Compressible Carbonaceous Particulate Material for Annular Pressure Mitigation
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Solution Overview
Problem
Current materials used to mitigate annular pressure build-up (APB) in oil and gas wells lack repeatable and efficient reversible volumetric contraction and expansion characteristics when subjected to high pressures, which can lead to unsafe conditions.
Innovation Solution
A compressible carbonaceous particulate material with fine closed porosity, characterized by reversible volumetric expansion/contraction of ≥3% between 4,000 psi and 10,000 psi, is developed through heat treatment of petroleum coke, maintaining integrity and compressibility even when milled to finer sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resilient or elastic particles are introduced into the annulus to mitigate APB, then the available volume of the annulus increases and pressure decreases, but the materials lack repeatable and efficient reversible volumetric contraction and expansion characteristics when subjected to high pressures
Solution Approach 1:
The patent employs porous carbonaceous particles with controlled pore structures that enable repeatable volumetric contraction and expansion. The porous structure allows the particles to compress under high pressure, increasing annular volume and mitigating pressure build-up, then rebound when pressure decreases, providing reliable cyclic performance.
Solution Approach 2:
The patent modifies physical parameters of carbonaceous particles including pore size distribution, particle density, and compressibility characteristics. These parameter changes enable the particles to exhibit consistent reversible volumetric changes (contraction of 3-30% and expansion of 3-30%) when subjected to pressures between 2,000-10,000 psi, ensuring repeatable APB mitigation.
2Ease of operation
If carbonaceous material is milled to finer particle sizes, then the material can be better integrated into fluid media, but the true density and compressibility characteristics may be affected
Solution Approach 1:
The patent applies different quality characteristics to different aspects of the particle structure. The external surface and overall particle morphology are optimized for fluid media integration, while the internal porous structure maintains consistent compressibility and rebound characteristics regardless of particle size. This local quality differentiation allows fine particles to be easily dispersed while retaining reliable mechanical properties.
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
The material effectively mitigates APB by maintaining high compressibility and rebound capability, suitable for use in drilling fluids and cement slurries, ensuring safer well operations and reduced pressure risks.
Implementation Method 1
a compressible carbonaceous particulate material is provided that has highly repeatable contraction and expansion characteristics when subjected to extremely high pressures
Implementation Method 2
the material reversibly expands and contracts by about 20% when subjected to pressures of up to 10,000 psi
Implementation Method 3
This is believed to be due to the abundant fine closed porosity within the resilient structure of the particulate material
Data Source
Figure 1A~2B
Figure 3a
Figure 3b
AI summary
A carbonaceous particulate material is provided that is characterized by having a reversible volumetric expansion/contraction in fluid media ("VR") of greater than or equal to (≥) 3% between 4,000 psi and 10,000 psi. The porous carbonaceous particulate material of the present disclosure is also characterized by having a true density, ("PT"), of 1.2 g/cc ≤PT≤ 2.0 g/cc, when milled to -200 mesh and has a d50 particle size distribution of about 15 μm. This is the consequence of the instant material exhibiting a high level of closed porosity with very small pores, in contrast with prior art materials that would have a wider range pore sizes for the closed pores.