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.

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Products

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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.

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Eco-friendly alternative to cenospheres

"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

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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

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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

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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

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5000

Gransphere

Advantages

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]

Controlled density and size

«Gransphere™» has a wide range of products made from various types of raw materials

25 / 600 100 / 150 200 / 75 500 / 30 1 500 / 10

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R&D

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

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Ecology and efficiency

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

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Electricity - sustainable development as a principle

Production

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Innovative process

  • Full-automated control of the process and product properties
  • Principally minimal energy consumption.

Innovative equipment

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.

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Gransphere application

Construction materials

  • Sealants and adhesives
  • Filler
  • Adhesives for tiles, putties, grouting
  • Floor grout
  • Bituminous materials
  • Light / insulating and fireproof plasters
  • Lightweight concrete
  • Heat and sound insulation panels
  • Dry masonry
  • Fiber cement boards
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Gransphere application

Plastics and composites

  • Pressure casting
  • Composite materials
  • Centrifugal molding
  • Wood plastic composite materials
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Gransphere application

Paints and coatings

  • Powder coatings
  • Construction paints
  • Heat reflective paints
  • Airless putty
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Gransphere application

Modeling and restoration

  • Putties
  • Materials for yachts and cars repair
  • Restoration materials
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Gransphere application

Construction materials
  • Sealants and adhesives
  • Filler
  • Adhesives for tiles, putties, grouting
  • Floor grout
  • Light / insulating and fireproof plasters
  • Lightweight concrete
  • Heat and sound insulation panels
  • Dry masonry
  • Fiber cement boards
  • Bituminous materials
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Plastics and composites
  • Pressure casting
  • Composite materials
  • Centrifugal molding
  • Wood plastic composite materials
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Paints and coatings
  • Powder coatings
  • Construction paints
  • Heat reflective paints
  • Airless putty
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Modeling and restoration
  • Putties
  • Materials for yachts and cars repair
  • Restoration materials
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Transition from cenospheres to Gransphere ceramospheres

“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™.

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«Gransphere™» in well cementing

«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. In 2020 more than 900 wells were cemented using «Gransphere™» -based grouting mixtures.

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Efficiency

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

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Wells construction

Strength / Density ratio

Field proof of strength

Wells construction

Field experience of «Gransphere» application

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

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Strength / Density ratio

Strength of the «Gransphere» casing

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.

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Field proof of strength

Strength of the «Gransphere» casing

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.

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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.