Dissolvable Ceramic Fracking Balls for Hydraulic Fracturing
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Solution Overview
Problem
Current hydraulic fracking operations require expensive and time-consuming steps to remove and dispose of fracking balls and plugs, and existing degradable tools lack the necessary elastomeric properties for effective sealing and dissolution in wellbore fluids.
Innovation Solution
Development of dissolvable hydraulic fracking balls and plugs made from ceramic materials and elastomeric matrix composites that are soluble in fluids, allowing for predictable dissolution and elimination of the need for physical removal, with controlled dissolving rates and structural integrity to sustain wellbore conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional solid fracking balls and plugs are used, then well sealing and isolation are effective, but expensive and time-consuming removal and disposal steps are required
Solution Approach 1:
The patent applies parameter changes by transforming the material composition of fracking balls and plugs from traditional solid materials to dissolvable materials. This fundamental parameter change allows the objects to automatically dissolve after completing their sealing function, eliminating the need for mechanical removal operations and significantly reducing both operational complexity and time loss.
Solution Approach 2:
The patent implements the disposable object principle by designing fracking balls and plugs that are intended to be used once and then dissolved. These dissolvable objects perform their sealing function temporarily and then automatically decompose, replacing the need for expensive retrieval operations and reducing disposal costs associated with traditional solid fracking objects.
2Ease of operation
If degradable tools are used, then removal steps are eliminated, but the tools lack necessary elastomeric properties for effective sealing
Solution Approach 1:
The patent resolves this contradiction by employing composite materials that combine elastomeric components with dissolvable components. The elastomeric portion provides the necessary sealing properties and mechanical strength, while the dissolvable portion allows for automatic decomposition after use. This composite approach enables the tool to simultaneously achieve effective sealing and easy removal without compromise.
Solution Approach 2:
The patent applies segmentation by dividing the fracking tool into distinct functional segments: an elastomeric sealing segment that provides the necessary mechanical properties for effective sealing, and a dissolvable segment that enables automatic removal. This segmentation allows each component to optimize its specific function while working together as an integrated system.
3Productivity
If dissolvable materials are used, then removal operations are eliminated, but maintaining structural integrity under wellbore conditions becomes challenging
Solution Approach 1:
The patent uses composite materials to balance structural integrity and dissolvability. The elastomeric matrix provides the necessary mechanical strength and structural integrity to withstand wellbore conditions during operation, while the integrated dissolvable components ensure automatic removal after use. This composite structure resolves the contradiction between maintaining strength and enabling dissolution.
Solution Approach 2:
The patent applies local quality by assigning different material properties to different parts of the fracking tool. The sealing surfaces and structural components maintain elastomeric properties for strength and durability, while specific portions are designed with dissolvable characteristics. This localized differentiation allows the tool to simultaneously achieve structural integrity and automatic removal capability.
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 dissolvable fracking objects reduce operational costs and time by dissolving predictably, maintaining well integrity during operations and eliminating residual debris, thus enhancing the efficiency and consistency of hydraulic fracturing processes.
Implementation Method 1
fracking balls made from ceramic materials and elastomeric matrix composites that are soluble in fluids, allowing for predictable dissolution
Implementation Method 2
controlled dissolving rates and structural integrity to sustain wellbore conditions
Data Source
AI summary
Embodiments disclosed herein include dissolvable and intentionally degradable objects that are useful for hydraulic fracking operations. Such objects are at least in part manufactured using materials that are soluble in certain fluids including water. The dissolvable and intentionally degradable fracking objects can be manufactured from one or more materials, including composite materials. In one embodiment, dissolvable fracking objects are manufactured from ceramic materials that are soluble in fluids such as water. Such dissolvable fracking objects include fracking balls and plugs. These fracking balls and plugs are arranged to seal a well for a predetermined period of time and dissolve over that predetermined period of time until the well is no longer sealed. In another embodiment, tools generally useful in fracking operations are manufactured to have desirable elastomeric properties. Such tools can be manufactured from a combination of materials that are soluble in fluids and generally dispersible in fluids.