WO2013022635A2 - Method of controlling corrosion rate in downhole article, and downhole article having controlled corrosion rate - Google Patents
Method of controlling corrosion rate in downhole article, and downhole article having controlled corrosion rate Download PDFInfo
- Publication number
- WO2013022635A2 WO2013022635A2 PCT/US2012/048792 US2012048792W WO2013022635A2 WO 2013022635 A2 WO2013022635 A2 WO 2013022635A2 US 2012048792 W US2012048792 W US 2012048792W WO 2013022635 A2 WO2013022635 A2 WO 2013022635A2
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- Prior art keywords
- article
- electrolyte
- ball
- metal
- acting
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 30
- 230000007797 corrosion Effects 0.000 title description 40
- 238000005260 corrosion Methods 0.000 title description 40
- 239000000463 material Substances 0.000 claims abstract description 87
- 239000003792 electrolyte Substances 0.000 claims abstract description 35
- 230000009257 reactivity Effects 0.000 claims abstract description 32
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 34
- 239000011248 coating agent Substances 0.000 claims description 26
- 238000000576 coating method Methods 0.000 claims description 26
- 229910000861 Mg alloy Inorganic materials 0.000 claims description 23
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 17
- 229910052759 nickel Inorganic materials 0.000 claims description 17
- 239000000956 alloy Substances 0.000 claims description 15
- 229910045601 alloy Inorganic materials 0.000 claims description 15
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 12
- 229910052749 magnesium Inorganic materials 0.000 claims description 12
- 239000011777 magnesium Substances 0.000 claims description 12
- 229910052782 aluminium Inorganic materials 0.000 claims description 11
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 10
- 239000010949 copper Substances 0.000 claims description 10
- 229910052802 copper Inorganic materials 0.000 claims description 9
- 229910052742 iron Inorganic materials 0.000 claims description 9
- 230000000149 penetrating effect Effects 0.000 claims description 9
- 229910000831 Steel Inorganic materials 0.000 claims description 8
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 8
- 239000012267 brine Substances 0.000 claims description 8
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 claims description 8
- 239000000347 magnesium hydroxide Substances 0.000 claims description 8
- 229910001862 magnesium hydroxide Inorganic materials 0.000 claims description 8
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 claims description 8
- 239000010959 steel Substances 0.000 claims description 8
- 239000011701 zinc Substances 0.000 claims description 8
- 229910052725 zinc Inorganic materials 0.000 claims description 8
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 7
- 229910052721 tungsten Inorganic materials 0.000 claims description 7
- 229910017052 cobalt Inorganic materials 0.000 claims description 6
- 239000010941 cobalt Substances 0.000 claims description 6
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 6
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 5
- 229910052804 chromium Inorganic materials 0.000 claims description 5
- 239000011651 chromium Substances 0.000 claims description 5
- 229910044991 metal oxide Inorganic materials 0.000 claims description 5
- 150000004706 metal oxides Chemical class 0.000 claims description 5
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 5
- 239000010937 tungsten Substances 0.000 claims description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 5
- 239000002253 acid Substances 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 claims description 3
- 229910000000 metal hydroxide Inorganic materials 0.000 claims description 3
- 229920000642 polymer Polymers 0.000 claims description 3
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 3
- RYTYSMSQNNBZDP-UHFFFAOYSA-N cobalt copper Chemical compound [Co].[Cu] RYTYSMSQNNBZDP-UHFFFAOYSA-N 0.000 claims 1
- 229910052751 metal Inorganic materials 0.000 description 70
- 239000002184 metal Substances 0.000 description 70
- 239000010410 layer Substances 0.000 description 9
- 150000002739 metals Chemical class 0.000 description 9
- 239000000843 powder Substances 0.000 description 5
- 230000008878 coupling Effects 0.000 description 4
- 238000010168 coupling process Methods 0.000 description 4
- 238000005859 coupling reaction Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 239000011572 manganese Substances 0.000 description 4
- 150000003839 salts Chemical class 0.000 description 4
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 3
- ZMXDDKWLCZADIW-UHFFFAOYSA-N N,N-Dimethylformamide Chemical compound CN(C)C=O ZMXDDKWLCZADIW-UHFFFAOYSA-N 0.000 description 3
- 239000011575 calcium Substances 0.000 description 3
- 239000012530 fluid Substances 0.000 description 3
- 235000012254 magnesium hydroxide Nutrition 0.000 description 3
- 229910052748 manganese Inorganic materials 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 230000003647 oxidation Effects 0.000 description 3
- 238000007254 oxidation reaction Methods 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- YEJRWHAVMIAJKC-UHFFFAOYSA-N 4-Butyrolactone Chemical compound O=C1CCCO1 YEJRWHAVMIAJKC-UHFFFAOYSA-N 0.000 description 2
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 2
- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 2
- 239000011149 active material Substances 0.000 description 2
- 238000005275 alloying Methods 0.000 description 2
- -1 brine) Chemical class 0.000 description 2
- 229910052793 cadmium Inorganic materials 0.000 description 2
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 description 2
- 229910052791 calcium Inorganic materials 0.000 description 2
- 239000003518 caustics Substances 0.000 description 2
- 239000003086 colorant Substances 0.000 description 2
- 238000005242 forging Methods 0.000 description 2
- 229910000037 hydrogen sulfide Inorganic materials 0.000 description 2
- 239000002608 ionic liquid Substances 0.000 description 2
- 230000000670 limiting effect Effects 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 239000011255 nonaqueous electrolyte Substances 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 239000011435 rock Substances 0.000 description 2
- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- 229910052712 strontium Inorganic materials 0.000 description 2
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 2
- ZSLUVFAKFWKJRC-IGMARMGPSA-N 232Th Chemical compound [232Th] ZSLUVFAKFWKJRC-IGMARMGPSA-N 0.000 description 1
- KMTRUDSVKNLOMY-UHFFFAOYSA-N Ethylene carbonate Chemical compound O=C1OCCO1 KMTRUDSVKNLOMY-UHFFFAOYSA-N 0.000 description 1
- FXHOOIRPVKKKFG-UHFFFAOYSA-N N,N-Dimethylacetamide Chemical compound CN(C)C(C)=O FXHOOIRPVKKKFG-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 229910052776 Thorium Inorganic materials 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 238000002048 anodisation reaction Methods 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000498 ball milling Methods 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
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- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
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- 238000009646 cryomilling Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000005137 deposition process Methods 0.000 description 1
- 238000005868 electrolysis reaction Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 230000001939 inductive effect Effects 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
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- 238000005259 measurement Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
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- 239000003607 modifier Substances 0.000 description 1
- 229910000510 noble metal Inorganic materials 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 230000036961 partial effect Effects 0.000 description 1
- 238000000053 physical method Methods 0.000 description 1
- 239000003880 polar aprotic solvent Substances 0.000 description 1
- RUOJZAUFBMNUDX-UHFFFAOYSA-N propylene carbonate Chemical compound CC1COC(=O)O1 RUOJZAUFBMNUDX-UHFFFAOYSA-N 0.000 description 1
- 230000002829 reductive effect Effects 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
- VSZWPYCFIRKVQL-UHFFFAOYSA-N selanylidenegallium;selenium Chemical compound [Se].[Se]=[Ga].[Se]=[Ga] VSZWPYCFIRKVQL-UHFFFAOYSA-N 0.000 description 1
- 230000011664 signaling Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
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- 238000006467 substitution reaction Methods 0.000 description 1
- JBQYATWDVHIOAR-UHFFFAOYSA-N tellanylidenegermanium Chemical compound [Te]=[Ge] JBQYATWDVHIOAR-UHFFFAOYSA-N 0.000 description 1
- 239000011573 trace mineral Substances 0.000 description 1
- 235000013619 trace mineral Nutrition 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B34/00—Valve arrangements for boreholes or wells
- E21B34/06—Valve arrangements for boreholes or wells in wells
- E21B34/063—Valve or closure with destructible element, e.g. frangible disc
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25F—PROCESSES FOR THE ELECTROLYTIC REMOVAL OF MATERIALS FROM OBJECTS; APPARATUS THEREFOR
- C25F3/00—Electrolytic etching or polishing
- C25F3/02—Etching
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25F—PROCESSES FOR THE ELECTROLYTIC REMOVAL OF MATERIALS FROM OBJECTS; APPARATUS THEREFOR
- C25F7/00—Constructional parts, or assemblies thereof, of cells for electrolytic removal of material from objects; Servicing or operating
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B29/00—Cutting or destroying pipes, packers, plugs or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/12—Packers; Plugs
Definitions
- Certain downhole operations involve placement of elements in a downhole environment, where the element performs its function, and is then removed.
- elements such as ball/ball seat assemblies and fracture (frac) plugs are downhole elements used to seal off lower zones in a borehole in order to carry out a hydraulic fracturing process (also referred to in the art as "fracking") to break up different zones of reservoir rock.
- frac hydraulic fracturing process
- the ball/ball seat or plugs are then removed to allow fluid flow to or from the fractured rock.
- Balls and/or ball seats, and frac plugs can be formed of a corrodible material so that they need not be physically removed intact from the downhole environment. In this way, when the operation involving the ball/ball seat or frac plug is completed, the ball, ball seat, and/or frac plug is dissolved away. Otherwise, the downhole article may have to remain in the hole for a longer period than is necessary for the operation.
- such elements can be formed of a material that reacts with the ambient downhole environment so that they need not be physically removed by, for example, a mechanical operation, but instead corrode or dissolve under downhole conditions.
- corrosion rates of, for example, an alloy used to prepare such a corrodible article can be controlled by adjusting alloy composition, an alternative way of controlling the corrosion rate of a downhole article is desirable.
- a method of removing a downhole assembly includes contacting, in the presence of an electrolyte, a first article including a first material and acting as an anode, and a second article including a second material having a lower reactivity than the first material and acting as a cathode, the downhole assembly including the first article in electrical contact with the second article, wherein at least a portion of the first article is corroded in the electrolyte.
- a method of producing an electrical potential in a downhole assembly includes contacting, with an electrolyte, a first article, the first article including a first material and acting as an anode, and a second article, the second article including a second material having a lower reactivity than the material of the first article and acting as a cathode, with a conductive element to form a circuit.
- a downhole assembly in another embodiment, includes a first article including a first material and acting as an anode, and a second article including a second material having a lower reactivity than the first material and acting as a cathode, the first and second articles being electrically connected by a conductive element to form a circuit, wherein in the presence of an electrolyte, the downhole assembly produces an electrical potential, and at least a portion of the first article is corroded.
- FIG. 1A shows a cross-sectional view of a downhole assembly 100a with a ball 120 made of a corrodible first metal, and a seat 110 having a seating portion 111 made of a second metal;
- FIGs. IB and 1C show a cross-sectional view of a downhole assembly (100b, 100c) with a ball 120 and a seat 111m shifting from a first position 110b to a second position 110c to place the seat 11 lm in contact with an insert 114 made of a second metal to initiate corrosion;
- FIG. 2 shows a cross-sectional view of a downhole assembly 200 with a ball 220 with a core 221 made of a corrodible first metal, a coating 222, and a seat 210 having a seating portion 211 made of a second metal, in which a bridging connection B electrically connects the ball 220 and seat 210;
- FIG. 3A shows a cross-sectional view of a downhole assembly 300 with a ball 320 with an axial core 321 of a first metal surrounded by an outer core 322, a seat 310 having a seating portion 311 made of a second metal; and
- FIG. 3B shows a cross-sectional view of a downhole assembly 300a after removal of axial core 321 in FIG. 3A, with a ball 320a with an channel 321a surrounded by an outer core 322, and a seat 310 having a seating portion 311 made of a second metal.
- the downhole device includes an assembly of two subunits, a first subunit prepared from a first material, and a second subunit prepared from a second material, the first material having a higher galvanic activity (i.e., is more reactive) than the second material.
- the first and second materials can each be, for example, a different metal from the galvanic series.
- the first and second materials contact each other in the presence of an electrolyte, such as for example brine.
- the first subunit is, for example, a ball, made of a corrodible, high reactivity metal such as magnesium, which is anodic
- the second subunit is, for example, a ball seat made of a non-corrodible, relatively low reactivity metal (as compared to the high reactivity metal used to form the ball) such as nickel, iron, cobalt, etc, which is cathodic.
- the first subunit is, for example, a ball seat, and the second, a ball.
- the high reactivity material corrodes at a faster or slower rate, respectively.
- a direct current electrical potential can be applied to (or generated by) the anodic and cathodic subunits via the electrical connection, to initiate the corrosion of the subunit made of high reactivity metal (e.g., the ball).
- the direct current source can be, for example, a battery placed downhole or at the surface, and electrically connected to the article.
- an electrochemical potential is generated between the anodic high reactivity metal subunit (i.e., the ball in the above example) and the cathodic low reactivity metal subunit (e.g., a ball seat).
- the cathodic subunit is protected from corrosion by the anodic subunit, where the anodic subunit corrodes as a sacrificial anode. Corrosion of metal subunits in brines and other electrolytes can be reduced by coupling them to more active metals. For example, a steel article electrically coupled to a magnesium article in the presence of brine is less prone to corrosion than a steel article not in electrical contact with a magnesium article.
- Electrically coupling the anodic ball and the cathodic ball seat with an electrolyte also produces an electrical potential useful to power a downhole device, such as, for example, a device for downhole signaling or sensing.
- a method of removing a downhole assembly thus includes contacting, in the presence of an electrolyte, a first article comprising a first material and acting as an anode, and a second article comprising a second material having a lower reactivity than the material of the first article and acting as a cathode, the downhole assembly including the first article in electrical contact with the second article, wherein at least a portion of the first article is corroded in the electrolyte.
- the first material includes any material suitable for use in a downhole environment, provided the first material is corrodible in the downhole environment relative to a second material having a different reactivity.
- the first material comprises a magnesium alloy.
- Magnesium alloys include any such alloy which is corrodible in a corrosive environment including those typically encountered downhole, such as an aqueous environment which includes salt (i.e., brine), or an acidic or corrosive agent such as hydrogen sulfide, hydrochloric acid, or other such corrosive agents.
- Magnesium alloys suitable for use include alloys of magnesium with aluminum (Al), cadmium (Cd), calcium (Ca), cobalt (Co), copper (Cu), iron (Fe), manganese (Mn), nickel (Ni), silicon (Si), silver (Ag), strontium (Sr), thorium (Th), zinc (Zn), zirconium (Zr), or a combination comprising at least one of these elements.
- Particularly useful alloys include magnesium alloy particles including those prepared from magnesium alloyed with Ni, W, Co, Cu, Fe, or other metals. Alloying or trace elements can be included in varying amounts to adjust the corrosion rate of the magnesium.
- magnesium alloys which include different combinations of the above alloying elements to achieve different degrees of corrosion resistance include but are not limited to, for example, those alloyed with aluminum, strontium, and manganese such as AJ62, AJ50x, AJ51x, and AJ52x alloys, and those alloyed with aluminum, zinc, and manganese which include AZ91A-E alloys.
- alloys having corrosion rates greater than those of the above exemplary alloys are contemplated as being useful herein.
- nickel has been found to be useful in decreasing the corrosion resistance (i.e., increasing the corrosion rate) of magnesium alloys when included in amounts less than or equal to about 0.5 wt%, specifically less than or equal to about 0.4 wt%, and more specifically less than or equal to about 0.3 wt%, to provide a useful corrosion rate for the corrodible downhole article.
- the above magnesium alloys are useful for forming the first article, and are formed into the desired shape and size by casting, forging and machining.
- powders of magnesium or the magnesium alloy are useful for forming the first article.
- the magnesium alloy powder generally has a particle size of from about 50 to about 250 micrometers (Dm), and more specifically about 60 to about 140 Dm.
- the powder is further coated using a method such as chemical vapor deposition, anodization or the like, or admixed by physical method such as cryo-milling, ball milling, or the like, with a metal or metal oxide such as Al, Ni, W, Co, Cu, Fe, oxides of one of these metals, or the like.
- Such coated magnesium powders are referred to herein as controlled electrolytic materials (CEM).
- CEM controlled electrolytic materials
- the CEM is then molded or compressed into the desired shape by, for example, cold compression using an isostatic press at about 40 to about 80 ksi (about 275 to about 550 MPa), followed by extrusion, forging, or sintering, or machining, to provide a core having the desired shape and dimensions.
- the magnesium alloy or CEM will thus have any corrosion rate necessary to achieve the desired performance of the article.
- the magnesium alloy or CEM used to form the core has a corrosion rate of about 0.1 to about 150 mg/cm 2 /hour, specifically about 1 to about 15 mg/cm 2 /hour using aqueous 3 wt% KC1 at 200°F (93°C).
- the first article optionally has a non-metallic coating on a surface of the first article.
- the coating includes a soluble glass, a soluble polymer, or a metal oxide or hydroxide coating (including an anodized coating).
- the non-metallic coating is an oxidation product of the metal of the first article, particularly where the first article comprises an active metal (relative to the second article).
- the non-metallic coating can be magnesium hydroxide formed by an anodic process.
- a hard metal oxide coating such as aluminum oxide can be applied to the surface of the first article by a deposition process.
- the non-metallic coating is removed by ambient conditions downhole, or by application of an electric potential.
- the coating is a soluble material such as a soluble glass or polymer
- the coating dissolves in the ambient downhole fluids, such as water, brine, distillates, or the like, to expose the underlying first material.
- a metal oxide or hydroxide is used, an electrical contact can be established between the first and second articles, and an electrical potential applied to perform electrolysis on the coating and induce corrosion.
- the second material is, in an embodiment, any metal having a lower reactivity than the first material, based on, for example, the saltwater galvanic series.
- the second material is also resistant to corrosion by a corrosive material.
- resistant means the second material is not etched or corroded by any corrosive downhole conditions encountered (i.e., brine, hydrogen sulfide, etc., at pressures greater than atmospheric pressure, and at temperatures in excess of 50°C).
- the high reactivity material e.g., high reactivity metal
- the order of metals, from more noble (i.e., less active and more cathodic) to less noble (i.e., more active, and more anodic) includes for example steel, tungsten, chromium, nickel, cobalt, copper, iron, aluminum, zinc, and magnesium.
- the second material includes steel, tungsten, chromium, nickel, copper, iron, aluminum, zinc, alloys thereof, or a combination comprising at least one of the foregoing, where the first material is magnesium or an alloy thereof.
- the first material is a magnesium alloy
- the second material is steel, nickel, cobalt, or copper.
- the second article is entirely fabricated of the second material, or the second article includes a layer of the second material.
- a layer includes a single layer, or multiple layers of the same or different materials.
- the underlying material is a metal, ceramic, or the like, and in an embodiment is, for example, fabricated from the first material such that it is separated from the first material of the first article by the layer(s) of second material.
- the first article and second article are not limited to any particular shape or function.
- the first and second articles are used together in a fitted assembly.
- the first article is CEM ball
- the second article is a ball seat.
- the first article is a CEM ball seat
- the second article is a ball.
- the first article is a CEM fracture plug and the second is the housing for the fracture plug.
- the first article is a CEM ball or frac plug
- the second article is the ball seat or housing (respectively), where this arrangement allows for greater adaptability of a system in which a variety of non-fixed articles (e.g., a ball) are all be used with one type of fixed article (such as a ball seat).
- a portion of the fixed article e.g., ball seat
- a more noble (second) metal such as zinc, aluminum, or nickel
- the first article comprises a non-corrodible core comprising the second material and at least partially penetrating the first article, and a corrodible surrounding structure comprising the first material, wherein only the surrounding structure is corroded.
- the first article in this way is partially composed of the first material and second material.
- the first article is a ball or elongated structure having one or more non-corrodible cores inserted part way into the article, or running axially or along a chord through the center of or off-center (respectively) of the ball or structure. Any dimension of the first article can be penetrated; in one embodiment, the longest dimension is traversed by the core.
- the first article includes a low reactivity core (e.g., nickel) partially penetrating the first article, and a corrodible surrounding structure (e.g., a magnesium alloy or CEM).
- the first article is a corrodible ball formed of a magnesium alloy or CEM, having one or more nickel cores or screws inserted into it.
- This arrangement provides for close contact of the first and second materials, where the corrosion of the first article is accelerated by placing the article downhole and electrically connecting one or more of the nickel screws with the magnesium alloy ball.
- the first article is a corrodible seat having one or more non-corrodible cores partially or fully penetrating (e.g., screwed) radially into the side. The presence of these cores provides additional contact between the first and second materials, and facilitates electrical contact with a second article (e.g., a ball where the first article is a seat, or vice versa).
- the first article comprises a corrodible core comprising the first material and at least partially penetrating the first article, and a non- corrodible surrounding structure comprising the second material, wherein only the core is corroded.
- the first article in this way includes a corrodible core penetrating through a long axis or diameter of the first article, and a non-corrodible surrounding structure. Application of a controlled corrosion to such first articles would then result in only the core being corroded, leaving a channel through the ball.
- the first article is a non-corrodible ball made of a low reactivity material (e.g., of aluminum or nickel), with one or more high reactivity (e.g., magnesium alloy) cores penetrating (e.g., screwed into or formed) therethrough.
- the first article is the seat having a corrodible core penetrating (e.g., screwed) radially through the side, where the corrosion and removal of the corrodible core opens to the underlying sidewall and any features (e.g., channels, etc) beneath. In this way, the ball (or seat) is used to allow a partial flow.
- the core comprises more than one metal in successive layers, each having a different reactivity.
- This arrangement can be used to selectively increase the flow, such as by forming the first article of concentric layers of increasingly noble metals (on the galvanic scale, such as layers of different magnesium alloys, which are corrodible relative to the surrounding structure), which would allow a gradual increase in the size of the channel as additional layers are corroded.
- the electrolyte includes an aqueous or non-aqueous electrolyte, depending on the application and controllability of ambient conditions.
- a non-aqueous electrolyte includes an ionic liquid, a molten salt, an ionic liquid dissolved in an oil, or a salt dissolved in a polar aprotic solvent such as ethylene carbonate, propylene carbonate, dimethylformamide, dimethylacetamide, gamma-butyrolactone, or other such solvents.
- a polar aprotic solvent such as ethylene carbonate, propylene carbonate, dimethylformamide, dimethylacetamide, gamma-butyrolactone, or other such solvents.
- the electrolyte is an aqueous electrolyte.
- Aqueous electrolytes include water or a salt dissolved in water, such as brine, an acid, or a combination comprising at least one of the foregoing.
- corroding the first article by the electrolyte is accomplished by electrically contacting the first and second articles in the presence of the electrolyte, optionally by inducing the corrosion by applying a potential to the first and second articles in the presence of the electrolyte.
- a direct current electrical potential can thus be applied to the anode and cathode (second and first articles, respectively, where the first and second articles are electrically insulated from one another and the cell is being run in reverse) via the electrical connection, to initiate the corrosion in the first article.
- the source of the direct current for this process can be, for example, a moving sleeve within the article, in which the sleeve is mechanically coupled to a power source (a battery, magneto, or a small generator which generates a current by induction).
- a power source a battery, magneto, or a small generator which generates a current by induction.
- the downhole assembly when electrically connected to provide a complete electrical circuit, produces electrical current by forming a galvanic cell in which the first and second articles (i.e., anode and cathode, comprising the first and second metals, respectively, where the cell is being run forward) are electrically connected by a bridging circuit in the presence of the electrolyte.
- the first and second articles are not in direct electrical contact with each other but are in electrical contact through (i.e., in common electrical contact with) an electrolyte, or where in physical contact are separated by, for example an insulating material such as a coating of Mg(OH) 2 or a non-conductive O-ring to prevent a short circuit of the cell.
- a method of producing an electrical potential in a downhole assembly includes contacting, with an electrolyte, a first article, the first article comprising a first metal and acting as an anode; and a second article, the second article comprising a second metal having a lower reactivity than the metal of the first article and acting as a cathode.
- the anode and cathode are in common electrical contact with each other via a conductive element (e.g., an electric load, such as a sensor or heater) to form a circuit.
- a downhole assembly includes a first article comprising a first material, and a second article comprising a second material having a lower reactivity than the material of the first article and acting as a cathode, the first and second articles being electrically connected by a conductive element (e.g., electric load) to form a circuit, wherein in the presence of an electrolyte, the downhole assembly produces an electrical potential, and at least a portion of the first article is corroded.
- a conductive element e.g., electric load
- FIG. 1A shows a cross-sectional view of a downhole assembly 100a.
- a ball 120 made of a corrodible first metal is seated in a seat 110 having a seating portion 111 made of a second metal and contained in a housing 112.
- the ball 120 and seat 110 are in direct electrical contact with each other when an electrolyte is present, or where no insulating layer (such as Mg(OH) 2 ) or other material separates ball 120 and seat 110.
- the ball 120 is seated in a movable seating portion 111m (initial assembly 100b in FIG. IB).
- the seat 111m comprises the first metal, and is a movable unit held initially in a first position 110b in contact with the sidewall 113 not comprising a second metal.
- the seat 111m is shifted longitudinally through a surrounding housing 112 from the first position (110b in FIG. IB), to a second position (110c in FIG. 1C) to provide the shifted assembly 100c in FIG. 1C, in which the seat 111m is in contact with an insert 114 formed of the second metal.
- insert 114 is electrically insulated from sidewall 113. In this way, the seat 11 lm is not corroded until it is moved into galvanic contact with the insert 114 of the second material. Also in an embodiment, the ball 120, seat 111m, and insert 114 are each formed of different materials of construction, where each is interchangeably made of the first metal, second metal, or a third metal having a reactivity intermediate to the first and second metals.
- FIG. 2 shows a cross-sectional view of a downhole assembly 200 with a ball 220 with a core 221 made of a corrodible first metal, a coating 222, and a seat 210 having a seating portion 211 made of a second metal and contained in a housing 212.
- the coating is, for example, an oxidation product of the metal of the corrodible first metal (e.g., Mg(OH)2 where the first metal is magnesium or a magnesium alloy).
- the presence of the coating electrically insulates the ball 220 from the seat 210, and hence, application of current by a power source electrically connected to a bridging connection (B) and which electrically connects the ball 220 and seat 210, initiates corrosion of ball 220, when an electrolyte is present.
- FIG. 3A shows a cross-sectional view of a downhole assembly 300 with a ball 320 with an axial core 321 of a first metal surrounded by an outer core 322, a seat 310 having a seating portion 311 made of a second metal and housing 312.
- An optional bridging connection B (not shown) electrically connects the ball 320 and seat 310, and initiates corrosion of axial core 321 by application of current, where an insulative coating (not shown) is present, or generates a potential.
- the axial core 321 can be made of the first metal, while the outer core 322 can be made of the second metal, where the axial core 321 corrodes leaving the outer core 322.
- the axial core 321 can be made of the second metal, while the outer core 322 can be made of the first metal, where the outer core 322 corrodes leaving the axial core 321.
- axial core 321 and outer core 322 remain in constant electrical contact. Because any Mg(OH)2 coating on the first metal is incomplete, electrolyte contacts both the axial and outer cores 321 and 322, respectively. In the embodiment, the part of the article made of the more reactive first metal will corrode faster, and the material of the seating portion 311 therefore does not govern the galvanic interaction.
- axial core 321 and outer core 322 remain in constant electrical contact. Because any Mg(OH) 2 coating on the first metal is incomplete, electrolyte contacts both the axial core 321 and the outer core 322. In this embodiment, the part of the article (e.g., the ball) made of the more active first metal will corrode faster, and the material of the seating portion 311 therefore does not affect the corrosion of the axial or outer cores 321 or 322.
- FIG. 3B shows a cross-sectional view of a downhole assembly 300a similar to that of FIG. 3A but after corrosion of the first metal (where the axial core 321a comprises the first metal), with a ball 320a having a channel 321a (corresponding to the axial core 321 in FIG. 3A, now removed) surrounded by an outer core 322, and a seat 310 having a seating portion 311 made of a second metal and contained in a housing 312.
- the channel 321a allows only a limited opening between zones above and below the seated ball, to restrict the flow of fluid between these to an intermediate level.
- a frack plug of the first metal and having a ball or check valve of the first metal has a cap of an additional active material, such as a reactive magnesium alloy powder that is more reactive than the first metal, placed on top of the plug.
- an additional active material such as a reactive magnesium alloy powder that is more reactive than the first metal
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Abstract
Description
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Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
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EP12822169.4A EP2739812B1 (en) | 2011-08-05 | 2012-07-30 | Method of controlling corrosion rate in downhole article, and downhole article having controlled corrosion rate |
BR112014002348-4A BR112014002348B1 (en) | 2011-08-05 | 2012-07-30 | METHOD OF REMOVING A WELL BACKGROUND SET, METHOD OF DEPRODUCING AN ELECTRIC POTENTIAL AND WELL BACKGROUND SET |
AU2012294758A AU2012294758B2 (en) | 2011-08-05 | 2012-07-30 | Method of controlling corrosion rate in downhole article, and downhole article having controlled corrosion rate |
CN201280036477.4A CN103732853A (en) | 2011-08-05 | 2012-07-30 | Method of controlling corrosion rate in downhole article, and downhole article having controlled corrosion rate |
CA2841926A CA2841926C (en) | 2011-08-05 | 2012-07-30 | Method of controlling corrosion rate in downhole article, and downhole article having controlled corrosion rate |
AP2014007411A AP2014007411A0 (en) | 2011-08-05 | 2012-07-30 | Method of controlling corrosion rate in downhole article, and downhole article having controlled corrosion rate |
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US13/204,359 | 2011-08-05 | ||
US13/204,359 US9057242B2 (en) | 2011-08-05 | 2011-08-05 | Method of controlling corrosion rate in downhole article, and downhole article having controlled corrosion rate |
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WO2013022635A3 WO2013022635A3 (en) | 2013-04-25 |
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PCT/US2012/048792 WO2013022635A2 (en) | 2011-08-05 | 2012-07-30 | Method of controlling corrosion rate in downhole article, and downhole article having controlled corrosion rate |
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US (1) | US9057242B2 (en) |
EP (1) | EP2739812B1 (en) |
CN (1) | CN103732853A (en) |
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BR (1) | BR112014002348B1 (en) |
CA (1) | CA2841926C (en) |
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Also Published As
Publication number | Publication date |
---|---|
EP2739812A4 (en) | 2015-12-16 |
BR112014002348B1 (en) | 2021-02-23 |
AU2012294758A1 (en) | 2014-01-16 |
AP2014007411A0 (en) | 2014-02-28 |
EP2739812A2 (en) | 2014-06-11 |
MY170351A (en) | 2019-07-23 |
AU2012294758B2 (en) | 2016-10-06 |
CA2841926C (en) | 2017-11-14 |
US9057242B2 (en) | 2015-06-16 |
CN103732853A (en) | 2014-04-16 |
US20130032357A1 (en) | 2013-02-07 |
BR112014002348A2 (en) | 2017-03-14 |
EP2739812B1 (en) | 2019-09-04 |
CA2841926A1 (en) | 2013-02-14 |
WO2013022635A3 (en) | 2013-04-25 |
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