Dissolvable Metal Matrix Composites for Hydraulic Fracturing
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Solution Overview
Problem
Conventional frac balls and plugs used in hydraulic fracturing are difficult to remove due to their material properties, which often break into large, problematic chunks.
Innovation Solution
A dissolvable metal matrix composite material is developed, comprising magnesium and aluminum with corrosion activators like iron, tungsten, nickel, or titanium, designed to dissolve uniformly into small particles, suitable for use as frac balls and plugs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional materials are used for frac balls and plugs, then the tools are strong and robust enough to function as oilfield tools, but they are difficult to remove or break apart into difficult to process chunks
Solution Approach 1:
The patent changes the material parameters by using a dissolvable metal matrix composite with specific composition (magnesium, aluminum, and corrosion activators) that allows the tool to maintain strength during operation but dissolve easily upon removal. The material parameters are designed to provide sufficient mechanical strength during use while enabling controlled dissolution in the wellbore environment for easy removal.
Solution Approach 2:
The patent employs a composite material system consisting of a metal matrix (magnesium and aluminum) combined with corrosion activators (iron, tungsten, nickel, or titanium). This composite structure provides the necessary strength and robustness during operation while enabling controlled dissolution through galvanic corrosion mechanisms, allowing easy removal without breaking into problematic chunks.
2Reliability
If conventional materials are used for frac balls and plugs, then the tools can perform their isolating function, but they break into large problematic chunks upon removal
Solution Approach 1:
The patent modifies the material's dissolution characteristics by selecting specific metal combinations and corrosion activators that control the dissolution mechanism. This ensures the material maintains structural integrity (reliability) during operation but dissolves uniformly into fine particles rather than breaking into large chunks, achieving both reliability and shape uniformity upon removal.
Solution Approach 2:
The composite material design with magnesium and aluminum as the metal matrix combined with specific corrosion activators creates a system that maintains structural reliability during use while providing controlled dissolution behavior. The composite structure ensures uniform dissolution into fine particles, preventing the formation of large problematic chunks and maintaining shape uniformity throughout the dissolution process.
3Ease of operation
If dissolvable material is used for frac balls and plugs, then the tools can be easily removed, but they must be sufficiently strong and robust to function as oilfield tools
Solution Approach 1:
The patent uses a composite material system where the metal matrix (magnesium and aluminum) provides the necessary strength and robustness for oilfield tool function, while the corrosion activators (iron, tungsten, nickel, or titanium) enable controlled dissolution. This composite approach allows the material to be sufficiently strong during operation yet easily removable through dissolution without compromising either requirement.
Solution Approach 2:
The patent changes the material parameters by selecting specific metal combinations and corrosion activators that create a dissolvable system. The composition is designed to provide sufficient mechanical strength for oilfield tool function while enabling controlled dissolution in the wellbore environment, achieving both ease of removal and adequate strength 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 material effectively isolates and removes frac zones by dissolving into fine particles, simplifying the process and avoiding the issues of conventional materials, which often leave large, difficult-to-process chunks.
Implementation Method 1
The corrosion activator is present in smaller amounts to facilitate rapid corrosion of the unitary body when exposed to an electrolyte solution such as a saline solution
Data Source
AI summary
A unitary body includes magnesium and aluminum and at least one of iron, tungsten, nickel, or titanium and has a dissolution rate of at least 5 mg/(cm2·hr). The magnesium and aluminum and/or the iron, tungsten, nickel, and/or titanium can be present in discrete solid regions. The unitary body can include multiple sections having different compositions and different dissolution rates. The unitary body can be formed using solid-state powder metallurgy processes.