Isolation plugs for enhanced geothermal systems
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Solution Overview
Problem
Current isolation plugs for geothermal wells lack the necessary high-temperature resistance and durability to effectively stimulate unconventional geothermal reservoirs, as they often fail to withstand the elevated temperatures encountered in these environments.
Innovation Solution
The development of high-strength, high-temperature elastomer elements and structural components, manufactured via additive manufacturing, which include degradable materials and reinforcing fibers, enabling the creation of isolation plugs that can operate reliably at temperatures of at least 400°F and maintain structural integrity during fracturing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional isolation plugs are used in geothermal wells, then manufacturing costs are lower and ease of manufacture is improved, but temperature resistance and reliability deteriorate at temperatures of 400°F and above
Solution Approach 1:
The patent employs composite materials comprising elastomer elements combined with reinforcing fibers (such as aramid, glass, or carbon fibers) to create isolation plugs that can withstand geothermal temperatures of 400°F and above. The composite structure integrates the flexibility and sealing capability of elastomers with the high-temperature strength of reinforcing fibers, resolving the contradiction between temperature resistance and manufacturability.
Solution Approach 2:
The patent modifies material parameters by selecting elastomers with glass transition temperatures above 400°F and incorporating heat-resistant reinforcing fibers. These parameter changes enable the isolation plug to maintain structural integrity and sealing performance at elevated geothermal temperatures while remaining manufacturable through established composite material processes.
2Ease of operation
If degradable materials are used in isolation plugs, then interventionist removal is eliminated, but structural strength and durability may be reduced
Solution Approach 1:
The patent applies local quality by using degradable materials specifically for components that need to be removed (such as the elastomer element), while incorporating non-degradable reinforcing fibers and structural components that require sustained strength. This localized application of degradability allows the plug to maintain structural integrity during operation while enabling eventual degradation for simplified removal.
Solution Approach 2:
The patent incorporates materials with dynamic properties that transition from stable and strong during operation to degradable after use. The degradable components remain structurally sound under geothermal conditions during the stimulation process, then gradually degrade over time to allow for intervention-free removal, thus resolving the contradiction between strength and ease of removal.
3Productivity
If additive manufacturing is used for isolation plugs, then customization speed and reduced capital costs are achieved, but manufacturing precision and material consistency may be compromised
Solution Approach 1:
The patent segments the isolation plug into multiple components (such as the elastomer element, reinforcing fiber structures, and metal components) that can be manufactured separately using additive manufacturing. This segmentation allows each component to be optimized for its specific manufacturing requirements while maintaining overall assembly precision, and enables rapid customization of individual components without compromising the entire structure's dimensional accuracy.
Data Source
AI summary
An element includes an elastomer having a temperature rating of at least 400° F. for enhanced geothermal system applications. The elastomer element may be manufactured via an additive manufacturing process, and the elastomer element may be a component of an isolation plug assembly having a plurality of structural components that may also be manufactured via the additive manufacturing process.