Oil-Disintegrable Polymeric Composite Downhole Tools
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Solution Overview
Problem
In downhole operations, self-disintegrable tools used for hydraulic fracturing often fail to disintegrate at the desired rate due to sand and debris accumulation, delaying well production as the circulation fluid cannot reach them effectively.
Innovation Solution
A load-bearing and oil-disintegrable tool made from a polymeric composite comprising oil-disintegrable polymers like polydicyclopentadiene, polyurethane, or high-density polyethylene, combined with reinforcing agents such as glass or carbon, which disintegrates when exposed to hydrocarbon fluids, ensuring efficient removal post-fracturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If self-disintegrable tools are used in downhole operations, then mechanical retrieval is eliminated and well production can start sooner, but sand and debris accumulation prevents the circulation fluid from reaching the tools, causing delayed disintegration
Solution Approach 1:
The patent changes the chemical parameters of the tool material by using polymers with specific functional groups (ester, carbonate, amide, urea, or imide linkages) that are sensitive to hydrocarbon fluids. This chemical parameter change enables the tool to disintegrate reliably when exposed to hydrocarbon-based circulation fluids, even in the presence of sand and debris accumulation.
Solution Approach 2:
The patent employs composite materials consisting of hydrocarbon-soluble polymers combined with reinforcing fibers or fillers. This composite structure maintains mechanical strength during operation while enabling controlled disintegration when the polymer matrix dissolves in hydrocarbon fluids, resolving the contradiction between structural integrity and disintegration reliability.
2Ease of operation
If the tool is made from oil-disintegrable polymer composite, then the tool can disintegrate upon contact with circulation fluid, but the tool must maintain high compressive strength to bear downhole loads
Solution Approach 1:
The patent uses composite materials where hydrocarbon-soluble polymers provide automatic disintegration capability while reinforcing fibers (such as glass, carbon, or metal fibers) or fillers provide the necessary compressive strength to bear downhole loads. The composite structure allows both properties to coexist.
Solution Approach 2:
The patent applies local quality by having different components of the composite material serve different functions: the polymer matrix provides disintegration capability where needed, while the reinforcing phase provides strength in load-bearing regions. This spatial differentiation of properties resolves the contradiction between ease of operation and strength.
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 tool maintains high compressive strength and disintegrates reliably when exposed to hydrocarbon fluids, facilitating timely well production by removing the need for mechanical retrieval and addressing the issue of sand and debris interference.
Implementation Method 1
a load-bearing and oil-disintegrable tool made from a polymeric composite comprising oil-disintegrable polymers like polydicyclopentadiene, polyurethane, or high-density polyethylene... which disintegrates when exposed to hydrocarbon fluids
Data Source
AI summary
A method for operating in a borehole penetrating a formation is disclosed. The method includes disposing in the borehole an assembly comprising a load-bearing and oil-disintegrable tool comprising a polymeric composite; performing a downhole operation; and disintegrating the load-bearing and oil-disintegrable tool with a hydrocarbon fluid. The polymeric composite comprises an oil-disintegrable polymer which is one or more of the following: a polydicyclopentadiene, polypropylene, polyurethane, polycarbonate, polysulfone, or a high density polyethylene, the polyurethane being a polyhedral oligomeric silsesquioxane-modified polyurethane, a lauryl methacrylate graft polyurethane copolymer, a divinylbenzene crosslinked polyurethane, or a combination comprising at least one of the foregoing.