Permeable Material Compacting Apparatus with Stepped Rollers
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Solution Overview
Problem
Existing methods for compacting permeable materials used in gravel packing require compaction or compression prior to deployment, which can be inefficient and lack control over the volume reduction process.
Innovation Solution
A permeable material compacting method and apparatus using multiple sets of rollers with orthogonal orientations to reduce the cross-sectional area of permeable materials, accompanied by heating and cooling devices to manage temperature and expansion, allowing for a controlled volume reduction and subsequent expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If permeable material is compacted using conventional methods, then volume reduction is achieved, but the process is inefficient and lacks control
Solution Approach 1:
The compaction process is divided into multiple stages using sequential roller sets (first set, second set, third set) with decreasing roller diameters. Each roller set performs a portion of the total volume reduction, allowing incremental and controlled compaction rather than attempting to achieve full compression in a single step.
Solution Approach 2:
The roller diameters are dynamically configured in a stepped sequence (largest to smallest) to progressively reduce the material volume. This dynamic progression allows the material to be compressed in controlled increments, improving both efficiency and precision of volume reduction.
2Productivity
If permeable material is compacted to reduce volume, then deployment efficiency improves, but material expansion during use must be minimized
Solution Approach 1:
The material is pre-compacted to a target volume reduction (e.g., 50-70% of original volume) before deployment. This preliminary compaction ensures the material is optimally packed for efficient deployment while maintaining enough structural integrity to minimize unwanted expansion during installation.
Solution Approach 2:
The compaction parameters (roller diameter, applied pressure, number of roller sets) are carefully controlled to achieve a specific residual volume. By adjusting these parameters, the material is compacted to an optimal state that balances deployment efficiency with stability during use.
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
Enables efficient and controlled compaction and expansion of permeable materials, improving the deployment process by reducing volume in a stepped manner and minimizing expansion during use, thus enhancing the material's performance in wellbore support.
Implementation Method 1
decreasing a cross sectional area of the permeable material as it passes between the at least one set of rollers
Implementation Method 2
rollers are configured and oriented relative to one another to compact permeable material
Implementation Method 3
heating and cooling devices to manage temperature and expansion
Implementation Method 4
heating and cooling devices to manage temperature and expansion
Data Source
AI summary
A permeable material compacting method includes feeding permeable material between at least one set of rollers, and decreasing a cross sectional area of the permeable material as it passes between the at least one set of rollers.