Shape-Memory Polymer Expansion and Filter Cake Removal Fluid
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Solution Overview
Problem
Current methods for deploying shape-memory articles in downhole applications face challenges in efficiently removing filter cakes while ensuring complete expansion of these articles, as existing carrier fluids have low flash points and breaker compositions that can break filter cakes too quickly, preventing full deployment before cake removal.
Innovation Solution
A dual-function fluid system comprising an acid component, a chelating agent, an activator, a viscosifier, water or brine, and optionally a surfactant or corrosion inhibitor is used to expand shape-memory articles and remove filter cakes, allowing for controlled expansion and delayed cake removal, ensuring the articles are fully deployed before cake removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If existing carrier fluids are used to expand shape-memory articles, then the articles can be deployed, but the flash point is low causing safety concerns and incomplete expansion before filter cake removal
Solution Approach 1:
The patent modifies the chemical composition parameters of the carrier fluid by incorporating esters, alcohols, and other high flash-point components alongside the activator. This parameter change raises the flash point above 100°F while maintaining the fluid's ability to trigger shape-memory polymer expansion through controlled chemical interaction.
Solution Approach 2:
The carrier fluid is formulated as a composite system containing multiple components: shape-memory activators (acids, bases, salts), high flash-point solvents (esters, alcohols, glycols), and optional additives. This composite structure enables simultaneous achievement of high flash point safety and effective polymer expansion triggering.
2Productivity
If breaker compositions are used to remove filter cakes, then cake removal can occur, but the cakes break too quickly preventing full deployment of shape-memory articles
Solution Approach 1:
The patent creates a dynamic, multi-stage fluid system where the carrier fluid progressively breaks down the filter cake over time. The composition enables initial slow breakdown to allow article deployment, followed by accelerated breakdown once the article is positioned, optimizing both deployment time and removal efficiency.
Solution Approach 2:
The carrier fluid performs preliminary action by first enabling complete shape-memory article expansion and positioning before aggressively breaking down the filter cake. The fluid's composition and action are timed to ensure the article is fully deployed and secured before the filter cake breakdown process reaches completion.
3Reliability
If multiple trips are made to deploy articles and remove filter cakes, then each operation can be completed thoroughly, but the number of trips increases reducing operational efficiency
Solution Approach 1:
The patent develops a universal carrier fluid that performs multiple functions: it acts as a shape-memory polymer activator, serves as a high flash-point carrier medium, functions as a filter cake breaker, and provides corrosion inhibition. This multi-functional fluid eliminates the need for separate operations and materials, allowing both article deployment and filter cake removal in a single trip.
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
The fluid system effectively removes filter cakes after shape-memory articles are fully expanded, maintaining greater than 80% return production permeability and allowing for efficient deployment and operation of shape-memory polymer articles in downhole applications.
Implementation Method 1
shape-memory article comprising a shape-memory polymer, wherein the device is disposed when the shape-memory article is in a compacted shape; exposing the shape-memory article to a fluid system to cause the shape-memory article to expand and conform to a surface of the borehole
Implementation Method 2
The fluid system comprises (i) an acid component, a chelating agent, or a combination thereof; exposing the filter cake to the fluid system; and removing the filter cake with the fluid system
Data Source
AI summary
A method includes disposing a device into a borehole in proximity to a subterranean formation where a filter cake has been formed adjacent thereto, the device comprising a support structure and a shape-memory article disposed at the support structure, the shape-memory article comprising a shape-memory polymer, wherein the device is disposed when the shape-memory article is in a compacted shape; exposing the shape-memory article to a fluid system to cause the shape-memory article to expand and conform to a surface of the borehole; exposing the filter cake to the fluid system; and removing the filter cake with the fluid system. The fluid system comprises (i) an acid component, a chelating agent, or a combination thereof; (ii) an activator, (iii) a viscosifier, (iv) water or a brine, and (v) optionally a surfactant.