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Ceramsite-Based Graphite Composite Thermally Conductive Proppant: Preparation, Characterization, and Performance

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A new graphite composite proppant enhances coalbed methane recovery by improving thermal conductivity and performance in low-permeability reservoirs. This novel material offers better stimulation and durability for unconventional oil and gas extraction.

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Area of Science:

  • Materials Science
  • Petroleum Engineering
  • Chemical Engineering

Background:

  • Coalbed methane (CBM) reservoirs face challenges due to low permeability and poor methane desorption, limiting recovery efficiency.
  • Effective proppants are crucial for hydraulic fracturing in unconventional reservoirs to maintain fracture conductivity and enhance production.

Purpose of the Study:

  • To develop and characterize a novel graphite composite thermally conductive proppant for improved CBM recovery.
  • To investigate the influence of graphite content and resin dosage on proppant properties.

Main Methods:

  • Fabrication of a composite proppant using ceramsite, epoxy resin, and graphite.
  • Systematic evaluation of structural, thermal, suspension, wettability, and adhesion properties.
  • Microscopic analysis to confirm interfacial structure and thermal conductive network.

Main Results:

  • Optimized proppant (20 wt% graphite, 1.0 g epoxy resin) exhibited 6.3x higher thermal conductivity (3.8 W/(m·K)).
  • Achieved good suspension stability (0.53 suspension ratio), hydrophobic surface (74.9° contact angle), and strong interfacial adhesion (125 nN).
  • Microscopy confirmed a continuous "resin-graphite-ceramsite" interface and a percolative thermal conductive network.

Conclusions:

  • The developed graphite composite proppant demonstrates superior thermal conductivity and mechanical performance.
  • This proppant shows significant potential for enhancing hydraulic fracturing in unconventional oil and gas reservoirs, particularly CBM.
  • Provides a viable design strategy for advanced thermally conductive proppants.