High Viscosity Elastomer Cement Additive for Fracture Sealing
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Solution Overview
Problem
Current cement compositions used in downhole environments are inadequate in resisting cyclic stresses and self-healing, leading to cracks and fractures that compromise zonal isolation and require costly remedial operations.
Innovation Solution
A free-flowing cement additive comprising a high viscosity elastomer with a viscosity between 50,000 and 300,000 centiPoise, deposited on an inert support, which enhances mechanical properties and self-sealing capabilities of set cement, allowing it to absorb and dissipate stresses and seal fractures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current cement compositions are used in downhole environments, then zonal isolation is achieved, but the cement develops cracks and fractures under cyclic stresses
Solution Approach 1:
The patent changes the physical state of elastomers from solid particles to liquid form with high viscosity (50,000-300,000 cP), allowing them to flow and self-seal cracks while maintaining adhesion to cement matrices, thereby improving both cyclic stress resistance and crack resistance simultaneously
Solution Approach 2:
The patent creates a composite system by depositing liquid elastomer on inert support particles, combining the adhesion benefits of elastomers with the structural stability of inert supports, resulting in cement compositions that resist both cyclic stresses and crack formation
2Reliability
If solid particulate elastomers are included in cement, then cyclic stress resistance is improved, but phase separation and poor adhesion occur
Solution Approach 1:
The patent transforms elastomers from solid particulate form to liquid form with controlled high viscosity, enabling them to remain homogeneous throughout the slurry without phase separation while still providing cyclic stress resistance
Solution Approach 2:
The inert support acts as an intermediary carrier that holds the liquid elastomer in suspension, preventing phase separation while allowing the elastomer to distribute uniformly throughout the cement slurry, maintaining both homogeneity and functional performance
3Reliability
If high viscosity elastomer is deposited on inert support, then self-healing capability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent pre-deposits liquid elastomer on inert support particles during manufacturing, creating a ready-to-use additive that requires no additional equipment or complex processing during cement slurry preparation, thus achieving self-healing capability without significantly increasing manufacturing complexity
Solution Approach 2:
The inert support particles serve as disposable carriers that simplify handling and distribution of the liquid elastomer, allowing standard manufacturing equipment to be used while achieving the self-healing function through the elastomer release mechanism
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 additive improves the tensile and compressive strength of cement, reduces brittleness, and provides self-healing properties, enhancing zonal isolation and stress resistance, thereby extending the life of the cement under downhole conditions.
Implementation Method 1
a high viscosity elastomer, the high viscosity elastomer having a viscosity between 50,000 centiPoise (cP) and 300,000 cP at room temperature
Implementation Method 2
provides self-healing properties, enhancing zonal isolation and stress resistance
Data Source
AI summary
A composition forming a free-flowing cement additive, the composition comprising a high viscosity elastomer, the high viscosity elastomer having a viscosity between 50,000 cP and 300,000 cP at room temperature; and an inert support, where the high viscosity elastomer is deposited on the inert support.