Hydrolysis-Expanded Metal Plug for Wellbore Pressure Isolation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing plug and abandonment methods in subterranean wells face challenges in effectively isolating pressure across reservoir zones, particularly due to issues with cement slurry contraction and poor placement, which can lead to leaks and inadequate sealing.

Innovation Solution

The use of an expandable metal plug that expands in response to hydrolysis to create a high-expansion, cement-like seal, eliminating the need for cement slurry and addressing issues of contraction and placement, with the metal plug designed to expand into the wellbore and annulus to provide a durable seal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If cement slurry is pumped down through the tubular string to form a plug, then the plug can seal the wellbore, but the cement slurry suffers from contraction, poor placement, and insufficient volume leading to leaks

Engineering Contradiction:

Improvesealing effectivenessVSAvoidcement slurry contraction

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent changes the physical and chemical parameters of the sealing material by using reactive metal powder instead of cement slurry. The metal powder undergoes hydrolysis reaction with formation water or injected water, transforming from a fine powder state to an expanded solid mass with different density and volume characteristics, eliminating contraction issues while maintaining reliable sealing.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The reactive metal powder undergoes a phase transition through hydrolysis reaction, converting from metallic powder to metal hydroxide/oxide compounds. This chemical phase change results in volumetric expansion and formation of a solid, stable plug structure that reliably seals the wellbore without the contraction problems associated with cement slurry setting.

Inventive Principle:

Principle #36Phase transitions

2Volume of stationary object

If cement slurry is pumped to achieve sufficient plug volume, then the plug can fill the wellbore, but poor placement and insufficient volume remain problematic

Engineering Contradiction:

Improveplug volumeVSAvoidplacement accuracy

Core Design Contradiction:

Volume of stationary objectVSManufacturing precision

Solution Approach 1:

The reactive metal powder is pre-positioned in the wellbore through the tubular string before the hydrolysis reaction occurs. This preliminary placement ensures the material is exactly where needed, and the subsequent in-situ expansion guarantees sufficient volume and proper distribution without the placement inaccuracies associated with pumping cement slurry.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The reactive metal powder performs self-service by automatically expanding through hydrolysis reaction with formation water or injected water. This self-expansion mechanism ensures the plug achieves sufficient volume and proper distribution without requiring precise pumping control or external intervention, eliminating poor placement and insufficient volume issues.

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If traditional milling technology is used to remove tubular sections and drill enlarged wellbores, then the wellbore can be prepared for plugging, but the process is complex and time-consuming

Engineering Contradiction:

Improvewellbore preparation feasibilityVSAvoidmilling tool complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The invention extracts and eliminates the need for complex milling tools and underreamers by using reactive metal powder that can be delivered through existing tubular strings. The metal powder expands in-situ to form the plug directly, removing the tubular section and creating the seal without requiring mechanical removal or enlargement of the wellbore.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical milling and underreaming system with a chemical reaction-based system. Instead of using mechanical tools to remove tubulars and enlarge wellbores, reactive metal powder is delivered through the tubular and expands through hydrolysis to directly form the plug, substituting complex mechanical operations with a simpler chemical process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 expandable metal plug effectively seals the wellbore and annulus, minimizing leaks and ensuring a reliable pressure isolation without the drawbacks of traditional cement slurry methods, suitable for both cased and open hole regions.

Implementation Method 1

at least a portion of the downhole member comprises a metal configured to expand in response to hydrolysis to seal the wellbore tubular

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Data Source

PatentUS12624611B2Expanding metal for plug and abandonment

Publication Date: 2026.05.12 HALLIBURTON ENERGY SERVICES INC

AI summary

Provided is an expandable metal plug for use in a wellbore tubular. The expandable metal plug, in one aspect, includes a downhole member positionable proximate a plug and abandonment section in a wellbore tubular, wherein at least a portion of the downhole member comprises a metal configured to expand in response to hydrolysis to seal the wellbore tubular.