumina, silica, and bauxite, which offer high crush resistance and conductivity compared to alternative proppants like sand. The increasing demand for oil and gas across the globe is driving the growth of the ceramic proppant market.

Contact us to discuss your requirements of sourcing ceramic proppant factories. Our experienced sales team can help you identify the options that best suit your needs.

The Ceramic Proppant Market is expected to grow at a CAGR of % during the forecast period. This growth can be attributed to the rising shale gas exploration activities, especially in regions like North America and the Middle East. The market is also witnessing a shift towards high-performance proppants to enhance well productivity and efficiency. Additionally, technological advancements in proppant manufacturing processes are further fueling market growth.

Some of the latest trends in the Ceramic Proppant Market include increasing investments in research and development to improve proppant properties, growing focus on sustainable and environmentally-friendly proppant solutions, and strategic partnerships and collaborations among key players to expand their product portfolios and market reach. Overall, the ceramic proppant market is expected to continue its growth trajectory in the coming years.

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Ceramic Proppant Major Market Players

The ceramic proppant market is highly competitive with key players such as Fores, Badger Mining, Carbo Ceramics, Imerys, and Momentive dominating the market. These companies have a strong presence in the industry and offer a wide range of products to cater to the growing demand for ceramic proppants in the oil and gas sector.

Carbo Ceramics, one of the leading players in the ceramic proppant market, has witnessed significant market growth in recent years. The company has been investing in research and development to develop innovative products to meet the evolving needs of the industry. Carbo Ceramics reported sales revenue of approximately $500 million in the previous fiscal year and is expected to maintain its growth trajectory in the coming years.

Imerys, another key player in the market, has also been experiencing steady market growth due to its extensive product portfolio and strong distribution network. The company reported sales revenue of around $ billion in the previous fiscal year, indicating its strong position in the ceramic proppant market.

Momentive, a global leader in specialty chemicals and materials, has also been expanding its presence in the ceramic proppant market. The company offers a wide range of high-quality proppants that are used in hydraulic fracturing operations. Momentive reported sales revenue of approximately $2 billion in the previous fiscal year and is poised for further growth in the market.

Overall, the ceramic proppant market is expected to grow significantly in the coming years due to the increasing demand for proppants in the oil and gas industry. Key players such as Carbo Ceramics, Imerys, and Momentive are well-positioned to capitalize on this growth and further expand their market presence.

 

What Are The Key Opportunities For Ceramic Proppant Manufacturers?

The global ceramic proppant market is witnessing steady growth due to the increasing demand for proppants in hydraulic fracturing operations. The market is expected to witness a CAGR of around 7% during the forecast period, driven by the rapid expansion of the oil and gas industry and the growing investments in unconventional oil and gas exploration. The market is also benefiting from the increasing focus on efficient and environmentally friendly fracturing techniques. With the rising demand for oil and gas, the ceramic proppant market is poised for significant growth in the coming years.

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Market Segmentation

The Ceramic Proppant Market Analysis by types is segmented into:

• Ultra-Low density ceramic proppants
• Medium density ceramic proppants
• High density ceramic proppants

Ceramic proppants are categorized into three types based on their density levels - ultra-low, medium, and high. Ultra-low density ceramic proppants are designed to provide better fracture conductivity in low-pressure reservoirs. Medium density ceramic proppants are versatile and suitable for a wide range of reservoir conditions. High density ceramic proppants are used in high-pressure reservoirs to provide long-term conductivity. Each type of ceramic proppant offers unique properties and benefits for enhancing the performance of hydraulic fracturing operations in oil and gas production.

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The Ceramic Proppant Market Industry Research by Application is segmented into:

• Oil and gas sector
• Construction
• Chemicals
• Others

Ceramic proppants are widely used in the oil and gas sector as a crucial component in hydraulic fracturing operations to enhance production and extraction of oil and gas reserves. In the construction industry, ceramic proppants are utilized in the manufacturing of high-strength and lightweight concrete structures. Furthermore, they find applications in the chemicals industry for catalyst production and water filtration systems. They are also used in various other markets such as agriculture and automotive for diverse applications.

In terms of Region, the Ceramic Proppant Market Players available by Region are:

• North America: United States Canada
• Europe: Germany France U.K. Italy Russia
• Asia-Pacific: China Japan South Korea India Australia China Taiwan Indonesia Thailand Malaysia
• Latin America: Mexico Brazil Argentina Korea Colombia
• Middle East & Africa: Turkey Saudi Arabia UAE Korea

The ceramic proppant market is expected to witness significant growth across key regions such as North America, Asia Pacific, Europe, USA, and China. Among these regions, North America is anticipated to dominate the market with a market share of approximately 40%, followed by Asia Pacific with 30%, Europe with 20%, USA with 5%, and China with 5%. This growth can be attributed to increasing shale gas exploration activities and advancements in hydraulic fracturing technologies driving the demand for ceramic proppants.

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