Porous Plug Water Rejection in Oil and Gas Wells
Solution Overview
Problem
Existing hydrocarbon production wells face challenges in reducing the production of water and minerals to the surface, leading to reduced well pressure and surface contamination, as well as the need for costly transportation of produced water.
Innovation Solution
A cylindrical apparatus with channels and flow control elements arranged in layers to form a gas-tight seal, integrated with a well tubing string and annular sealing device, which allows oil and gas to flow while rejecting water, utilizing differential pressure to control fluid flow and reduce water production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If water is produced to the surface along with oil and gas, then all fluids can be extracted from the well, but well pressure is reduced and surface contamination occurs
Solution Approach 1:
The patent employs a porous plug composed of multiple porous elements arranged in series within the wellbore. These porous elements create a size-based filtration system where hydrocarbon molecules (oil and gas) can pass through the porous structure while water molecules are blocked due to their larger effective size and polar nature. This selective permeability allows continuous production of hydrocarbons while preventing water from reaching the surface, thereby maintaining well pressure and avoiding contamination.
2Productivity
If water is hauled away in trucks or barges, then produced water is removed from the well, but operational costs increase
Solution Approach 1:
The porous plug system operates passively using the natural flow dynamics and pressure differentials already present in the wellbore. The hydrocarbons flow through the porous elements under their own pressure, while water is automatically blocked by the pore size constraints. This self-regulating mechanism eliminates the need for external pumping, trucking, or barging operations to remove water, significantly reducing operational costs and energy consumption while maintaining continuous water separation.
3Productivity
If minerals are extracted at the surface, then mineral production is achieved, but additional processing requirements increase
Solution Approach 1:
The porous plug selectively extracts hydrocarbons (oil and gas) from the fluid mixture in the wellbore while blocking water and dissolved minerals. By removing hydrocarbons at the pore level within the wellbore, the system prevents minerals from being brought to the surface with water. This upstream extraction approach eliminates the need for complex downstream mineral processing facilities, reducing both capital investment and operational complexity while maintaining mineral production value.
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
Effectively reduces the amount of water brought to the surface, maintaining well pressure and preventing contamination by selectively allowing oil and gas to flow while rejecting water, optimizing hydrocarbon production and reducing operational costs.
Implementation Method 1
the plurality of elements are arranged in at least two layers and fitted together to form a gas tight seal at normal atmospheric pressure
Implementation Method 2
utilizing differential pressure to control fluid flow and reduce water production
Data Source
AI summary
An oil and gas downhole device is disclosed wherein the device separates the oil and gas from undesired water, which returns to the formation. The device includes a plurality of channels filled with elements fit tightly to a gas tight seal at atmospheric pressure with interstitial spaces. Under pressure the device allows oil and gas to pass but not water within its operating range of pressures. Also included is a method for using the device.