Laser Wellbore Casing Using Consolidated Drill Cuttings

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Solution Overview

Problem

Conventional wellbore drilling and casing operations are time-consuming and resource-intensive, requiring significant investments in materials and equipment, which can occupy large surface footprints.

Innovation Solution

Utilizing high-powered laser technology to consolidate drill cuttings into a casing on the wellbore's inner wall by heating and melting them, potentially combined with mechanical rotary drilling, thereby eliminating the need for large casing materials and equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional drilling and casing operations are used, then wellbore casing can be formed, but the process is time-consuming and requires large equipment footprints

Engineering Contradiction:

Improvecasing formation speedVSAvoidtime required for casing operations

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces conventional mechanical casing installation with a laser-based thermal consolidation process. The laser head emits a laser beam that heats and consolidates drill cuttings to form the casing, eliminating the need for traditional mechanical casing pipes and cementing operations. This substitution of mechanical systems with optical/thermal energy directly addresses the time-consuming nature of conventional casing operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes changes in temperature parameter to transform the state of drill cuttings from loose fragments to consolidated casing material. By controlling the laser beam energy, the temperature of the drill cuttings is raised to a point where they melt and solidify into a cohesive casing structure, enabling rapid formation without conventional time-intensive processes.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If conventional casing materials and equipment are used, then wellbore casing can be formed, but significant resources and large surface footprints are required

Engineering Contradiction:

Improvecasing formation efficiencyVSAvoidcasing materials consumption

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent employs self-service by utilizing the drill cuttings themselves as the casing material. Instead of importing and installing external casing pipes and cement, the system uses the waste drill cuttings generated during drilling, heats them with laser energy, and consolidates them to form the casing. This transforms waste material into a useful structural component, eliminating the need for separate casing materials.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent converts the harmful waste product of drilling operations (drill cuttings) into a beneficial structural element (casing). The drill cuttings, which would normally be discarded, are heated and consolidated to form the wellbore casing, turning waste into a valuable resource and eliminating the need for separate casing materials.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If laser beam is used to heat drill cuttings, then casing can be formed rapidly, but energy consumption increases

Engineering Contradiction:

Improvecasing formation speedVSAvoidlaser energy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent employs periodic or pulsed laser action to heat the drill cuttings. Rather than continuous laser exposure, the system uses controlled pulses or intermittent beam application, which allows for efficient energy transfer while preventing excessive energy consumption. This periodic action enables rapid casing formation with optimized energy use.

Inventive Principle:

Principle #19Periodic action

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

Reduces the time and resource requirements for wellbore casing, allowing for smaller equipment footprints and alignment with net-zero targets by leveraging laser precision and efficiency.

Implementation Method 1

A laser head, attached to the wellbore drill bit, emits a laser beam that is incident on a portion of the drill cuttings. The laser beam heats the portion of the drill cuttings to consolidate and form a casing of the wellbore.

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

Emitting the laser beam on the portion of the drill cuttings causes the laser beam to push the portion of the drill cuttings towards an inner wall of the wellbore before the laser beam heats the portion of the drill cuttings to consolidate and form the casing of the wellbore.

Methodology Applied

Scientific EffectLaser radiation pressure: Radiation Pressure

Data Source

PatentEP4526543B1Wellbore drilling and completion systems using laser head

Publication Date: 2026.03.25 SAUDI ARABIAN OIL CO

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AI summary

Wellbore drilling and completion systems using a laser head implement methods of completing a wellbore. A wellbore drill bit is rotated through a subterranean zone to form a wellbore. Rotating the wellbore drill bit through the subterranean zone causes portions of the subterranean zone to be released as drill cuttings into the wellbore. A laser head, attached to the wellbore drill bit, emits a laser beam that is incident on a portion of the drill cuttings. The laser beam heats the portion of the drill cuttings to consolidate and form a casing of the wellbore.