Carbon capture and underground storage (CCUS) is a process in which carbon dioxide (CO2) is captured and sequestered before it enters the atmosphere. The CO2 is transported and stored (carbon sequestration) in a subterranean geological formation. Typically, the CO2 is captured from a chemical plant or a biomass power plant, and then stored underground. Accordingly, effective seals and anchors that are robust for environments rich in carbon dioxide are desired.
These drawings illustrate certain aspects of some examples of the present disclosure and should not be used to limit or define the disclosure.
The present disclosure relates to creating a swellable metal packer that swells in the presence of carbon dioxide rather than with water or oil. The result is a sealing and anchoring system that provides a permanent and safe solution for storing CO2 underground. The swellable packer may include a metal (including metal alloys) that may react with the CO2 from the CCUS. The CO2 chemically transforms the metal into a hydrated-metal-carbonate (HMC). The HMC is similar to metal hydroxides in that there is a chemical reaction that causes the material to expand. The hydrated-metal carbonate forms a metal-carbonate material rather than only a metal-hydroxide material.
In some examples, the CO2 may be part of the wellbore fluid that causes the metal expansion. The presence of CO2 results in a final product that is more than a metal hydroxide. The final product is a single type or a combination of several different hydrated-metal-carbonates. The CO2 results in the formation of HMCs (expansion of the metal), and humidity or additional water content facilitates the chemical reaction. In some examples, carbon monoxide may be used rather than CO2.
The expansion of metal is caused by a chemical reaction (e.g., via a wellbore fluid) that converts the metal into a metal oxide or metal hydroxide, and with CO2 incorporation, the metal oxide or metal hydroxide transforms into an HMC, with a corresponding expansion of the solid phase of the material. As noted above, the chemical reaction is facilitated with the wellbore fluid such as water, especially brine. For example, magnesium converts/corrodes to magnesium hydroxide (Mg to Mg(OH)2) in the presence of water. Other metals include aluminum, zinc, silicon, calcium, and iron. The metal differs from the metal oxide in that the metal is shiny, lustrous, conductive, and malleable.
The metal can be alloyed to change the strength or the reaction speeds. For example, copper, iron, or nickel can be used accelerate the reaction speed. In some examples, the metal may be made from extrusion, powder metallurgy, forging, or casing. The metal may be mixed with a polymer. The extent of HMC formation depends on several parameters such as for example, porosity of initially formed metal hydroxide, temperature, humidity level, CO2 concentration, pressure, and/or timing and duration of CO2 infusion (e.g., introduction of CO2 to the metal or contact of the CO2 with the metal).
In some examples, the CO2 may be added to the wellbore fluids prior to the initial setting (expansion) of the packer, during the setting of the packer, or after the setting phase of the packer. Adding CO2 after an initial water-set results in a seal with reduced permeability and increased strength. The seal may include a bridge plug, vee packing, a seal gland, and/or a packing seal. The carbon dioxide injection into the well which contains the metal, results in permanent CO2 storage due to mineralization of the byproducts of the chemical reaction. Additionally, reaction of the metal with the CO2 reduces porosity of the final product, resulting in improved mechanical properties for the packer, such as a higher differential pressure capacity.
This disclosure describes the formation of a series of final products other than metal hydroxide (Mg(OH)2) in expanding metal technology, due to inclusion of carbon dioxide (CO2) in the wellbore fluid. When CO2 is incorporated into the fluid (e.g., brine, water), metal hydroxide (such as Mg(OH)2) is formed from the metal (such as Mg) and water. Then, the metal hydroxide further reacts to yield a range of hydrated metal carbonates (HMCs).
The formation of HMCs expands the rock-like material beyond the volume of the metal hydroxide. The carbonate process is an expansive process which reduces the porosity and enhances the sealing and anchoring performance of the packer. The carbonate process may include the following reactions (e.g., Equations (1)-(6)) that result in HMCs.
Mg+H2O→MgO+H2 (1)
MgO+H2O→Mg(OH)2 (2)
Mg(OH)2+CO2+2H2O→MgCO3·3H2O(Nesquehonite) (3)
2Mg(OH)2+CO2+2H2O→Mg2CO3(OH)2·3H2O(Artinite) (4)
5Mg(OH)2+4CO2→Mg5(CO3)+(OH)2·4H2O(Hydromagnesite) (5)
5Mg(OH)2+4CO2+H2O→Mg5(CO3)+(OH)2·5H2O(Dypingite) (6)
Equations (1) and (2) illustrate conversion of a metal to a metal hydroxide (e.g., corrosion of metal in presence of water). Equations (3) to (6) illustrate conversion of the metal hydroxide to different HMCs (e.g., Nesquehonite, Artinite, Hydromagnesite, and/or Dypingite) due to CO2. For example, a solid Mg alloy is first corroded with water to form Mg(OH)2 and then further reacted with CO2 to produce HMCs. The HMCs provide compressive strengths several times higher than that of Mg(OH)2. Although Mg is shown in the Equations, it should be noted that any suitable metal may be used.
A source of the CO2 and/or CO (carbon monoxide) may include captured and stored CO2/CO that is emitted from industrial activities. In some examples, the CO may be used in addition to the CO2 or to replace the CO2. The CO2/CO may be in a liquid, a gas, or in a supercritical state. Introduction of the CO2/CO may be performed at multiple stages of the well lifecycle. In some examples, the CO2/CO infusion occurs while the metal is reacting with the downhole fluid (e.g., water). This may result in dissolution of the CO2/CO in the water to form carbonic acid, which may accelerate transformation of the metal to the HMC.
In other examples, the CO2/CO infusion occurs after the downhole fluid is removed from the well. The CO2/CO infusion may occur seconds, minutes, hours, or even years after the downhole fluid is removed. In another example, the CO2/CO may already be present in the well and the metal packer may be placed into the wellbore with existing CO2/CO for infusion to occur. In another example, the CO2/CO is created downhole. The CO2/CO can result from a chemical reaction, such as an acid reacting with a carbonate during wellbore cleanup.
A tool string 118 extends from the derrick 112 and the rig floor 114 downwardly into the wellbore 120. The tool string 118 may be any mechanical connection to the surface, such as, for example, wireline, slickline, jointed pipe, or coiled tubing. As depicted, the tool string 118 suspends the downhole tool 100 for placement into the wellbore 120 at a desired location to perform a specific downhole operation. In some examples, the downhole tool 100 may be hydraulically pumped into the wellbore 120. The downhole tool 100 may include any type of wellbore zonal isolation device including, but not limited to, a frac plug, a bridge plug, a packer, a wiper plug, or a cement plug. The well system 110 may also include a fluid source 130 (e.g., a tank including CO2 or water/brine or CO), a pump 132, and conduit 134 for directing the fluid into the wellbore 120. The fluid may be pumped/injected into the well to activate the tool 100 (e.g., swell a packer).
A source of the CO2/CO may include captured and stored CO2/CO that is emitted from industrial activities. The CO2/CO may be in a liquid, a gas, or in a supercritical state. Introduction of the CO2/CO may be performed at multiple stages of the well lifecycle. In some examples, the CO2/CO infusion occurs while the tool/metal is reacting with a wellbore fluid (e.g., water). This may result in dissolution of the CO2/CO in the wellbore fluid to form carbonic acid, which may accelerate transformation of the metal to the HMC.
The CO2/CO may be introduced into the wellbore 120 to contact the metal 302 and react with the metal 302 while the metal 302 is submerged in wellbore fluid 306 such as water (e.g., brine). The CO/CO may be injected down a tool string or down the casing, for example. As noted above, the chemical reaction is facilitated with water, especially brine.
In some examples, adding CO2/CO after an initial water-set results in a seal with reduced permeability and increased strength. The CO2/CO injection into the well (wellbore 120) which contains the metal 302, results in permanent CO2/CO storage due to mineralization of the byproducts of the chemical reaction. Additionally, reaction of the metal with the CO2/CO reduces porosity of the final product, resulting in improved mechanical properties for the tool 100 (packer), such as a higher differential pressure capacity.
At step 602, the tool may be contacted with the CO2/CO (e.g., see
In some examples, adding CO2/CO after an initial water-set results in a seal with reduced permeability and increased strength. The CO2/CO injection into the well (wellbore) which contains the metal, results in permanent CO2/CO storage due to mineralization of the byproducts of the chemical reaction. Additionally, reaction of the metal with the CO2/CO reduces porosity of the final product, resulting in improved mechanical properties for the tool (packer), such as a higher differential pressure capacity.
At step 604, HMCs form on the tool (e.g., see
Accordingly, the systems and methods of the present disclosure allow for activation of metal seals with CO2/CO to store the CO2/CO underground. The systems and methods may include any of the various features disclosed herein, including one or more of the following statements.
Statement 1. A method comprises contacting a tool with carbon dioxide (CO2) and or carbon monoxide (CO), the tool comprising metal: forming hydrated metal carbonates (HMCs) on the tool due to contact of the CO2 and/or the CO with the metal of the tool; and expanding a size and/or reducing a porosity of the tool due to formation of the HMCs.
Statement 2. The method of the statement 1, wherein the tool is disposed in a wellbore.
Statement 3. The method of the statement 1 or the statement 2, wherein the wellbore includes water.
Statement 4. The method of any one of the statements 1-3, further comprising sealing a well with at least the HMCs, the tool disposed in the well.
Statement 5. The method of any one of the statements 1-4, further comprising containing the CO2 and/or the CO in a subterranean formation with the HMCs.
Statement 6. The method of any one of the statements 1-5, further comprising removing wellbore fluid from a wellbore with the CO2 and/or the CO, the tool disposed in the wellbore.
Statement 7. The method of any one of the statements 1-6, wherein HMCs of different chemical compositions are formed on the tool.
Statement 8. A method comprising: disposing a tool in a wellbore, the tool comprising metal: corroding the metal with a fluid of the wellbore to provide corroded metal; contacting the corroded metal with carbon dioxide (CO2) and/or CO: forming hydrated metal carbonates (HMCs) on the tool due to contact of the CO2 and/or the CO with the corroded metal: and expanding a size and/or reducing a porosity of the tool due to formation of the HMCs.
Statement 9. The method of the statement 8, further comprising plugging the wellbore with the tool due to formation of the HMCs.
Statement 10. The method of the statement 8 or 9, wherein the fluid includes water.
Statement 11. The method of any one of the statements 8-10, further comprising containing the CO2 and/or the CO in a subterranean formation with the HMCs.
Statement 12. The method of any one of the statements 8-11, wherein HMCs of different chemical compositions are formed on the tool.
Statement 13. The method of any one of the statements 8-12, further comprising removing the fluid of the wellbore with the CO2 and/or the CO, the tool disposed in the wellbore.
Statement 14. The method of any one of the statements 8-13, wherein the fluid of the wellbore comprises water.
Statement 15. A system comprising: a source in fluid communication with a well, the source configured to provide carbon dioxide (CO2) and/or CO to the well: and a tool disposed in the well, the tool configured to form hydrated metal carbonates (HMCs) upon contact with the CO2 and/or the CO.
Statement 16. The system of any one of the statements 13-15, wherein the HMCs include HMCs of different chemical compositions.
Statement 17. The system of any one of the statements 13-16, wherein the well includes a wellbore fluid configured to corrode the tool.
Statement 18. The system of any one of the statements 13-17, wherein the wellbore fluid includes water.
Statement 19. The system of any one of the statements 13-18, wherein the tool comprises the HMCs.
Statement 20. The system of any one of the statements 13-19, wherein the HMCs are configured to increase a size and/or reduce a porosity of the tool.
Statement 21. A downhole tool comprising a portion configured to define a plug with formed hydrated metal carbonates (HMCs), the HMCs configured to form on the portion, and expand a size and/or reduce a porosity of the downhole tool, upon exposure of the downhole tool to CO2 and/or CO.
Statement 22. The downhole tool of the statement 21, wherein the downhole tool is positioned in a wellbore to receive the CO2 and/or the CO.
Statement 23. The downhole tool of the statement 21 or 22, wherein the HMCs include HMCs with different chemical compositions.
Statement 24. The downhole tool of any one of the statements 21-23, wherein the portion extends along a circumference of the downhole tool.
Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations may be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. The preceding description provides various examples of the systems and methods of use disclosed herein which may contain different method steps and alternative combinations of components. It should be understood that, although individual examples may be discussed herein, the present disclosure covers all combinations of the disclosed examples, including, without limitation, the different component combinations, method step combinations, and properties of the system. It should be understood that the compositions and methods are described in terms of “comprising.” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the elements that it introduces.
For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.
Therefore, the present examples are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular examples disclosed above are illustrative only and may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual examples are discussed, the disclosure covers all combinations of all of the examples. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative examples disclosed above may be altered or modified and all such variations are considered within the scope and spirit of those examples. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.