Hierarchical Reactive Composite for Controlled Wellbore Disintegration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing disintegrating materials used in well completion processes have limitations such as limited strength and poor reliability, making them unsuitable for long-term storage and reliable disintegration upon activation.
Innovation Solution
A hierarchically-designed reactive composite system with a core and surface layers, where the core is designed to react at a high rate and the surface layers inhibit reaction until activated by specific conditions like temperature, pH, or chemicals, allowing for controlled disintegration in well environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reactive materials are used for disintegration in well completion, then disintegration function is achieved, but reliability and strength are poor
Solution Approach 1:
The system is divided into two distinct segments: a protective coating layer and a reactive core material. The coating layer maintains structural integrity and strength during storage and handling, while the reactive core provides the disintegration function. This segmentation allows each component to optimize its specific function without compromising the other.
Solution Approach 2:
The protective coating is applied in advance to the reactive core material before use. This preliminary protective action prevents premature reaction during storage, handling, and installation, ensuring the component remains strong and intact until the intended activation moment in the well environment.
2Reliability
If reactive materials are used for disintegration, then disintegration function is achieved, but storage stability deteriorates
Solution Approach 1:
The protective coating acts as an intermediary barrier between the reactive core material and the external environment (water, oxygen, other chemicals). This intermediary layer prevents direct contact that would trigger unwanted reactions during storage, while allowing controlled activation when needed in the well environment.
Solution Approach 2:
The reactive core material is extracted and isolated from direct environmental exposure by enclosing it within the protective coating. This extraction of the reactive material from harmful environmental interactions during storage maintains stability while preserving the disintegration function for later activation.
3Productivity
If unprotected reactive materials are used, then disintegration occurs rapidly, but control over disintegration timing is lost
Solution Approach 1:
The protective coating is applied in advance to prevent premature reaction, ensuring the component remains stable during storage and installation. The coating is designed to remain intact until the intended activation moment, providing reliable timing control.
Solution Approach 2:
The coating material is selected with specific properties (thickness, chemical composition, permeability) that control the timing and conditions of activation. By adjusting these parameters, the system achieves both rapid disintegration when activated and precise control over when activation occurs.
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 the formation of components that can be stored for extended periods and reliably disintegrate upon activation, improving the efficiency and reliability of well completion processes by ensuring controlled and repeatable disintegration.
Implementation Method 1
The core can be designed to dissolve, corrode, react, fracture, etc. when exposed to the water and/or to saltwater/electrolytes... thereby causing the component to dissolve or disintegrate in the well. The core can be designed to generate heat when exposed to various environments
Implementation Method 2
reactive materials, which dissolve or corrode when exposed to acid, salt, or other wellbore conditions
Implementation Method 3
dissolve, corrode, react, fracture, etc. when exposed to the water and/or to saltwater/electrolytes
Implementation Method 4
one or more surfaces or protective layers that inhibits or prevents the core from reacting and/or disintegrating until a desired time or event. The one or more surfaces or protective layers are designed to be inert unless exposed to an activation conditions
Data Source
AI summary
An engineered composite system designed to be passive or inert under one set of conditions, but becomes active when exposed to a second set of conditions. This system can include a dissolving or disintegrating core, and a surface coating that has higher strength or which only dissolves under certain temperature and pH conditions, or in selected fluids. These reactive materials are useful for oil and gas completions and well stimulation processes, enhanced oil and gas recovery operations, as well as in defensive and mining applications requiring high energy density and good mechanical properties, but which can be stored and used for long periods of time without degradation.