Thermite Charges as Primary Energy Source for Well Perforation

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Solution Overview

Problem

Existing well perforation and fracing technologies rely heavily on explosive materials, which are not always efficient, and thermite material, when used, typically constitutes a small percentage of the charge weight, not serving as a primary energy source.

Innovation Solution

Thermite material is utilized as a primary energy source in well perforation and fracing charges, comprising a pyrotechnic mixture of a fuel source and an oxide compound, with a molar ratio of 1:1-10, and can represent up to 100% of the charge weight, either in the core, case, or both, to provide a high-energy deflagration mechanism.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If explosive materials are used as the primary energy source in charges, then the charges can provide high energy release for well perforation, but the efficiency and effectiveness are limited and thermite material cannot serve as the primary energy source when used in small percentages

Engineering Contradiction:

Improveenergy release efficiencyVSAvoidperforation effectiveness

Core Design Contradiction:

Use of energy by moving objectVSProductivity

Solution Approach 1:

The patent fundamentally changes the composition parameter of the charge by using thermite material as the primary energy source comprising at least 50% (preferably at least 75%, more preferably at least 90%, and most preferably 100%) of the total charge weight, replacing the conventional approach where thermite was used in small percentages (<5%) as a liner material only. This parameter change enables thermite to serve as the primary energy source, providing high energy release for effective well perforation and fracing operations.

Inventive Principle:

Principle #35Parameter changes

2Strength

If thermite material is used as a liner material comprising less than 5% of the total charge weight, then the charge structure can be maintained, but the thermite material cannot provide sufficient energy release to serve as the primary energy source

Engineering Contradiction:

Improvecharge structure integrityVSAvoidenergy release capability

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The patent reverses the conventional role assignment by making thermite material the primary energy source comprising at least 50% of the total charge weight, rather than using it as a minor structural component. This parameter change allows the charge structure to be maintained through proper formulation while enabling thermite to provide sufficient energy release for effective well perforation and fracing operations.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If explosive materials are used for well perforation, then the perforation process can be completed, but the ability to heat fluids and create pressure for fracing is insufficient

Engineering Contradiction:

Improveperforation completionVSAvoidfluid heating capability

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The patent replaces conventional explosive materials with thermite material as the energy source. This substitution provides both the mechanical energy needed for perforation and the thermal energy required for fracing operations. The thermite material's ability to generate high temperatures heats brine or other fluids injected into the well, creating pressure to fracture the formation and enable oil or gas flow.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The thermite-based charge system performs multiple functions: it creates perforations in the well casing and formation, heats injected fluids to generate fracing pressure, and can directly fracture formations through thermal stress. This multi-functionality eliminates the need for separate perforation and fracing operations, improving operational efficiency and effectiveness.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 use of thermite material as a primary energy source in well perforation and fracing charges enables efficient energy release, creating fractures in well formations and enhancing fluid flow by heating brine fluids and increasing pressure, thus improving the effectiveness of the perforation process.

Implementation Method 1

after ignition, thermite material typically exhibits deflagration rather than explosion

Methodology Applied

Scientific EffectDeflagration: Deflagration

Implementation Method 2

thermite material includes a pyrotechnic mixture of a fuel source, which is a zero valent oxidizable element (E(0)), and an oxide compound (XO) that provides oxygen for oxidizing or burning the fuel source

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Implementation Method 3

The pressure is exerted into the well formation and creates fractures or extends and expands existing fractures present in target zones of the well formation

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS8685187B2Perforating devices utilizing thermite charges in well perforation and downhole fracing

Publication Date: 2014.04.01 SCHLUMBERGER TECH CORP

AI summary

Disclosed are thermite charges for use in well perforation and downhole fracing. The thermite charges have a core, and optionally a case, where at least one of the core and the case includes thermite material.