Autonomous Inflow Control Device Using Wettability-Operable Fluid Selector
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Solution Overview
Problem
Wellbore systems face challenges in controlling fluid flows where viscosity differences between desired and undesired fluids are very small, making it difficult to effectively manage fluid production, especially in regions like the Arabian Peninsula where viscosity differences are less than 1 centipoise, leading to sensitivity to manufacturing tolerances and inefficient flow control.
Innovation Solution
The implementation of surface energy dependent flow resistors within autonomous inflow control devices that utilize support structures with hydrophobic and hydrophilic materials to maximize surface area exposure, allowing for differential resistance based on fluid composition, enabling efficient control of fluid flows by varying resistance paths through the use of vortex chambers and control passageways.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If viscosity dependent flow resistors are used to control fluid flows, then flow control is achieved, but the system becomes sensitive to manufacturing tolerances and ineffective when viscosity differences are very small (less than 1 centipoise)
Solution Approach 1:
The patent changes the controlling parameter from viscosity dependence to surface energy dependence. The flow resistors are made of materials whose surface energy properties (hydrophobicity/hydrophilicity) differ significantly between desired and undesired fluids, allowing effective flow control even when viscosity differences are minimal. This parameter change eliminates sensitivity to manufacturing tolerances while maintaining productivity.
Solution Approach 2:
The patent uses composite materials with specific surface energy characteristics in the flow resistors. These materials are designed to selectively interact with different fluid compositions based on surface energy principles, enabling the system to distinguish between desired and undesired fluids without relying on small viscosity differences, thereby reducing manufacturing precision requirements.
2Productivity
If surface area of flow resistors is increased to maximize surface energy effects, then flow control based on wettability improves, but device complexity increases
Solution Approach 1:
The patent employs porous materials for the flow resistors, which inherently provide large surface area within a compact structure. The porous architecture maximizes the surface area available for wettability-based flow control without requiring complex external support structures, thus improving flow control effectiveness while minimizing device complexity.
Solution Approach 2:
The patent transitions from considering only the one-dimensional flow path to utilizing the three-dimensional surface area of the flow resistor materials. By maximizing surface area in multiple dimensions through porous structures and extended geometries, the system enhances surface energy effects without proportionally increasing overall device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively controls fluid flows by providing less resistance to desired fluids and more resistance to undesired fluids, even when viscosity differences are minimal, enhancing the productivity of wellbore systems by optimizing fluid composition and reducing sensitivity to manufacturing tolerances.
Implementation Method 1
the flow of a fluid composition between the inlet and the outlet is permitted or restricted based on the wettability of the support structure by the fluid composition
Implementation Method 2
support structures with hydrophobic and hydrophilic materials to maximize surface area exposure
Implementation Method 3
support structures with hydrophobic and hydrophilic materials to maximize surface area exposure
Implementation Method 4
enabling efficient control of fluid flows by varying resistance paths through the use of vortex chambers and control passageways
Data Source
AI summary
Flow control systems are described for variably resisting flow of a fluid composition dependent on the surface energy of the fluid composition. Surface energy is a measure of the wettability of a surface with a particular the fluid. Surface energy dependent flow resistors of the present disclosure include a support structure extending across and/or filling a control passageway such that the surface area exposed to a fluid may be maximized. The flow control systems described may autonomously distinguish between fluid compositions having high and low proportions of a desired fluid component even when the fluid compositions have substantially equal viscosities. Flow control valves are described which may be employed in downhole production and injection equipment.