Granula-SpecCement Group of Companies, being a developer and dominant producer of lightweight grouting materials using microspheres, has consistently invested in research and development of technologies for the production of microspheres from natural and environmentally friendly and affordable mineral raw materials since 2018 (the Gransphere project).
Gransphere OOO Company has studied and improved the existing solutions and developed its own technology for pre-preparation of the charge from the composition of perlite/natural volcanic glass and the technological process of its spheralization. All technological processes of our production are conducted under the management of the latest automated control system.
Innovative material Microspheres from "Gransphere" mineral raw materials - a lightweight filler that sets new standards
"Gransphere ™" is a synthesized product, the characteristics of which are controlled by the selection of the raw material composition and thermodynamic parameters of the fully automated spheralization process.
"Gransphere™", a new step in the development of lightweight fillers - hollow microspheres
Parameters
Actual Value
Bulk density
350…400 kg/m³
Apparent density
0,76…0,80 g/cm³
Particle size (D50)
120 micron
Operating pressure
3000 psi
3000
Gransphere
Parameters
Actual Value
Bulk density
380…420 kg/m³
Apparent density
0,78…0,82 g/cm³
Particle size (D50)
120 micron
Operating pressure
3500 psi
3500
Gransphere
Parameters
Actual Value
Bulk density
400…450 kg/m³
Apparent density
0,80 … 0.83 g/cm³
Particle size (D50)
100 micron
Operating pressure
4000 psi
4000
Gransphere
Parameters
Actual Value
Bulk density
420…450 kg/m³
Apparent density
0,83 … 0.85 g/cm³
Particle size (D50)
100 micron
Operating pressure
5000 psi
5000
Gransphere
Vitrified impermeable surface, closed porosity
High isostatic compressive strength
Spherical shape for perfect rheology
Pozzolanic activity and excellent adhesion to cement and surfaces
Zero water absorption, stable water demand
Uniformity and white color
Inertness, incombustibility and high melting point
Excellent insulating properties
Environmentally friendly technologies and raw materials
Particles size
d90 [µm] / d90 [US mesh]
«Gransphere™» has a wide range of products made from various types of raw materials
Basis of the dominant position of the group of companies is the research and development design institutes of mineral processing of AO “NIIproektasbest” and well construction technologies of
OOO “UralNIPIneft”, as well as specialized accredited laboratories
All this as a whole is the sum of competencies in the enrichment of mineral raw materials for the production of high-quality lightening and expanding mineral additives used in the development and production of backfill materials for difficult thermobaric conditions
Waste-free use of available natural mineral raw materials
Environmentally friendly technologies for its processing. Technological processes run on electricity
Energy transfer by IR radiation (no heat loss)
Complete absence of exhaust gases, lowest noise and dust levels
Electricity - sustainable development as a principle
Innovative process
Flameless Spheralization Technology
Controlled mode of IR heat treatment of particles with the formation of hollow microspheres with a given density and completely closed porosity, as a result, with zero water absorption.
Gransphere application
Construction materials
Gransphere application
Plastics and composites
Gransphere application
Paints and coatings
Gransphere application
Modeling and restoration
“Granula-SpecCement” Group of Companies has mastered production, and a large-scale transition in the design of lightweight cement mortars from cenospheres to “ransphere ™” ceramospheres is systematically carried out.
Based on our 20-year experience, formulations of lightweight grouting mixes based on «Gransphere™» have been developed and introduced into the field: PetroCEM Lite™, CTOS™.
«Gransphere™» has confirmed its manufacturability and interchangeability with respect to the cenosphere when cementing well casing strings in the fields in the Priobye,
Nadym-Pur-Tazovskoye oil and gas region, Yamalo-Nenets Autonomous Okrug and Eastern Siberia. Since 2020 more than 2 700 wells have been cemented using «Gransphere™»-based grouting mixtures.
The pozzolanic activity of «Gransphere™» allows particles to more effectively integrate into the cement stone matrix during hardening, providing excellent adhesion to cement and surfaces
The abrasive effect contributes to cleaning the wellbore during flushing and pumping
The acoustic properties of «Gransphere™», as an ultrasound conductor, contribute to an increase in the rate of passage of the ACBL signal compared to the cenosphere, all other things being equal
Wells construction
Strength / Density ratio
Field proof of strength
Wells construction
Indicators of the quality of production strings cementing with ЦТОС-4-100 grouting mixture (1,400 kg/m3).
Excerpts of acoustic cementometry data from 100 production wells of the Priobye fields.
2 500 meters
Column vertical lowering depth
60°C – 70°C
Bottom hole dynamic temperature
Strength / Density ratio
Density growth under pressure.
The true density of «Gransphere™» is similar to the density of cenospheres and, depending on the brand, is regulated in the range from 0.75 to 0.95 SG (g/cm³).
< 2000 psi
Significantly surpasses cenosphere in strength
2000 – 2500 psi
Ceramosphere and cenosphere have similar indicators for the growth of cement slurry density
> 3000 psi
Values of these additives are very close, and taking into account the economic advantages of «Gransphere™», they can be easily adjusted by the recipe.
Field proof of strength
Ratio of the densities of the grouting slurry during mixing and after squeezing at the wellhead.
The laboratory test data reliably agree with the results of numerous field studies on measuring the densities of the cement slurry at the moment of mixing and after exiting the annular space at the wellhead.
The parameters of the production casing running depth, temperature and pressure conditions of cementing and the applied formulations are similar to those on the “Wells Construction” tab.
The increase in the density of the cement slurry after passing through the bottomhole was no more than 2-3%, which is also typical for most compositions on ash microspheres.
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