Synthesis of Lightweight Aluminosilicate Proppants from Low-Grade Kaolinitic Clay And Industrial Waste

This study presents the synthesis of lightweight aluminosilicate ceramic proppants using Angren kaolinitic clay and ash–slag industrial waste as raw materials. The effects of composition and sintering temperature (1200–1250 °C) on phase composition and physicomechanical properties were investigated. The results show that increasing the sintering temperature enhances densification, promotes mullite formation, and improves mechanical strength and chemical stability. The optimal composition (CA-3) exhibited low bulk density (1.43 g/cm³), low crushing ratio (6.58%), and high acid resistance (5.56%). XRD analysis confirmed increased crystallinity and mullite development at higher temperatures. The developed proppants demonstrate competitive properties and offer a cost-effective and environmentally sustainable alternative to conventional materials.

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