Propellant Insert Burn Rate Control in Wellbore Fuel Sources

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Solution Overview

Problem

Downhole fuel sources used in wellbore operations often require specific burn rates for optimal performance, but existing formulations are complex and pose manufacturing challenges, making it difficult to achieve desired burn rate adjustments.

Innovation Solution

The use of a propellant insert within a fuel source body, where the propellant insert has a different burn rate than the propellant, allowing for the alteration of the burn rate by creating divided volumes and utilizing various chemical compositions to either accelerate or decelerate the burn rate, thereby achieving a controlled pressure output.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If downhole fuel sources use complex formulations to achieve specific burn rates, then the desired burn rate control is improved, but the manufacturing complexity and handling difficulty increase

Engineering Contradiction:

Improveburn rate controlVSAvoidformulation complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The fuel source is segmented into multiple propellant grains with different burn rates disposed within the same housing. Each grain can have different formulations optimized for specific burn rates, and they work together to achieve the desired overall burn rate profile without requiring a single complex formulation

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the fuel source contain propellant grains with locally optimized properties. Fast-burning grains are placed in specific locations while slow-burning grains are placed in other locations, allowing each region to contribute its optimal burn characteristics to the overall system performance

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If downhole fuel sources use complex formulations to achieve specific burn rates, then the desired burn rate control is improved, but the ease of manufacture deteriorates

Engineering Contradiction:

Improveburn rate controlVSAvoidmanufacturing ease

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system uses composite construction by combining multiple propellant grains with different burn rate characteristics in a single fuel source assembly. This allows the system to achieve complex burn rate profiles using simpler, standardized propellant formulations rather than requiring a single complex custom formulation

Inventive Principle:

Principle #40Composite materials

3Productivity

If the burn rate is increased to achieve faster operation, then the productivity is improved, but the pressure control precision deteriorates

Engineering Contradiction:

Improveoperation speedVSAvoidpressure control precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fuel source provides periodic or staged energy release through multiple propellant grains burning at different rates. This allows for controlled pressure profiles with distinct phases of energy release, enabling both fast operation and precise pressure control through the staged combustion process

Inventive Principle:

Principle #19Periodic action

4Ease of manufacture

If standard propellants are used without chemical alteration, then the ease of manufacture is improved, but the adaptability to different burn rate requirements deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidburn rate adjustment capability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fuel source design is universal and adaptable to different burn rate requirements by simply changing the combination and arrangement of propellant grains with different burn rates. The same housing and ignition system can accommodate various grain configurations to meet different operational requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11435170B2System and method for altering a burn rate of a propellant

Publication Date: 2022.09.06 BAKER HUGHES CO

AI summary

A system and apparatus for providing an apparatus for use in a wellbore. The apparatus includes an apparatus body defining a volume, a propellant disposed within the volume, wherein the propellant has a first burn rate, and at least one propellant insert disposed within the propellant, wherein the propellant insert has a second burn rate, and the second burn rate is different than the first burn rate.