NEAR-NET SHAPE INJECTION MOLDING OF FRAC BALLS
This presentation is the property of its rightful owner.
Sponsored Links
1 / 18

NEAR-NET SHAPE INJECTION MOLDING OF FRAC BALLS PowerPoint PPT Presentation


  • 80 Views
  • Uploaded on
  • Presentation posted in: General

NEAR-NET SHAPE INJECTION MOLDING OF FRAC BALLS. Presentation by C. Andrew Rosenholm Director of Business Development Bruce Diamond Corp. January 17 th , 2013 ERG Winter Meeting - Houston, TX.

Download Presentation

NEAR-NET SHAPE INJECTION MOLDING OF FRAC BALLS

An Image/Link below is provided (as is) to download presentation

Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author.While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server.


- - - - - - - - - - - - - - - - - - - - - - - - - - E N D - - - - - - - - - - - - - - - - - - - - - - - - - -

Presentation Transcript


Near net shape injection molding of frac balls

NEAR-NET SHAPE INJECTION MOLDING OF FRAC BALLS

Presentation by C. Andrew Rosenholm

Director of Business Development

Bruce Diamond Corp.

January 17th, 2013

ERG Winter Meeting - Houston, TX


Near net shape injection molding of frac balls

  • The standard ball used today in sliding-sleeve hydraulic fracking is manufactured from G10/FR4 - a thermosetting industrial fiber glass composite laminate consisting of a continuous filament glass cloth material with an epoxy resin binder.

  • There is a “weak” and “strong” plane to laminated balls due to the two-dimensional nature of the layup – nearly a 50% difference in strength


Near net shape injection molding of frac balls

G10/FR4 BALLS

INEFFICIENT METHOD OF MANUFACTURE

FROM PLATE TO SPHERE


Near net shape injection molding of frac balls

STEP 1: SAW PLATE

INTO BARS, THEN CUT

INTO SQUARES


Near net shape injection molding of frac balls

STEP 2: TURN SQUARE BLANK

INTO A SPHERE


Near net shape injection molding of frac balls

STEP 3: GRIND

TURNED SPHERE

INTO BALL


Near net shape injection molding of frac balls

56% OF THE MATERIAL IS WASTED!


Near net shape injection molding of frac balls

INJECTION MOLDING:

A MORE EFFICIENT METHOD

OF MANUFACTURE


Near net shape injection molding of frac balls

INJECTION MOLDED BALLS ARE FORMED

TO NEAR-NET-SHAPE PRIOR TO GRINDING –

NO TURNING OR MACHINING NECESSARY!


Near net shape injection molding of frac balls

INJECTION MOLDING CAN REPLACE

COMPOSITE AND THERMOSET

MATERIALS FOR A FRACTION

OF THE COST!


Near net shape injection molding of frac balls

  • ADVANTAGES OF INJECTION MOLDING:

  • WIDE RANGE OF MECHANICAL AND THERMAL PROPERTIES TO CHOOSE FROM

  • SPECIFIC GRAVITIES RANGE FROM A LITTLE MORE THAN WATER TO AS HEAVY AS LEAD


Near net shape injection molding of frac balls

  • WHAT LITTLE WASTE THERE IS CAN BE REGROUND AND REUSED

  • MOLDING MACHINE CYCLE TIMES ARE A FRACTION OF THE TIME IT TAKES TO MACHINE COMPOSITE


Near net shape injection molding of frac balls

A UNIQUE QUALITY OF INJECTION MOLDED BALLS IS NON-DIRECTIONALITY, I.E.: THERE IS NO “WEAK” ORIENTATION TO THE BALL


Near net shape injection molding of frac balls

  • ADDITIONAL FEATURES POSSIBLE

  • WITH INJECTION MOLDING:

  • MULTI-LAYER BALL (THINK GOLF BALL) – MULTI-MATERIAL

  • INSERTED RFID CHIPS

  • INSERTED TRACERS


Near net shape injection molding of frac balls

ARE INJECTION MOLDED BALLS AS GOOD AS G10 BALLS USED IN SLIDING-SLEEVE HYDRAULIC FRACTURING?

CUSTOM PEEK and PAI RESINS HAVE BEEN DEVELOPED AND TESTED THAT HAVE PROPERTIES SUPERIOR TO G10 – LIGHTER AND STRONGER


Near net shape injection molding of frac balls

CAN THERMOPLASTICS SUBSTITUTE FOR THE HEAVY PHENOLIC BALLS USED WITH PLUG-AND-PERF FRAC PLUGS?

INJECTION MOLDED BALLS IN 1.000” ⌀ , 1.750” ⌀ AND 2.125” ⌀ ARE IN USE THAT PERFORM BETTER THAN PHENOLIC AND COST LESS


Near net shape injection molding of frac balls

CONCLUSION:

TWO YEARS OF PHYSICAL TESTING USING INDUSTRY-STANDARD TEST EQUIPMENT AND METHODS HAS LED TO THE SELECTION AND COMMERCIALIZATION OF THE RESINS WE ARE MOLDING WITH CURRENTLY. R&D CONTINUES WITH NEW RESINS BEING SAMPLED CONTINUOUSLY.


Near net shape injection molding of frac balls

Brought to you by:

www.brucediamondcorp.com/frac


  • Login