Permeable Foam Filter with Particulate Additives for Wellbore Solids Control

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Solution Overview

Problem

Existing wellbore filtration devices are prone to clogging and require frequent maintenance due to harsh downhole conditions, leading to significant downtime and reduced productivity in hydrocarbon extraction.

Innovation Solution

A fluid flow device comprising a permeable foam mass created by adding a particulate additive to materials that form a substantially impermeable mass, allowing controlled fluid flow while inhibiting particles above a selected size, formed from materials like polymeric foams with cell structures and particulate additives like clay or nano-particles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If complex assembly filtering devices are used, then filtration capability is improved, but device complexity and maintenance requirements increase

Engineering Contradiction:

Improvefiltration capabilityVSAvoidassembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent uses foam material with controlled porosity as the filtering medium. The foam's cellular structure provides filtration capability while maintaining structural simplicity. The porous nature allows fluid passage while capturing contaminants, replacing complex mechanical filter assemblies with a single porous element.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent creates a composite material by combining foam base material with particulate additives. This composite structure enhances filtration performance and durability while maintaining simplicity. The particulate additives embedded in the foam matrix provide additional filtering mechanisms and structural reinforcement.

Inventive Principle:

Principle #40Composite materials

2Reliability

If traditional filter devices are used, then filtration is achieved, but frequent maintenance and replacement are required due to clogging

Engineering Contradiction:

Improvefiltration functionVSAvoidservice life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent modifies the physical and chemical parameters of the filtering material by incorporating particulate additives with specific size distributions, surface properties, and compositional characteristics. These parameter changes enhance the material's resistance to clogging and improve its ability to handle harsh downhole conditions, extending service life.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a disposable foam filter element that is designed to be replaced rather than maintained. This approach eliminates complex maintenance procedures and allows for quick replacement of the entire filter assembly, reducing downtime and operational complexity despite the single-use nature of the component.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If filtering devices are placed in harsh downhole environment, then fluid filtration is achieved, but device breakdown occurs frequently

Engineering Contradiction:

Improvefluid filtrationVSAvoiddevice durability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent creates a composite structure combining foam material with particulate additives that provide enhanced mechanical strength and chemical resistance. The particulate reinforcement within the foam matrix improves durability against harsh downhole conditions including high temperature, pressure, and corrosive environments while maintaining filtration functionality.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies particulate additives at specific locations and concentrations within the foam structure to enhance local strength and resistance properties. This localized reinforcement strategy provides targeted durability improvements in areas most susceptible to breakdown while maintaining overall filter performance.

Inventive Principle:

Principle #3Local quality

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 solution provides a durable and effective filtration system that reduces maintenance needs, maintains productivity by allowing controlled fluid flow while filtering out unwanted solids, and is designed to withstand harsh downhole conditions.

Implementation Method 1

a substantially permeable member made by combining a particulate additive with one or more materials that when processed by themselves form a substantially impermeable mass

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

permeable foam mass created by adding a particulate additive to materials that form a substantially impermeable mass, allowing controlled fluid flow

Methodology Applied

Scientific EffectPorosity: Porosity

Data Source

PatentUS8528640B2Wellbore flow control devices using filter media containing particulate additives in a foam material

Publication Date: 2013.09.10 BAKER HUGHES CO

AI summary

An embodiment of an apparatus may include a permeable member made by combining a particulate additive to one or more materials, which materials when processed without the particulate additive form a substantially impermeable mass, wherein the permeable member inhibits flow of solid particles above a particular size through the permeable member.