Effects of sintering temperature on microstructure and properties of low-grade bauxite-based ceramic proppant

Low density and high strength ceramic proppant was prepared by sintering high aluminium type low-grade bauxite and high iron type low-grade bauxite at the temperature range from 1300℃ to 1360℃. The phase composition and micromorphology of ceramic proppant were, respectively, characterized by X-ray diffraction (XRD) and scanning electron microscope (SEM). The bulk density, apparent density, and breakage ratio of ceramic proppant were tested using standard methods. The results show that mullite crystal and corundum crystal are fully developed, the spatial network structure of rod-shaped mullite is formed, and corundum crystal is evenly distributed in the sample when the sintering temperature is 1340℃. At this temperature, the bulk density of the sample is 1.42 g/cm³, the apparent density is 2.67 g/cm³, and the breakage ratio is 5.1% under the closure pressure of 52 MPa. Then, the growth mechanism of mullite crystal in ceramic proppant was explored. The results reveal that the mullite crystal in ceramic proppant conforms to the layer growth theory. The secondary crystal nucleus is formed in the growth process and shows a step growth mechanism. With the increase in sintering temperature, the preferred orientation growth of mullite crystal finally forms needle-like morphology.