Layered Thermite Composition for Well Plugging Without Gas Leakage
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Solution Overview
Problem
Existing thermite compositions used for plugging and abandoning petroleum wells face issues such as excessive combustion leading to explosions, equipment damage, operator injury, and inadequate sealing, resulting in natural gas leakage due to insufficient metal for tube closure and inefficient cutting of petroleum tubing.
Innovation Solution
A thermite composition comprising a tube-sealing composition with aluminium and metal oxide, a gas leakage-preventing composition with metals having a melting point of 100-300°C, and a tube-opening composition, layered to ensure efficient tube destruction and sealing, using a controlled thermite reaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermite composition is used to melt metal for well plugging, then high temperature and energy are generated to melt and expand metal to block the well, but excessive combustion occurs leading to explosions and equipment damage
Solution Approach 1:
The thermite composition is divided into multiple functional layers: a first thermite composition layer for controlled reaction, a second thermite composition layer for additional heat generation, and a metal layer for plugging. This segmentation allows the reaction to proceed in a controlled manner rather than causing uncontrolled explosion.
Solution Approach 2:
The patent modifies the thermite composition by incorporating specific metal powders (aluminum, magnesium, iron) in controlled proportions and adding binders to regulate the reaction rate. This parameter adjustment transforms the violent exothermic reaction into a controlled heat source that melts metal without causing explosions.
2Power
If thermite composition is used to cut petroleum tubing, then high energy is generated to cut the tubing, but insufficient metal remains for adequate sealing resulting in gas leakage
Solution Approach 1:
The composition is segmented into distinct functional layers: the first thermite layer provides controlled reaction and cuts the tubing, while the second thermite layer and metal layer ensure sufficient molten metal remains for sealing the wellbore, preventing gas leakage.
Solution Approach 2:
Different regions of the composition have different properties: the first thermite layer is optimized for controlled reaction and cutting, while the second thermite layer and metal layer are optimized for generating sufficient molten metal volume for sealing. This local differentiation ensures both cutting and sealing functions are achieved.
3Reliability
If traditional cement injection method is used to close the well, then the well is permanently closed, but the process is time-consuming and requires multiple steps including testing and platform removal
Solution Approach 1:
The patent replaces the mechanical cement injection and solidification process with a chemical thermite reaction that directly generates high temperature to melt and expand metal for well plugging. This substitution eliminates the need for cement setting time, multiple testing steps, and sequential platform removal, significantly reducing the overall time required.
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 composition effectively seals petroleum wells, preventing gas leakage and ensuring complete tube removal with minimal environmental impact by controlling the thermite reaction and enhancing sealing efficiency.
Implementation Method 1
The thermite reaction is a reduction reaction of a metal compound, especially the reduction of metal oxide using aluminium (Al) and magnesium (Mg), which are reducing metals commonly used due to their low melting point and high exothermic rate.
Implementation Method 2
The thermite reaction is a reduction reaction of a metal compound, especially the reduction of metal oxide using aluminium (Al) and magnesium (Mg)
Implementation Method 3
The heat generated is high up to 2,000° C. and causes the metal to be in a liquid state
Data Source
AI summary
A thermite composition for a process of plugging and abandoning a petroleum well comprises a tube-scaling composition and a gas leakage-preventing composition. The tube-scaling composition comprises aluminium and a metal oxide, and the gas leakage-preventing composition comprises a metal or an alloy with a melting point ranging from 100-300° C. The tube-scaling composition is arranged at the bottom, followed by the gas leakage-preventing composition. The thermite composition further comprises a tube-opening composition comprising aluminium and a metal oxide. The process of plugging and abandoning a petroleum well using the thermite composition involves introducing the thermite composition which is arranged in layers in the petroleum well to be plugged and abandoned, and initiating an ignition to trigger a thermite reaction, which melts the metal for tube sealing and prevents gas leakage.