Degradable Downhole Tool Components Using Hydrolysable Materials
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Solution Overview
Problem
Current methods for removing downhole tools or components in oil and natural gas exploration require time-consuming and expensive milling or drilling operations, necessitating the development of degradable/dissolvable materials with improved mechanical strength and degradability in aqueous environments.
Innovation Solution
The use of inorganic hydrolysable compound-containing materials, such as aluminum carbide, calcium carbide, and magnesium nitride, which degrade or dissolve in aqueous environments, allowing for the design of downhole tools with components that lose integrity after completing their functions, thereby eliminating the need for milling or drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional milling or drilling operations are used to remove downhole tools, then complete removal is achieved, but the process is time-consuming and expensive
Solution Approach 1:
The patent changes the material parameters of downhole tool components from conventional non-degradable materials (steel, aluminum) to degradable materials (magnesium alloys, zinc alloys, calcium alloys, or their composites). This parameter change enables the components to naturally degrade through corrosion and oxidation in the downhole environment, eliminating the need for mechanical removal operations and significantly reducing removal time and cost
Solution Approach 2:
The patent applies the disposable principle by designing downhole tool components that are intentionally made from degradable materials with limited service lives. These components (such as mandrels, housings, or structural elements) are designed to degrade after completing their functional purpose, transforming from permanent components to temporary, disposable elements that eliminate complex removal operations
2Ease of manufacture
If degradable/dissolvable materials are used for downhole tool components, then removal operation is eliminated, but mechanical strength may be compromised
Solution Approach 1:
The patent employs composite materials combining degradable metals (magnesium, zinc, calcium alloys) with reinforcing elements or matrix materials to achieve both degradability and sufficient mechanical strength. The composite structure allows the material to maintain integrity during service while enabling controlled degradation after use, resolving the contradiction between ease of removal and mechanical strength
Solution Approach 2:
The patent modifies material parameters by selecting specific degradable alloys and controlling their composition, microstructure, and physical properties. Through parameter optimization (alloy composition, heat treatment, microstructural control), the materials achieve the necessary balance between mechanical strength for service operation and degradability for easy removal
3Ease of manufacture
If degradable materials are used to eliminate milling operations, then disposal cost is reduced, but control over degradation timing and rate must be managed
Solution Approach 1:
The patent controls degradation timing and rate by adjusting material parameters such as alloy composition, thickness, surface coating, and environmental exposure conditions. These parameter changes enable predictable degradation behavior that can be tailored to match the operational lifecycle of the downhole tool, simplifying disposal control while maintaining ease of removal
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 approach enables efficient and cost-effective removal of downhole tools by utilizing materials that degrade in wellbores, enhancing operational efficiency and reducing disposal costs in oil and gas exploration and production.
Implementation Method 1
at least one component comprised of an inorganic hydrolysable compound-containing material. The component comprised of the inorganic hydrolysable compound-containing material is degradable/dissolvable, and it is designed for limited service lives. The component comprised of the inorganic hydrolysable compound-containing material degrades/dissolves substantially in aqueous environment such as fresh water, water-containing solution, or moist air within a wellbore
Data Source
AI summary
A component of a downhole tool utilized in oil and natural gas exploration and production comprises inorganic hydrolysable compound-containing materials. The inorganic hydrolysable compounds grant the component the degradability/dissolution in aqueous environment. The inorganic hydrolysable compounds include, but not are limited to, hydrolysable carbides, nitrides, and sulfides, such as aluminum carbide (Al4C3), calcium carbide (CaC2), magnesium carbide (Mg2C3 or MgCl2), manganese carbide (Mn3C), aluminum nitride (AlN), calcium nitride (Ca3N2), magnesium nitride (Mg3N2), aluminum sulfide (Al2S3), aluminum magnesium carbide (Al2MgCl2), and aluminum zinc carbide (Al4Zn2C3).