Dissolvable Borate Fracturing Balls With Controlled Strength and Dissolve Rate
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Solution Overview
Problem
Existing selective fracturing tools in downhole applications require manual retrieval of balls or parts post-fracturing operations, which is costly and cumbersome, necessitating a more efficient and dissolvable solution.
Innovation Solution
A method of forming dissolvable borate parts by mixing boron and alkali compounds, heating to remove water, molding, and cooling at controlled rates to create anhydrous boron compounds with adjustable dissolve rates and mechanical strength, suitable for downhole environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual retrieval methods (drilling, backpressure suction) are used to remove balls after fracturing, then the balls can be removed from downhole, but the process is costly and cumbersome
Solution Approach 1:
The patent applies the disposable principle by designing fracturing balls made of dissolvable glass composition that automatically dissolve after completing their fracturing function. The balls are intended to be temporary devices that degrade and disappear after use, eliminating the need for complex retrieval operations. The glass composition dissolves in downhole conditions, leaving no solid material to recover, thereby simplifying operations and reducing time loss.
2Ease of operation
If dissolvable glass composition is used to make fracturing balls, then manual retrieval is eliminated, but the balls must maintain mechanical strength to withstand downhole pressures during operation
Solution Approach 1:
The patent applies parameter changes by carefully controlling the chemical composition parameters of the glass (specific ratios of oxides like SiO2, B2O3, Al2O3, and alkali metals) and processing parameters (melting temperature, cooling rate) to achieve the desired balance between strength and dissolvability. By adjusting these parameters, the glass balls gain sufficient mechanical strength for fracturing operations while maintaining the ability to dissolve after use.
Solution Approach 2:
The patent applies composite materials by creating a complex glass composition that combines multiple oxide components with specific functional properties. The composite glass structure integrates network formers (SiO2, B2O3) for strength with modifiers (alkali oxides) that control dissolvability, achieving a material that simultaneously provides mechanical integrity and controlled degradation.
3Productivity
If cooling rate is increased to reduce manufacturing time, then production efficiency improves, but internal stresses may develop affecting ball integrity
Solution Approach 1:
The patent applies periodic action by implementing a multi-stage cooling process with different cooling rates at different stages. The cooling occurs in periods: initial rapid cooling to reduce manufacturing time, followed by slower cooling phases to relieve internal stresses. This periodic variation in cooling rate allows the patent to achieve both high productivity and ball integrity.
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 method produces borate parts that are strong enough to withstand downhole pressures, dissolve at controlled rates, and eliminate the need for manual retrieval, enhancing operational efficiency and reducing costs.
Implementation Method 1
heating the mixture to a melting temperature and dwelling at the melting temperature for a sufficient time to release the water in the mixture and form an anhydrous boron compound
Implementation Method 2
heating the mixture to a melting temperature and dwelling at the melting temperature for a sufficient time to release the water in the mixture
Implementation Method 3
cooling the anhydrous boron compound to form a solid, wherein the anhydrous boron compound is cooled to below a strain point of the solid at a minimum cooling rate
Implementation Method 4
molding the anhydrous boron compound in a mold
Data Source
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AI summary
A method of forming a dissolvable part of amorphous borate includes: preparing a mixture comprising one or more boron compounds and one or more alkali compounds, at least one of the one or more boron compounds and the one or more alkali compounds being hydrous; heating the mixture to a melting temperature for a predetermined time to melt the mixture and release water from the mixture to form an anhydrous boron compound that is moldable, wherein the amount of alkali compound being selected to achieve an alkali oxide content of between about 10 to 25%; with the anhydrous boron compound at a molding temperature, molding the anhydrous boron compound in a mold; and cooling the anhydrous boron compound to form a solid..