Controlled-Porosity Ceramic Materials for High Temperature Downhole Applications
Development of high performance downhole components and materials will enable geothermal exploration and production capabilities in high pressure and high temperature applications. Conventional well materials are challenged in corrosive environments and the thermal cycling typical of geothermal wells. An ideal replacement for many of these components is a ceramic material formed in place. Such a form can be achieved with the alumino-thermite reaction, an engineered fuel/oxidizer reaction complemented with additives to yield specific product properties. These reactions can produce strong, dense, corrosion-resistant, predominantly ceramic matrices with very high inherent service temperatures (greater than 1000°C). The objective of this effort is to explore the viability of forming high porosity ceramic features in-place for applications such as platforms, well screens or borehole stabilization features. The initial Phase I effort evaluated the application environment and developed performance specifications for the ceramic application. Thermite/diluent systems were developed and tested to achieve a range of permeability, porosity, mechanical strength, corrosion resistance, and reaction properties under ambient conditions. Pressurized experiments evaluated the ability to sustain the reaction to completion and retain some porosity in the products at pressures typical of deep emplacements. Based on the material development and scaled test results, a conceptual design was developed for three specific applications: screen and sand control, bridge plug or drillable packer, and borehole stabilization/lost circulation remedy. The Phase II research showed that thermite reaction products show promise in geothermal applications where aggressive fluids and thermal cycling challenge standard cements and metal components. The three application scenarios were evaluated as to their viability. Corrosion resistance of thermite ceramic products was evaluated in a comprehensive testing program, and a reaction kinetics model was developed to predict the impact of temperature on reaction propagation rates. Significant results are: • Of the three applications evaluated, the bridge plug/platform is the most viable. It has been successfully demonstrated in a dry open granite borehole and implemented in the isol8 Fusion tool to form a platform beneath alloy plugs. The flowing thermite plug could not meet the sealing requirements in oil and gas, however, so the design evolved to use thermite as a heater (non-consumed) to melt low temperature alloy which bonded to the casing. • The porous screen concept was the most ambitious and proved extremely difficult (if not impossible) to form. While it was clear that non-condensable gas could be generated to provide sufficient porosity under the downhole conditions, it became obvious that the molten thermite product remained in a fluid state too long to ‘freeze’ the gas bubbles in place, preventing formation of a porous matrix. • The lost circulation remedy appeared viable, but field testing would be required to determine if enough molten material could be emplaced to cause flow reductions. Drilling testing would also be required to confirm that the thermite product could be penetrated without causing drill damage or deviation. • The corrosion study performed by Brookhaven National Laboratory exposed various forms of the thermite ceramic product to thermal cycling, high CO2, and acid conditions, and compared these results with the performance of well cement. The thermite products proved superior under these conditions. • Finally, a kinetic reaction model was developed to predict reaction propagation rates at elevated temperature. This is useful as higher temperature environments are considered, to aid in the design of the tool functions which rely on the thermite reaction rate.
- Research Organization:
- isol8 Inc.
- Sponsoring Organization:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE), Renewable Power Office. Geothermal Technologies Office
- DOE Contract Number:
- SC0017209
- OSTI ID:
- 1910163
- Type / Phase:
- SBIR (Phase II)
- Report Number(s):
- DOE-isol8-17209
- Country of Publication:
- United States
- Language:
- English
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