Proppant particles formed from slurry droplets and method of use

Abstract

Proppant particles formed from slurry droplets and methods of use are disclosed herein. The proppant particles can include a sintered ceramic material and can have a size of about 80 mesh to about 10 mesh and an average largest pore size of less than about 20 microns. The methods of use can include injecting a hydraulic fluid into a subterranean formation at a rate and pressure sufficient to open a fracture therein and injecting a fluid containing a proppant particle into the fracture, the proppant particle including a sintered ceramic material, a size of about 80 mesh to about 10 mesh, and an average largest pore size of less than about 20 microns.

What is claimed is: 
     
         1 . A proppant particle, comprising:
 a sintered ceramic material and having:
 a size of about 80 mesh to about 10 mesh; 
 a porosity; and 
 an average surface roughness of from about 0.1 micron to about 4 microns. 
   
     
     
         2 . The proppant particle of  claim 1 , wherein the sintered ceramic material has an alumina concentration of at least about 40 wt %. 
     
     
         3 . The proppant particle of  claim 2 , wherein the sintered ceramic material has an alumina concentration of at least about 95 wt %. 
     
     
         4 . The proppant particle of  claim 1 , further comprising a plurality of proppant particles comprising a sintered ceramic material and having a size of about 80 mesh to about 10 mesh, a porosity, and an average surface roughness of from about 0.1 micron to about 4 microns, wherein the plurality of the proppant particles has a bulk density of about 1.35 g/cc to about 2.1 g/cc. 
     
     
         5 . The proppant particle of  claim 4 , wherein the proppant particles have a specific gravity of about 2.5 g/cc to about 4.0 g/cc. 
     
     
         6 . The proppant particle of  claim 1 , wherein the proppant particle has a surface roughness of less than about 2 microns. 
     
     
         7 . A ceramic particle for use in a subterranean formation, the ceramic particle comprising:
 a sintered ceramic material;   a size of about 80 mesh to about 10 mesh;   a porosity; and   a surface roughness of less than about 2 microns.   
     
     
         8 . The ceramic particle of  claim 7 , wherein the sintered ceramic material has an alumina concentration of at least about 40 wt %. 
     
     
         9 . The ceramic particle of  claim 8 , wherein the sintered ceramic material has an alumina concentration of at least about 95 wt %. 
     
     
         10 . The ceramic particle of  claim 7 , wherein the porosity is an interconnected porosity of at least about 25%. 
     
     
         11 . The ceramic particle of  claim 7 , further comprising a plurality of proppant particles comprising a sintered ceramic material and having a size of about 80 mesh to about 10 mesh, a porosity, and an average surface roughness of less than about 2 microns, wherein a plurality of the proppant particle has a bulk density of about 1.35 g/cc to about 2.1 g/cc. 
     
     
         12 . The ceramic particle of  claim 11 , wherein the proppant particle has a specific gravity of about 2.5 g/cc to about 4.0 g/cc. 
     
     
         13 . The ceramic particle of  claim 7 , wherein the proppant particle has a surface roughness of from about 0.1 microns to about 2 microns. 
     
     
         14 . A proppant particle, comprising:
 a sintered ceramic material;   a porosity; and   a surface roughness of 4 microns or less.   
     
     
         15 . The proppant particle of  claim 14 , wherein the sintered ceramic material has an alumina concentration of at least about 40 wt %. 
     
     
         16 . The proppant particle of  claim 15 , wherein the sintered ceramic material has an alumina concentration of at least about 95 wt %. 
     
     
         17 . The proppant particle of  claim 14 , wherein the porosity is an interconnected porosity of at least about 25%. 
     
     
         18 . The proppant particle of  claim 14 , wherein a plurality of the proppant particle has a bulk density of about 1.35 g/cc to about 2.1 g/cc. 
     
     
         19 . The proppant particle of  claim 18 , wherein the proppant particle has a specific gravity of about 2.5 g/cc to about 4.0 g/cc. 
     
     
         20 . The proppant particle of  claim 14 , wherein the proppant particle has a surface roughness of from about 0.8 microns to about 1.6 microns.