Degradable Composite Diverter Seals for High-Pressure Well Applications
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Solution Overview
Problem
Current degradable perforation balls and diverter systems have limited temperature ranges, leading to softening and shape changes, which compromises their ability to hold pressure and may result in incomplete degradation, causing fluid flow issues in wells.
Innovation Solution
A degradable thermoplastic elastomer or degradable metallic composite ball with a controlled crush strength or plastically-deformable matrix, optionally incorporating high aspect metallic flakes or microballoons, designed to conform to well openings and resist further deformation to form a seal, while being removable through fluid-induced degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If degradable perforation balls are used to seal well openings, then they can be removed through degradation without intervention tools, but they have limited temperature ranges causing softening and shape changes that compromise pressure holding ability
Solution Approach 1:
The patent employs composite materials consisting of a degradable matrix (such as polylactic acid, polyglycolic acid, or their copolymers) combined with reinforcing elements like metal shavings, ceramic particles, or fibrous materials. This composite structure enables the ball to maintain structural integrity and pressure holding capability at elevated temperatures while retaining degradability through fluid exposure, thereby resolving the contradiction between ease of removal and reliability under thermal stress
Solution Approach 2:
The patent modifies the physical and chemical parameters of the degradable ball by adjusting the molecular weight, crystallinity, and cross-linking density of the polymer matrix, as well as the composition and distribution of reinforcing materials. These parameter changes enable the ball to withstand higher temperatures without softening or deforming, while maintaining its ability to degrade completely after serving its sealing function
2Ease of operation
If degradable materials are used to seal openings, then they can be removed by degradation and flowback without coiled tubing or intervention tools, but they may soften and change shape compromising their ability to hold pressure
Solution Approach 1:
The patent utilizes composite materials where a degradable polymer matrix is reinforced with temperature-stable materials such as metal shavings (aluminum, iron, stainless steel), ceramic particles, or synthetic fibers. This composite construction provides shape stability and structural integrity at operating temperatures while preserving the degradability of the matrix, enabling easy removal through flowback without intervention tools
Solution Approach 2:
The patent applies different material properties to different parts of the sealing ball. The outer shell or surface may contain higher concentrations of reinforcing materials to maintain shape stability, while the inner matrix remains highly degradable for complete removal. This local differentiation of material quality allows the ball to simultaneously achieve shape stability during operation and ease of removal afterward
3Strength
If degradable thermoplastic elastomer or metallic composite ball is used to conform to well openings and form seals, then it can withstand high pressure differentials, but it requires controlled crush strength and deformability to maintain seal integrity
Solution Approach 1:
The patent designs the sealing ball with dynamic mechanical properties that allow it to deform under installation pressure to conform to the well opening geometry, then resist further deformation under operating pressure differentials. The controlled crush strength and deformability are achieved through the composite structure, where the degradable matrix provides flexibility during deformation while the reinforcing materials prevent excessive deformation and maintain seal integrity under pressure
Solution Approach 2:
The patent carefully controls the mechanical parameters of the composite ball, including the crush strength, elastic modulus, and yield strength, by adjusting the composition, size, and distribution of reinforcing materials within the degradable matrix. These parameter optimizations enable the ball to exhibit appropriate deformability during installation while maintaining sufficient strength to withstand high pressure differentials during operation
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 solution provides a temporary sealing mechanism that can withstand high pressure differentials and maintain seals for extended periods without being pushed through the opening, while ensuring complete removal and minimal debris, thus preventing fluid flow issues.
Implementation Method 1
A degradable thermoplastic elastomer or degradable metallic composite ball with a controlled crush strength or plastically-deformable matrix... designed to conform to well openings and resist further deformation to form a seal
Implementation Method 2
A degradable thermoplastic elastomer or degradable metallic composite ball with a controlled crush strength or plastically-deformable matrix... designed to conform to well openings and resist further deformation to form a seal
Implementation Method 3
The solution provides a temporary sealing mechanism... while ensuring complete removal and minimal debris, thus preventing fluid flow issues
Implementation Method 4
removable through fluid-induced degradation
Data Source
AI summary
A variable stiffness engineered degradable ball or seal having a degradable phase and a stiffener material. The variable stiffness engineered degradable ball or seal can optionally be in the form of a degradable diverter ball or scaling element which can be made neutrally buoyant.