Water-Soluble Ceramic Well Tooling With Controlled Downhole Dissolution
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Solution Overview
Problem
The removal of downhole well tooling in extreme conditions is challenging, requiring intricate and time-consuming processes, and existing solutions do not align with sustainability goals.
Innovation Solution
Manufacturing water-soluble ceramic tooling using sodium silicate and ceramic refractory coatings, designed to dissolve predictably in well fluids, eliminating the need for removal and promoting environmental sustainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional tooling is used in downhole wells, then the tooling can withstand extreme conditions, but the removal process becomes intricate and time-consuming
Solution Approach 1:
The patent applies the disposable principle by creating tooling that is intentionally designed to dissolve after serving its purpose. The water-soluble ceramic tooling is engineered to maintain structural integrity during operation but then dissolve harmlessly in well fluids, eliminating the need for complex removal operations and reducing time loss associated with traditional tool retrieval.
2Reliability
If traditional tooling is used in downhole wells, then the tooling can withstand extreme conditions, but chemical or mechanical removal is required which increases complexity
Solution Approach 1:
The disposable principle eliminates removal process complexity by designing tooling that self-destructs through controlled dissolution. Instead of requiring complex chemical or mechanical removal operations, the tooling simply dissolves harmlessly in the well environment, transforming a complex removal problem into a simple dissolution process.
Solution Approach 2:
The patent applies parameter changes by modifying the material properties of the tooling to be water-soluble rather than permanently durable. This fundamental change in material parameter (from impermeable to soluble) transforms the end-of-life scenario from complex removal to simple dissolution, eliminating the need for specialized removal procedures.
3Loss of time
If water-soluble tooling is used, then the need for tooling removal is eliminated, but the tooling must withstand high temperatures and pressures before dissolving
Solution Approach 1:
The patent applies composite materials by creating a water-soluble ceramic tooling that combines the strength needed to withstand extreme downhole conditions with the property of controlled dissolution. The ceramic matrix provides mechanical strength and heat resistance, while the water-soluble characteristics enable predictable dissolution after the tooling serves its function, achieving both durability during operation and ease of disposal afterward.
Solution Approach 2:
The patent uses parameter changes to control the dissolution behavior of the tooling. By adjusting the water-solubility parameters of the ceramic material, the tooling can be engineered to maintain structural integrity at high temperatures and pressures during operation, then dissolve predictably when exposed to well fluids, achieving the desired balance between durability and disposability.
4Loss of substance
If water-soluble ceramic tooling is manufactured, then sustainability is improved by minimizing waste, but the manufacturing process requires specific materials like sodium silicate
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the ceramic material to be water-soluble rather than conventional ceramic. This parameter change enables the tooling to dissolve harmlessly after use, minimizing waste and improving sustainability. The use of sodium silicate as a binding agent facilitates this water-soluble property while maintaining manufacturability through existing ceramic processing techniques.
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 water-soluble tooling withstands high temperatures and pressures, dissolves harmlessly in water, reducing waste and lead times, and enabling complex geometries, thus enhancing sustainability and efficiency in downhole operations.
Implementation Method 1
The quantity of sodium silicate corresponds to an amount of refined sodium silicate with a high melting point of about 1,400 degrees Celsius (C)
Implementation Method 2
The primary quantity of ceramic refractory coating corresponds to the coating material utilized to control the period when the manufactured tooling starts dissolving
Implementation Method 3
The water-soluble tooling of the present invention is designed to facilitate the sustainable and ecofriendly disposal of well tooling to eliminate the need for removal of the well tooling
Data Source
AI summary
The system and method of manufacturing water-soluble ceramic downhole well tooling enables the manufacturing of sustainable and ecofriendly well tooling that can be disposed of inside downhole wells to eliminate the need for removal processes. A quantity of sodium silicate up is heated to a melting point to form molten sodium silicate ceramic. Once the molten sodium silicate ceramic is obtained, the molten sodium silicate ceramic is poured into the casting mold to shape the molten sodium silicate ceramic to the desired tool piece shape. Then, the molten sodium silicate ceramic is cooled within the casting mold to form the specific tool piece. Once cooled, the specific tool piece is removed from the casting mold to separate the formed tool piece from the casting mold. Finally, the primary quantity of ceramic refractory coating is applied to the specific tool piece to form a primary external coat layer.