Stimuli-Responsive Porous Material for Downhole Flow Control
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Solution Overview
Problem
Existing downhole flow control devices in subterranean formations face challenges in withstanding high pressures and require acid introduction to create flow ports, which limits their effectiveness and reliability.
Innovation Solution
A flow control assembly utilizing porous materials, such as shape memory foam or magnetic memory alloys, that can temporarily block fluid flow and open in response to environmental stimuli like temperature or magnetic fields, allowing for pressure sealing and controlled fluid flow without the need for acid introduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum or PLA plugs are used to create flow ports, then flow control can be achieved, but the assembly cannot withstand high pressure and requires acid introduction
Solution Approach 1:
The patent applies parameter changes by utilizing the phase transition and structural transformation of shape memory material at specific temperatures. The material transitions from an austenite phase (blocking flow) to a martensite phase (allowing flow) when exposed to temperature changes, eliminating the need for acid introduction and enabling high pressure resistance while maintaining flow control capability
Solution Approach 2:
The invention directly employs phase transitions of shape memory material as the core mechanism. The material undergoes reversible phase transformation between austenite and martensite structures in response to temperature stimuli, enabling the flow control assembly to switch between closed and open states without chemical dissolution, thereby resolving the contradiction between pressure resistance and operational simplicity
2Ease of operation
If acid is introduced to dissolve plugs for flow control, then flow ports can be created, but the process becomes more complex and less reliable
Solution Approach 1:
The patent replaces the chemical dissolution mechanism (acid dissolving plugs) with a physical/structural mechanism (shape memory material transformation). The flow control is achieved through temperature-induced structural changes in the shape memory material rather than chemical dissolution, simplifying the overall system by eliminating acid introduction equipment and chemical handling requirements
Solution Approach 2:
The shape memory material performs the flow control function autonomously in response to temperature stimuli without requiring external chemical agents. The material self-regulates the flow state based on environmental temperature conditions, eliminating the need for complex acid introduction systems and reducing overall device complexity
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 reliable high-pressure sealing and controlled fluid flow in subterranean formations by using stimuli-responsive porous materials that can open and close in response to wellbore conditions, enhancing the operational efficiency and durability of downhole devices.
Implementation Method 1
The porous material can be shape memory foam
Implementation Method 2
The stimulus being a magnetic field from a device provided in the wellbore from a surface of the wellbore
Data Source
AI summary
A flow control assembly can be disposed in a wellbore and can include a porous material. The porous material can be a temporary plug in a flow path. The porous material may respond to stimuli in a wellbore by creating a flow path, or otherwise allowing fluid to flow in a flow path. The porous material may be located in a port of tubing or proximate, such as adjacent, to an opening in the port.