AU2021463035B2

AU2021463035B2 - Controlled actuation of a reactive metal

Info

Publication number: AU2021463035B2
Application number: AU2021463035A
Authority: AU
Inventors: Michael Linley Fripp; Brandon T. Least
Original assignee: Halliburton Energy Services Inc
Current assignee: Halliburton Energy Services Inc
Priority date: 2021-08-31
Filing date: 2021-09-01
Publication date: 2025-09-18
Anticipated expiration: 2041-09-01
Also published as: MX2024001395A; GB2622507A; CA3220527A1; AU2025230727A1; AU2021463035A1; FR3126441B1; NL2032583B1; NO20231340A1; DK202330395A1; FR3126441A1; GB202318905D0; NL2032583A

Abstract

Apparatus and methods for initiating the reaction of a reactive metal element of a downhole device. An example method introduces the downhole device into a wellbore; wherein the downhole device comprises the reactive metal element; wherein the reactive metal element has a first volume; and wherein the reactive metal element is separated from a reaction-inducing fluid by a frangible casing. The frangible casing is removed and the reactive metal element is contacted with the reaction-inducing fluid to produce a reaction product having a second volume greater than the first volume.

Description

CONTROLLED CONTROLLED ACTUATION ACTUATIONOFOF A REACTIVE METAL A REACTIVE METAL

TECHNICAL FIELD TECHNICAL FIELD The present disclosure relates to the use of a reactive metal element, and more particularly,

to methods and apparatus for controlling the actuation of a reactive metal element.

BACKGROUND In some wellbore operations, a swellable material may be used for sealing and/or

anchoring. A few examples of apparatus that utilize swellable materials include packers, sealing

elements, and liner hangers. A packer may be used to seal and isolate a wellbore zone. Expandable

sealing elements may be used for a variety of wellbore applications including forming annular

seals and zonal isolation. Liners may be suspended from a casing string or set cement layer with

a liner hanger. The liner hanger anchors and seals to the interior of the casing string or set cement

layer and suspends the liner below the casing string or set cement layer.

Some species of swellable materials comprise elastomers. Elastomers such as rubber may

swell when contacted with a swell-inducing fluid. The swell-inducing fluid may diffuse into the

elastomer where a portion of the fluid may be retained within the internal structure of the

elastomer. Swellable materials such as elastomers may be limited to use in specific wellbore

environments (e.g., those without high salinity and/or high temperatures). In some wellbore

operations, it may be important to time the actuation of the swellable material to prevent

premature actuation. The present disclosure provides improved apparatus and methods for

controlling the actuation of a reactive metal element in wellbore applications.

BRIEF DESCRIPTION OF THE DRAWINGS Illustrative examples of the present disclosure are described in detail below with reference

to the attached drawing figures, which are incorporated by reference herein, and wherein:

FIG. 1 is an illustration of a reactive metal element shaped into a lattice structure in

accordance with the examples disclosed herein;

FIG. 2 is a cross-section of an example downhole device comprising a reactive metal

element in accordance with the examples disclosed herein;

FIG. 3 is a cross-section of the example downhole device of FIG. 2 after breaking of the

frangible casing in accordance with the examples disclosed herein;

FIG. FIG. 44 is is aa cross-section cross-section of of the the example example downhole downhole device device of of FIGs. FIGs. 11 and and 22 with with an an

additional modification in accordance with the examples disclosed herein;

FIG. 5 is a cross-section of another example downhole device comprising a reactive metal

element in accordance with the examples disclosed herein;

FIG. 6 is a cross-section of the example downhole device of FIG. 5 after breaking of the

frangible casing in accordance with the examples disclosed herein;

FIG. 7 is a cross-section of an example setting tool comprising a reactive metal element

in accordance with the examples disclosed herein; and

FIG. 8 is a cross-section of the example setting tool of FIG. 7 after breaking of the

frangible casing in accordance with the examples disclosed herein.

The illustrated figures are only exemplary and are not intended to assert or imply any

limitation with regard to the environment, architecture, design, or process in which different

examples may be implemented.

DETAILED DESCRIPTION The present disclosure relates to the use of a reactive metal element, and more particularly,

In the following detailed description of several illustrative examples, reference is made to

the accompanying drawings that form a part hereof, and in which is shown by way of illustration

examples that may be practiced. These examples are described in sufficient detail to enable those

skilled in the art to practice them, and it is to be understood that other examples may be utilized,

and that logical structural, mechanical, electrical, and chemical changes may be made without

departing from the spirit or scope of the disclosed examples. To avoid detail not necessary to

enable those skilled in the art to practice the examples described herein, the description may omit

certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the illustrative examples is defined only by the appended claims.

Unless otherwise indicated, all numbers expressing quantities of ingredients, properties

such as molecular weight, reaction conditions, and SO so forth used in the present specification and

associated claims are to be understood as being modified in all instances by the term "about."

Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following

specification and attached claims are approximations that may vary depending upon the desired

properties sought to be obtained by the examples of the present disclosure. At the very least, and

not as an attempt to limit the application of the doctrine of equivalents to the scope of the claim,

each numerical parameter should at least be construed in light of the number of reported

significant digits and by applying ordinary rounding techniques. It should be noted that when

"about" is at the beginning of a numerical list, "about" modifies each number of the numerical

list. Further, in some numerical listings of ranges some lower limits listed may be greater than

some upper limits listed. One skilled in the art will recognize that the selected subset will require

the selection of an upper limit in excess of the selected lower limit.

Unless otherwise specified, any use of any form of the terms "connect," "engage,"

"couple," "attach," or any other term describing an interaction between elements is not meant to

limit the interaction to direct interaction between the elements and may also include indirect

interaction interaction between between the the elements elements described. described. Further, Further, any any use use of of any any form form of of the the terms terms "connect," "connect,"

"engage," "couple," "attach," or any other term describing an interaction between elements

includes items integrally formed together without the aid of extraneous fasteners or joining

devices. In the following discussion and in the claims, the terms "including" and "comprising"

are used in an open-ended fashion, and thus should be interpreted to mean "including, but not

limited to." Unless otherwise indicated, as used throughout this document, "or" does not require

mutual exclusivity.

The terms uphole and downhole may be used to refer to the location of various

components relative to the bottom or end of a well. For example, a first component described as

uphole from a second component may be further away from the end of the well than the second

component. component.Similarly, a first Similarly, component a first described component as beingasdownhole described from a second being downhole fromcomponent a second component

may be located closer to the end of the well than the second component.

Examples of the methods and apparatus described relate to the use of a reactive metal

element, and more particularly, to methods and apparatus for controlling the actuation of a

reactive metal element. The reactive metal element comprises a reactive metal which, after

reaction, provides an expansion of its metal to seal, anchor, and/or fill voids in the annular space.

The The reactive reactive metal metal provides provides this this expansion expansion after after contacting contacting aa specific specific reaction-inducing reaction-inducing fluid, fluid, such as a brine, where it produces a reaction product having a larger volume than the base reactive metal reactant. This increase in metal volume of the reaction product provides for an expansion of the metal reaction product into any adjacent void space. This expansion may be sufficient to to seal the adjacent void space, to anchor a conduit proximate the adjacent void space, and/or to simply fill the adjacent void space. The reaction product solidifies within the adjacent void space in order to perform for further wellbore operations. The formation of the reaction products results in the volumetric expansion of the reactive metal element allowing for an improvement in zonal isolation. The solidified reaction products also improve the anchoring of any surrounding conduit, positioning it in the wellbore and allowing for secure suspension. Advantageously, the reactive metal elements may be used in a variety of wellbore applications. Yet a further advantage is that the reactive metal elements provide expansion in high-salinity and/or high-temperature environments. An additional advantage is that the reactive metal elements comprise a wide variety of metals and metal alloys and react upon contact with reaction-inducing fluids, including a variety of wellbore fluids. The reactive metal elements may be used as replacements for other types of expandable elements (e.g., elastomeric elements), or they may be used in combination with other types of expandable elements. One other advantage is that in some examples, the reactive metal elements may be placed on existing conduits without impact to or adjustment of the conduit outer diameter or exterior profile to accommodate the reactive metal element. In some examples, the reactive metal elements are free of elastomeric materials and may be usable in wellbore environments where elastomeric materials may be prone to breakdown.

In some wellbore applications, the timing of the actuation of the reactive metal elements

may be important. As such, controlling the time of contact of the reaction metal element and the

reaction-inducing fluid may prevent premature actuation of the reactive metal element such that

the reactive metal element is not actuated until in the desired position and at the desired time.

Advantageously, the reactive metal element may be sealed from contact with the reaction-

inducing fluid by a barrier with a controlled rupturing. As a further advantage, the reactive metal

element may be interspersed with a non-reactive fluid which would prevent reaction until

dispersed by the inflowing reaction-inducing fluid.

The reactive metals expand by undergoing a reaction in the presence of a reaction-

inducing fluid (e.g., a brine) to form a reaction product (e.g., metal hydroxides). The resulting

reaction products occupy more volumetric space relative to the base reactive metal reactant. This

difference in volume allows the reactive metal element to expand to fill void space at the interface

of the reactive metal element and any adjacent surfaces. It is to be understood that the use of the

term "fill" does not necessarily mean a complete filling of the void space, and that the reaction

product may partially fill the void space in some examples. Magnesium may be used to illustrate the volumetric expansion of the reactive metal as it undergoes reaction with the reaction-inducing fluid. A mole of magnesium has a molar mass of 24 g/mol and a density of 1.74 g/cm³, resulting in a volume of 13.8 cm³/mol. Magnesium hydroxide, the reaction product of magnesium and an aqueous reaction-inducing fluid, has a molar mass of 60 g/mol and a density of 2.34 g/cm³, resulting in a volume of 25.6 cm³/mol. The magnesium hydroxide volume of 25.6 cm³/mol is an

85% increase in volume over the 13.8 cm³/mol volume of the mole of magnesium. As another

example, a mole of calcium has a molar mass of 40 g/mol and a density of 1.54 g/cm³, resulting

in a volume of 26.0 cm³/mol. Calcium hydroxide, the reaction product of calcium and an aqueous

reaction-inducing fluid, has a molar mass of 76 g/mol and a density of 2.21 g/cm³, resulting in a

volume of 34.4 cm³/mol. The calcium hydroxide volume of 34.4 cm³/mol is a 32% increase in

volume over the 26.0 cm³/mol volume of the mole of calcium. As yet another example, a mole of

aluminum has a molar mass of 27 g/mol and a density of 2.7 g/cm³, resulting in a volume of 10.0

cm³/mol. Aluminum hydroxide, the reaction product of aluminum and an aqueous reaction-

inducing fluid, has a molar mass of 63 g/mol and a density of 2.42 g/cm³, resulting in a volume

of 26 cm³/mol. The aluminum hydroxide volume of 26 cm³/mol is a 160% increase in volume

over the 10 cm³/mol volume of the mole of aluminum. The reactive metal may comprise any

metal or metal alloy that undergoes a reaction to form a reaction product having a greater volume

than the base reactive metal or alloy reactant.

The reactive metals undergo a chemical transformation whereby the metals chemically

react with the reaction-inducing fluid, and upon reaction form a metal hydroxide that is the

principal component of the expanded reactive metal element. The solidified metal hydroxide is

larger in volume than the base reactive metal, allowing for expansion into the annular space

around the reactive metal element (e.g., an adjacent void space).

Examples of suitable metals for the reactive metal include, but are not limited to,

magnesium, calcium, aluminum, tin, zinc, beryllium, barium, manganese, or any combination

thereof. Preferred metals include magnesium, calcium, and aluminum.

Examples of suitable metal alloys for the reactive metal include, but are not limited to,

alloys of magnesium, calcium, aluminum, tin, zinc, beryllium, barium, manganese, or any

combination thereof. Preferred metal alloys include alloys of magnesium-zinc, magnesium-

aluminum, calcium-magnesium, or aluminum-copper. In some examples, the metal alloys may

comprise alloyed elements that are not metallic. Examples of these non-metallic elements include,

but are not limited to, graphite, carbon, silicon, boron nitride, and the like. In some examples, the

metal is alloyed to increase reactivity and/or to control the formation of oxides.

In some examples, the metal alloy is also alloyed with a dopant metal that promotes

corrosion or inhibits passivation and thus increases hydroxide formation. Examples of dopant metals include, but are not limited to, nickel, iron, copper, carbon, titanium, gallium, mercury, cobalt, iridium, gold, palladium, or any combination thereof.

In some examples, the reactive metal comprises an oxide. As an example, calcium oxide

reacts with water in an energetic reaction to produce calcium hydroxide. One mole of calcium

oxide occupies 9.5 cm³ whereas one mole of calcium hydroxide occupies 34.4 cm³. This is a

260% volumetric expansion of the mole of calcium oxide relative to the mole of calcium

hydroxide. Examples of metal oxides suitable for the reactive metal may include, but are not

limited to, oxides of any metals disclosed herein, including magnesium, calcium, aluminum, iron,

nickel, copper, chromium, tin, zinc, lead, beryllium, barium, gallium, indium, bismuth, titanium,

manganese, cobalt, or any combination thereof.

It is to be understood that the selected reactive metal is chosen such that the formed

reaction product does not dissolve or otherwise degrade in the reaction-inducing fluid in a manner

that prevents its solidification in a void space. As such, the use of metals or metal alloys for the

reactive metal that form relatively insoluble reaction products in the reaction-inducing fluid may

be preferred. As an example, the magnesium hydroxide and calcium hydroxide reaction products

have very low solubility in water. As an alternative or an addition, the reactive metal element may

be positioned and configured in a way that constrains the degradation of the reactive metal

element in the reaction-inducing fluid due to the geometry of the area in which the reactive metal

element is disposed. This may result in reduced exposure of the reactive metal element to the

reaction-inducing fluid, but may also reduce degradation of the reaction product of the reactive

metal metal element, element,thereby prolonging thereby the life prolonging the of the of life reaction product in the reaction the void product in space. As anspace. As an the void

example, the volume of the area in which the reactive metal element is disposed may be less than

the potential expansion volume of the volume of reactive metal disposed in said area. In some

examples, this volume of area may be less than as much as 50% of the expansion volume of

reactive metal. Alternatively, this volume of area may be less than 90% of the expansion volume

of reactive metal. As another alternative, this volume of area may be less than 80% of the

expansion volume of reactive metal. As another alternative, this volume of area may be less than

70% of the expansion volume of reactive metal. As another alternative, this volume of area may

be less than 60% of the expansion volume of reactive metal. In a specific example, a portion of

the reactive metal element may be disposed in a recess within the conduit to restrict the exposure

area to only the surface portion of the reactive metal element that is not disposed in the recess.

In some some examples, examples,thethe formed formed reaction reaction products products of the of the reactive reactive metal may metal reaction reaction be may be

dehydrated under sufficient pressure. For example, if a metal hydroxide is under sufficient contact

pressure and resists further movement induced by additional hydroxide formation, the elevated

pressure may induce dehydration of the metal hydroxide to form the metal oxide. As an example, magnesium hydroxide may be dehydrated under sufficient pressure to form magnesium oxide and water. As another example, calcium hydroxide may be dehydrated under sufficient pressure to form calcium oxide and water. As yet another example, aluminum hydroxide may be dehydrated under sufficient pressure to form aluminum oxide and water.

The reactive metal elements may be formed in a solid solution process, a powder

metallurgy process, or through any other method as would be apparent to one of ordinary skill in

the art. Regardless of the method of manufacture, the reactive metal elements may be slipped over

the conduit and held in place via any sufficient method. The reactive metal elements may be

placed over the conduit in one solid piece or in multiple discrete pieces. Once in place, the reactive

metal element may be held in position with end rings, stamped rings, retaining rings, fasteners,

adhesives, set screws, swedging, or any other such method for retaining the reactive metal element

in position. In some alternative examples, the reactive metal element may not be held in position

and may slide freely on the exterior of the tubular. As discussed above, the reactive metal elements

may be formed and shaped to fit over existing conduits and may not require modification of the

outer diameter or profile of the liner hanger in some examples. Alternatively, the conduit may be

manufactured to comprise a recess in which the reactive metal element may be disposed. The

recess may be of sufficient dimensions and geometry to retain the reactive metal elements in the

recess. In alternative examples, the reactive metal element may be cast onto the conduit. In some

alternative examples, the diameter of the reactive metal element may be reduced (e.g., by

swaging) when disposed on the conduit. In some examples, the reactive metal elements may be

disposed over the length of the conduit (e.g., the singular conduit joint of the conduit string that

is threaded or coupled to other conduit joints to form a conduit string). In alternative examples,

the reactive metal element may be placed on only a portion of the conduit joint. In some examples,

the reactive metal elements may be placed on all conduit joints to form continuous covering of

the conduit string. In other examples, the reactive metal elements may be placed on only some of

the conduit joints of the conduit string (e.g., at locations where cement assurance issues may

occur).

In some optional examples, the reactive metal element may be shaped such as to increase

the available surface area for reaction. Such shapes may comprise pieces, pellets, latices, and the

like. FIG. 1 is an illustration of a lattice-shaped reactive metal element. In some optional

examples, a foam may be used as the lattice. In further optional embodiments, a non-reactive

material such as non-reactive fluid or non-reactive solid may be dispersed within the shaped

reactive metal element to delay contact with the reaction-inducing fluid. For example, the voids

within the lattice and the exterior of the lattice may be covered with a non-reactive material. In

other example, the exterior and interstitial spaces between pieces or pellets of the reactive metal element may be filled with the non-reactive material. Examples of the non-reactive material may include non-reactive fluids including, but not limited to, air, nitrogen, carbon dioxide, liquid hydrocarbons, liquid waxes, oleaginous fluids, distilled water, glycerin, alcohol, or any combination. The non-reactive fluid may be displaced via fluid pressure from the reaction- inducing fluid upon contact and/or fluid pressure from the hydrogen gas produced by the reaction of the reactive metal and the reaction-inducing fluid as the reaction process begins on a portion of the reactive metal element. Examples of the non-reactive material may include non-reactive solids including, but not limited to, polylactic acid, polyglycolic acid, plastics, solid waxes, or any combination. any combination. TheThe non-reactive non-reactive solidsolid material material may be may be degraded degraded via time via time and/or and/or increasing increasing wellbore temperature. The degraded remnants may then be displaced by fluid pressure from the reaction-inducing fluid upon contact and/or fluid pressure from the hydrogen gas produced by the reaction of the reactive metal and the reaction-inducing fluid as the reaction process begins on a portion of the reactive metal element. Upon displacement of the non-reactive material, the reactive metal of the reactive metal element may contact the reaction-inducing fluid and may react to perform the desired wellbore operation.

In some optional examples, the reactive metal element may include a removable barrier

coating. The removable barrier coating may be used to cover the exterior surfaces of the reactive

metal element and prevent contact of the reactive metal with the reaction-inducing fluid. The

removable barrier coating may be removed after other wellbore operations are completed. The

removable barrier coating may be used to delay reaction and/or prevent premature expansion with

the reactive metal element. Examples of the removable barrier coating include, but are not limited

to, any species of plastic shell, organic shell, paint, dissolvable coatings (e.g., solid magnesium

compounds or an aliphatic polyester), a meltable material (e.g., with a melting temperature less

than 550° F), or any combination thereof. When desired, the removable barrier coating may be

removed from the reactive metal element with any sufficient method. For example, the removable

barrier coating may be removed through dissolution, a phase change induced by changing

temperature, corrosion, hydrolysis, melting, or the removable barrier coating may be time-delayed

and degrade after a desired time under specific wellbore conditions.

In some optional examples, a removable casing may cover the exterior surfaces of the

reactive metal element and prevent contact of the reactive metal with the reaction-inducing fluid.

The removable casing may be removed after other wellbore operations are completed. The

removable casing may be used to delay reaction and/or prevent premature expansion of the

reactive metal element. Examples of the removable casing include, but are not limited to, frangible

casings that are easily broken, degraded, destroyed, melted, shattered, etc. The frangible casing

may be removed through forces such as torque, tension, puncturing, impacting, degradation from

PCT/US2021/048628

fluid contact and/or wellbore conditions such as pressure and/or temperature, or a combination of

forces. For example, the frangible casing may rip under strain from a sufficient applied axial

force. The frangible casing may comprise any frangible material sufficient for breaking, ripping,

shattering, degrading, melting, etc. Examples of the frangible material include, but are not limited

to, sufficiently thin metals; sufficiently brittle polymers such as acrylic, polystyrene, etc.;

cellulosic materials such as paper and waxed paper; ceramic materials; and the like. The degree

of thinness and/or brittleness of the frangible material will be determined by the species of

material chosen and the potential force available to break the frangible casing. One of ordinary

skill in the art will be readily able to determine the potential force available and thus the potential

material properties necessary to remove the frangible casing upon application of said force. In

some additional optional examples, the frangible casing may be stressed during manufacture

through the inclusion of stress risers such as cracks, grooves, etc. The stress risers may allow for

a relatively lower applied force to break the frangible casing and may also allow for frangible

casing to break in a consistent pattern. Upon removal, the reactive metal of the reactive metal

element may contact the reaction-inducing fluid and may react to perform the desired wellbore

operation.

In some optional examples, the reactive metal element may include an additive which may

be added to the reactive metal element during manufacture as a part of the composition, or the

additive may be coated onto the reactive metal element after manufacturing manufacturing.The Theadditive additivemay may

alter one or more properties of the reactive metal element. For example, the additive may improve

expansion, add texturing, improve bonding, improve gripping, etc. Examples of the additive

include, but are not limited to, any species of ceramic, elastomer, glass, non-reacting metal, the

like, or any combination thereof.

The reactive metal element may be used to expand into any void spaces that are proximate

to the reactive metal elements. Without limitation, the reactive metal elements may be used to fill

any voids in adjacent space, which may include annular spaces adjacent to a conduit, as well as

defects in cement sheaths such as cracks within a cement sheath, channels formed from gas

channeling through a cement sheath, microannuli formed between the cement sheath and the

conduit which may be formed from temperature cycling, stress load cycling, conduit shrinkage,

etc.

As described above, the reactive metal elements comprise reactive metals and as such,

they are non-elastomeric materials. As non-elastomeric materials, the reactive metal elements do

not possess elasticity, and therefore, they may irreversibly expand when contacted with a reaction-

inducing fluid. The reactive metal elements may not return to their original size or shape even

after the reaction-inducing fluid is removed from contact.

Generally, the reaction-inducing fluid induces a reaction in the reactive metal to form a

reaction product that occupies more space than the unreacted reactive metal. Examples of the

reaction-inducing fluid include, but are not limited to, saltwater (e.g., water containing one or

more more salts saltsdissolved therein), dissolved brinebrine therein), (e.g.,(e.g., saturated saltwater, saturated which may which saltwater, be produced may befrom produced from

subterranean formations), seawater, or any combination thereof. Generally, the reaction-inducing

fluid may be from any source provided that the fluid does not contain an excess of compounds

that may undesirably affect other components in the sealing element. In the case of saltwater,

brines, and seawater, the reaction-inducing fluid may comprise a monovalent salt or a divalent

salt. Suitable monovalent salts may include, for example, sodium chloride salt, sodium bromide

salt, potassium chloride salt, potassium bromide salt, and the like. Suitable divalent salt can

include, for example, magnesium chloride salt, calcium chloride salt, calcium bromide salt, and

the like. In some examples, the salinity of the reaction-inducing fluid may exceed 10%.

Advantageously, the reactive metal elements of the present disclosure may not be impacted by

contact with high-salinity fluids. One of ordinary skill in the art, with the benefit of this disclosure,

should be readily able to select a reaction-inducing fluid for inducing a reaction with the reactive

metal elements.

The reactive metal elements may be used in high-temperature formations (e.g., in

formations with zones having temperatures equal to or exceeding 350° F). Advantageously, the

use of the reactive metal elements of the present disclosure may not be impacted in high-

temperature formations. In some examples, the reactive metal elements may be used in both high-

temperature formations and with high-salinity fluids. In a specific example, a reactive metal

element may be positioned on a conduit and used to fill a void in a cement sheath after contact

with a brine having a salinity of 10% or greater while also being disposed in a wellbore zone

having a temperature equal to or exceeding 350° F.

FIG. 2 is a cross-section of an example downhole device, generally 5. In this specific

example, the downhole device 5 may be a sealing system such as a packer. The downhole device

5 comprises a reactive metal element 10 disposed within a void space 15. The void space 15 may

be carved into the downhole device 5, or the downhole device 5 may be manufactured to comprise

a suitable void space 15. The geometry of the void space 15 is designed such that an opening 20

is presented to the exterior of the downhole device 5. The downhole device 5 may be deployed

and run in hole until the opening 20 is adjacent an annular space into which the reactive metal

element 10 is to be deployed upon reaction. Covering at least a portion of the reactive metal

element 10 is a frangible casing 25. The frangible casing 25 may cover the portion of the reactive

metal element 10 exposed to the opening 20 or may cover more of the reactive metal element 10,

including covering of the entirety of the reactive metal element 10. The reactive metal element

10 may be deployed in a desired shape such as a lattice, pellets, or pieces within the void space

15. In some optional examples, a non-reactive material may be deployed in the void space 15 and

interspersed within the reactive metal element 10 to assist in preventing premature reaction. A

sliding piston 30, or other such actuating component, may be disposed adjacent to the void space

15 containing the reactive metal element 10. Translation of the sliding piston 30 is prevented by

a body lock ring 35. The body lock ring 35 is exemplary in nature and may be substituted for any

other such locking mechanism SO so as to prevent undesired translation of the sliding piston 30.

FIG. 3 is a cross-section of the example downhole device 5 of FIG. 1 after the frangible

casing 25has casing 25 hasbeen been broken. broken. WhenWhen desired desired forthe for use, use, the body body lock ringlock ring 35 may be 35 may be to disengaged disengaged to

allow for translation of the sliding piston 30. Translation of the sliding piston 30 may occur as a

result of increasing localized fluid pressure in the wellbore, or may be actuated by hydraulic,

mechanical, pneumatic or other such mechanisms as would be readily apparent to one of ordinary

skill in the art. The sliding piston 30 applies axial pressure to the void space 15 SO so as to compress

the frangible casing 25 and the reactive metal element 10 disposed within. The frangible casing

25 is broken into pieces thereby allowing portions of the reactive metal element 10 to be exposed

to the exterior annular space adjacent the opening 20. In some examples, the compression may

push the pieces, pellets, and/or lattice structure of the reactive metal element 10 into the annular

space. The exposed reactive metal of the reactive metal element 10 may now be in a position to

contact a circulating reaction-inducing fluid. Upon contact with the reaction-inducing fluid, the

reactive metal within the reactive metal element 10 will react to form the reaction product, thereby

providing a filling expansion into any adjacent space contactable by the reaction product to

perform a sealing, filling, or anchoring operation as desired.

FIG. 4 is a cross-section of the example downhole device 5, of FIGs. 2 and 3 with

modification. In this specific example, the downhole device 5 may be a sealing system such as a

packer. The downhole device 5 comprises a reactive metal element 10 disposed within a void

space 15. The void space 15 may be carved into the downhole device 5 or the downhole device 5

may be manufactured to comprise a suitable void space 15. The geometry of the void space 15 is

designed designedsuch suchthat an an that opening 20 is20presented opening to the to is presented exterior of the downhole the exterior of the device 5. The downhole device 5. The

downhole device 5 may be deployed and run in hole until the opening 20 is adjacent an annular

space into which the reactive metal element 10 is to be deployed upon reaction. Covering at least

a portion of the reactive metal element 10 is a frangible casing 25. The frangible casing 25 may

cover the portion of the reactive metal element 10 exposed to the opening 20 or may cover more

of the reactive metal element 10, including covering of the entirety of the reactive metal element

10. The reactive metal element 10 may be deployed in a desired shape such as a lattice, pellets,

or pieces within the void space 15. In some optional examples, a non-reactive material may be deployed in the void space 15 and interspersed within the reactive metal element 10 to assist in preventing premature reaction. A sliding piston 30, or other such actuating component, may be disposed adjacent to the void space 15 containing the reactive metal element 10. Translation of the sliding piston 30 is prevented by a body lock ring 35. The body lock ring 35 is exemplary in nature and may be substituted for any other such locking mechanism SO so as to prevent undesired translation of the sliding piston 30. The interior diameter of the downhole device 5 comprises openings 40 that extend starting from a flowpath 45 within the interior of the downhole 5 through the body of the downhole device 5 and into the void space 15. A sliding component 50 (e.g., a sleeve, piston, or other translatable member) is disposed within the flowpath 45. The sliding component 50 blocks fluid flow within flowpath 40 and seals flowpath 45 with sealing elements

55. When the downhole device 5 is positioned as desired, the sliding component 50 may be

removed allowing for a reaction inducing fluid to enter into openings 40 to allow for expansion

and sealing of the reactive metal element 10 within the flowpath 45 as the reactive metal reacts

and expands within the flowpath 45. Additionally, the sliding piston 30 may be compressed in

some examples to allow sealing, anchoring, etc. as described in FIG. 3 above.

FIG. 5 is a cross-section of an example downhole device, generally 100. In this specific

example, the downhole device 100 may be a sealing system such as a packer. The downhole

device 100 comprises a reactive metal element 105 disposed within a void space 110. In the

illustrated example, the void space 110 exists between two end rings 115 disposed on the exterior

surface of the body 120 of the downhole device 100. The geometry of the void space 110 is

designed such that an opening 125 is presented to the exterior of the downhole device 100. The

downhole device 100 may be deployed and run in hole until the opening 125 is adjacent an annular

space into which the reactive metal element 105 is to be deployed upon reaction. Covering at least

a portion of the reactive metal element 105 is a frangible casing 130. The frangible casing 130

may cover the portion of the reactive metal element 105 exposed to the opening 125 or may cover

more of the reactive metal element 105, including covering of the entirety of the reactive metal

element 105. This specific reactive metal element 105 is illustrated as a solid piece and is not a

lattice, pellet, or discrete pieces. Adjacent to the reactive metal element 105 is a non-reactive

material 140 such as a non-reactive fluid.

FIG. 6 is a cross-section of the example downhole device 100 of FIG. 5 after the frangible

casing 130 has been broken. When desired for use, axial force may be applied to one or both of

the end rings 115 resulting in translation of at least one of the end rings 115 towards the reactive

metal element 105. Translation of the end rings 115 may occur as a result of increasing localized

fluid pressure in the wellbore, or may be actuated by hydraulic, mechanical, pneumatic or other

such mechanisms as would be readily apparent to one of ordinary skill in the art. The end rings

115 apply axial pressure to the void space 110 SO so as to compress the frangible casing 130. The

frangible frangible casing casing 130 130 is is broken broken into into pieces pieces thereby thereby allowing allowing portions portions of of the the reactive reactive metal metal element element

105 to be exposed to the exterior annular space adjacent the opening 125. The exposed reactive

metal of the reactive metal element 105 may now be in a position to contact a circulating reaction-

inducing fluid. Upon contact with the reaction-inducing fluid, the reactive metal within the

reactive metal element 105 will react to form the reaction product, thereby providing a filling

expansion into any adjacent space contactable by the reaction product to perform a sealing, filling,

or anchoring operation as desired.

FIG. 7 is a cross-section of an example downhole device, generally 200. In this specific

example, the downhole device 200 is a setting tool. The downhole device 200 comprises a reactive

metal element 205 disposed on the exterior of the downhole device 200. In the illustrated example,

the reactive metal element 205 is wedge shaped and moves along its slope as a part of the

operation of the downhole device 200. Covering at least a portion of the downhole device 200 is

a frangible casing 210. The frangible casing 210 covers the portion of the downhole device 200

containing the reactive metal element 205. This specific reactive metal element 205 is illustrated

as as a a solid solid piece piece and and is is not not a a lattice, lattice, pellet, pellet, or or discrete discrete pieces. pieces. A A sliding sliding piston piston 215 215 or or other other

translatable member is disposed within the center throughbore of the downhole device 200.

FIG. 8 is a cross-section of the example downhole device 200 of FIG. 7 after the frangible

casing 210 has been broken. When desired for use, axial force may be applied the sliding piston

215 resulting in translation of the sliding piston 215. Translation of the sliding piston 215 may

occur as a result of increasing localized fluid pressure in the wellbore, or may be actuated by

hydraulic, mechanical, pneumatic or other such mechanisms as would be readily apparent to one

of ordinary skill in the art. The sliding piston 215 applies axial pressure via a flanged or wedged

structure 225 which is further translated to the wedge-shaped reactive metal element 205. The

reactive metal element 205 is then shunted outward radially into the frangible casing 210 which

is then broken into pieces thereby allowing portions of the reactive metal element 205 to be

exposed to any exterior annular space. The exposed reactive metal of the reactive metal element

205 may now be in a position to contact a circulating reaction-inducing fluid. Upon contact with

the reaction-inducing fluid, the reactive metal within the reactive metal element 205 will react to

form the reaction product, thereby providing a filling expansion into any adjacent space

contactable by the reaction product to perform a sealing, filling, or anchoring operation as desired.

It should be clearly understood that the examples illustrated by FIGs. 1-8 are merely

general applications of the principles of this disclosure in practice, and a wide variety of other

examples are possible. Therefore, the scope of this disclosure is not limited in any manner to the

details of any of the FIGURES described herein.

It is also to be recognized that the disclosed reactive metal elements may also directly or

indirectly affect the various downhole equipment and tools that may come into contact with the

reactive metal elements during operation. Such equipment and tools may include, but are not

limited to: wellbore casing, wellbore liner, completion string, insert strings, drill string, coiled

tubing, slickline, wireline, drill pipe, drill collars, mud motors, downhole motors and/or pumps,

surface-mounted motors and/or pumps, centralizers, turbolizers, scratchers, floats (e.g., shoes,

collars, valves, etc.), logging tools and related telemetry equipment, actuators (e.g.,

electromechanical devices, hydromechanical devices, etc.), sliding sleeves, production sleeves,

plugs, screens, filters, flow control devices (e.g., inflow control devices, autonomous inflow

control devices, outflow control devices, etc.), couplings (e.g., electro-hydraulic wet connect, dry

connect, inductive coupler, etc.), control lines (e.g., electrical, fiber optic, hydraulic, etc.),

surveillance lines, drill bits and reamers, sensors or distributed sensors, downhole heat

exchangers, valves and corresponding actuation devices, tool seals, packers, cement plugs, bridge

plugs, and other wellbore isolation devices, or components, and the like. Any of these components

may be included in the systems generally described above and depicted in any of the FIGURES.

Provided are methods for initiating the reaction of a reactive metal element of a downhole

device. An example method comprises introducing the downhole device into a wellbore; wherein

the downhole device comprises the reactive metal element; wherein the reactive metal element

has has aa first first volume; volume; and and wherein wherein the the reactive reactive metal metal element element is is separated separated from from aa reaction-inducing reaction-inducing

fluid by a frangible casing. The method further comprises removing the frangible casing and

contacting the reactive metal element with the reaction-inducing fluid to produce a reaction

product having a second volume greater than the first volume.

Additionally or alternatively, the method may include one or more of the following

features individually or in combination. The reactive metal element may be in the shape of a

lattice. The reactive metal element may be comprised of discrete pieces. The reactive metal

element may be disposed within a void space of the downhole device and a non-reactive material

may be interspersed within the reactive metal element while the reactive metal element is disposed

within the void space. The non-reactive material may be selected from the group consisting of air,

nitrogen, carbon dioxide, liquid hydrocarbon, liquid wax, oleaginous fluid, distilled water,

polylactic acid, polyglycolic acid, plastic, solid wax, glycerin, alcohol, and any combination

thereof. The frangible casing may comprise a material selected from the group consisting of metal,

polymer, cellulosic material, ceramic material, and any combination thereof. The reactive metal

element may comprise a metal selected from the group consisting of magnesium, calcium,

aluminum, tin, zinc, beryllium, barium, manganese, and any combination thereof. The reactive

PCT/US2021/048628

metal element may comprise a metal alloy selected from the group consisting of magnesium-zinc,

magnesium-aluminum, calcium-magnesium, aluminum-copper, and any combination thereof.

Provided are downhole devices comprising reactive metal elements. An example

downhole device comprises a reactive metal element, and a frangible casing covering at least a

portion of the reactive metal element.

Additionally or alternatively, the downhole device may include one or more of the

following features individually or in combination. The reactive metal element may be in the shape

of a lattice. The reactive metal element may be comprised of discrete pieces. The reactive metal

Provided are systems for initiating the reaction of a reactive metal element of a downhole

device. An example system comprises a reactive metal element, a frangible casing covering at

least a portion of the reactive metal element, and a reaction-inducing fluid capable of reacting

with the reactive metal element to produce a reaction product having a second volume that is

greater than the first volume.

Additionally or alternatively, the system may include one or more of the following

element may comprise a metal selected from the group consisting of magnesium, calcium, aluminum, tin, zinc, beryllium, barium, manganese, and any combination thereof. The reactive metal element may comprise a metal alloy selected from the group consisting of magnesium-zinc, magnesium-aluminum, calcium-magnesium, aluminum-copper, and any combination thereof.

The preceding description provides various examples of the apparatus, 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 systems 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 element 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.

One or more illustrative examples incorporating the examples disclosed herein are

presented. Not all features of a physical implementation are described or shown in this application

for the sake of clarity. Therefore, the disclosed systems and methods 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, as the teachings of the present disclosure may be

modified and practiced in different but equivalent manners apparent to those skilled in the art

having the benefit of the teachings herein. Furthermore, no limitations are intended to the details

of construction or design herein shown other than as described in the claims below. It is therefore

evident that the particular illustrative examples disclosed above may be altered, combined, or

PCT/US2021/048628

modified, and all such variations are considered within the scope of the present disclosure. The

systems and methods illustratively disclosed herein may suitably be practiced in the absence of

any element that is not specifically disclosed herein and/or any optional element disclosed herein.

Although the present disclosure and its advantages have been described in detail, it should

be understood that various changes, substitutions and alterations can be made herein without

departing from the spirit and scope of the disclosure as defined by the following claims.

Claims

WHAT IS CLAIMED IS: 20 Aug 2025

1. A method for initiating the reaction of a reactive metal element of a downhole device comprising: 5 introducing the downhole device into a wellbore; wherein the downhole device comprises the reactive metal element; wherein the reactive metal element consists of a metal or a metal alloy; wherein the reactive metal element has a first volume; wherein the reactive metal element is separated from a reaction-inducing fluid by a frangible casing; wherein the downhole device 2021463035

further comprises a sliding piston positioned proximate to the frangible casing such that both the 10 sliding piston and the frangible casing are adjacent to one another in a longitudinally axial direction of the downhole device; removing the frangible casing by translating the sliding piston towards the frangible casing in the longitudinal axial direction to apply sufficeint pressure to the frangible casing in the longitudinal axial direction to break the frangible casing; and 15 contacting the reactive metal element with the reaction-inducing fluid to produce a metal hydroxide reaction product having a second volume greater than the first volume.

2. The method of claim 1, wherein the reactive metal element is in the shape of a lattice.

20 3. The method of claim 1, wherein the reactive metal element is comprised of discrete pieces.

4. The method of claim 1, wherein the reactive metal element is disposed within the downhole device.

25 5. The method of claim 1, wherein the frangible casing comprises a material selected from the group consisting of metal, polymer, cellulosic material, ceramic material, and any combination thereof.

6. The method of claim 1, wherein the reactive metal element comprises a metal selected 30 from the group consisting of magnesium, calcium, aluminum, tin, zinc, beryllium, barium, manganese, and any combination thereof.

7. The method of claim 1, wherein the reactive metal element comprises a metal alloy selected from the group consisting of magnesium-zinc, magnesium-aluminum, calcium- 35 magnesium, aluminum-copper, and any combination thereof.

8. The method of claim 1, wherein the reactive metal element consists of a metal alloy selected from the group consisting of magnesium-zinc, magnesium-aluminum, calcium- magnesium, or aluminum-copper. 5 2021463035 wo 2023/033817

1/4

FIG. FIG. 1 1