Self-propagating high-temperature synthesized ceramic materials for oil and gas wells: application and the challenges

摘要

With various developments taking place in oil and gas exploration, challenging areas in hostile subsurface conditions are encountered often. The common problems faced in wells are associated with sand control, lost circulation, casing damage, and sealing of the wells at the time of abandonment. Solutions to these problems have already been established and are being used currently but high reservoir pressure and temperature conditions limit the selection of material to be used in such extreme conditions. So, to mitigate these problems, specially synthesized ceramic materials are used instead of conventional sand screens, cement plug, scab liners, and sealing plug. Self-propagating High-temperature Synthesis (SHS) is the process of forming composite materials at downhole. High temperature source is not required for synthesiszing these ceramic materials as the reactions are highly exothermic providing enough heat that can overcome the activation energy of the reactants thereby sustaining the reaction. Use of these in situ synthesized ceramic materials will serve the same purpose as conventional materials but with improved resistance to high temperatures and eroding and corroding agents. This alternate approach that increases the life span of materials saves non-productive rig time and considerable cost. A wide range of reactants and additives are used providing flexibility in synthesizing the ceramic composite of desired properties.