Frac Silica Sand Processing Line

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Frac Silica Sand Processing Line

Frac sand is an essential proppant for oil and gas extraction, processed from quartzite with high strength, good sphericity and low impurity content. It props rock fractures during fracturing operations to sustain flow conductivity, boost oil and gas recovery efficiency, and is suitable for fracturing reconstruction of deep and high-pressure oil & gas reservoirs.

Petroleum fracturing sand processing line that utilizes optimized sand-making and classification processes to ensure stable, large-scale continuous production. The complete set of equipment operates with high efficiency and stability, offering lower energy consumption and reduced operation and maintenance (O&M) costs. The resulting fracturing sand features uniform particles, high sphericity, clean surfaces, and strong compressive strength. It also boasts significant advantages such as low density, high conductivity, and stable performance, fully meeting the stringent operational standards required for high-pressure deep-well environments.

PROCESS DESCRIPTION

  • 01
    Crushing and Pre-screening
    Fracturing sand has specific compressive strength requirements for the raw ore, which is generally categorized into natural sand and manufactured sand. Natural sand is directly fed into the washing section after pre-screening. Manufactured sand (with a diameter of ≤400 mm) first undergoes coarse crushing by a jaw crusher, followed by fine crushing by a cone crusher, and finally shaping by a vertical shaft impact (VSI) crusher. This process produces particles with a diameter ranging from 0.125 to 0.85 mm, ensuring a sphericity of >0.8. Oversized particles (e.g., >20 mesh) are then screened by a vibrating screen and returned to the crushing system for reprocessing.
  • 02
    Washing
    A two-stage washing process is carried out using a screw sand washer and a dedicated fracturing sand scrubber. The turbidity is strictly controlled to ≤100 FTU to effectively remove clay and surface impurities.
  • 03
    Dewatering and Drying
    The qualified slurry undergoes preliminary dewatering via a dewatering screen. After being drained for a certain period, the material enters a rotary drum dryer to reduce the moisture content to ≤1%.
  • 04
    Screening and Classification
    Finally, a rectangular gyratory screen is used to precisely screen the dried material to obtain the target product with a particle size of 0.125–0.85 mm. This ensures that the finished sand achieves a sphericity of ≥0.9, fully meeting the quality standards for petroleum fracturing sand.

PROCESSING FLOW

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Quartz powder is non-toxic and pollution-free, possessing advantages such as high temperature resistance, acid and alkali resistance, high insulation, and chemical stability. As a high-end inorganic non-metallic raw material, it is widely used in electronics, integrated circuits, chemicals, plastics, high-end coatings, rubber, and many other industries.

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