Hollow Sintered Ceramic Ball for Hydraulic Fracturing Sealing
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Solution Overview
Problem
Hydraulic fracturing operations in oil and gas wells require devices that can effectively seal and control fluid flow, but existing solutions lack the ability to easily break and remove sealing components after use.
Innovation Solution
Sintered ceramic balls with a hollow structure, composed of an incomplete ball portion and a plug, are designed to provide a high compressive strength for sealing during hydraulic fracturing, while features like furrows and striations allow them to break into smaller pieces for easy removal, and a liquid-filled option enhances crush strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic balls are made with high compressive strength for effective sealing, then sealing performance is improved, but the balls become difficult to break and remove after use
Solution Approach 1:
The ceramic ball is segmented into two functional zones: an outer shell with high compressive strength for sealing, and an inner core with lower strength containing furrows and striations that promote controlled breakage. This segmentation allows the ball to maintain structural integrity during sealing while enabling easy fragmentation for removal after use.
Solution Approach 2:
Different regions of the ceramic ball have different mechanical properties. The outer shell possesses high compressive strength to withstand well pressures and maintain sealing, while the inner core has reduced strength and includes intentional weakness features (furrows and striations) that facilitate breakage. This local quality differentiation resolves the contradiction between needing strength for sealing and ease of breakage for removal.
2Strength
If ceramic balls are made solid to maximize strength, then compressive strength is improved, but the balls become too heavy and difficult to convey away
Solution Approach 1:
The ceramic ball employs a nested structure with a hollow interior cavity containing the plug. This nesting approach reduces the overall weight and material consumption while maintaining the external dimensions needed for sealing. The hollow structure significantly lowers weight compared to a solid ball of the same outer size, facilitating easier conveyance and removal after the sealing function is completed.
3Weight of moving object
If ceramic balls are made hollow to reduce weight, then ease of conveyance is improved, but the balls lose structural strength
Solution Approach 1:
The ceramic ball utilizes a composite structure combining a hollow ceramic shell with an internal plug component. The ceramic shell provides the necessary external strength and sealing capability, while the internal plug reinforces the hollow structure and prevents collapse. This composite approach maintains adequate compressive strength despite the hollow configuration, enabling both weight reduction and structural integrity.
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 sintered ceramic balls effectively seal during hydraulic fracturing, withstand significant pressures, and can be broken and flushed away, improving operational efficiency and reducing post-operation cleanup.
Implementation Method 1
a method of making a sintered ceramic ball is provided, the method comprising: forming an incomplete ball portion, the incomplete ball portion including an exterior surface and a wall with an opening contiguous with a hollow space radially interior to an inner surface of the wall; after forming the incomplete ball portion, inserting a plug into the opening of the incomplete ball portion; and after inserting the plug into the opening of the incomplete ball portion, sintering the incomplete ball portion and the plug to form a sintered ceramic ball
Data Source
AI summary
A sintered ceramic ball is described that includes an incomplete ceramic ball portion with a wall with an exterior surface, the wall having an interior space located radially interior of an inner surface of the wall. The incomplete ceramic ball portion also has an exterior surface, the exterior surface having an exterior surface area. The sintered ceramic ball further includes a ceramic plug joined with the incomplete ceramic ball portion to form a continuous exterior ball surface. The ceramic plug includes an exterior plug surface and a plug wall. The plug surface includes an exterior plug surface area, wherein the exterior plug surface area is between about 5% to 49.9% of the sum of the exterior surface area of the incomplete ceramic ball portion and the exterior plug surface area. The interior space of the sintered ceramic ball is sealed within the wall and the plug wall.