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NEAR-NET SHAPE INJECTION MOLDING OF FRAC BALLS

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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.

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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

slide2
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
slide3
G10/FR4 BALLS

INEFFICIENT METHOD OF MANUFACTURE

FROM PLATE TO SPHERE

slide4
STEP 1: SAW PLATE

INTO BARS, THEN CUT

INTO SQUARES

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STEP 3: GRIND

TURNED SPHERE

INTO BALL

slide8
INJECTION MOLDING:

A MORE EFFICIENT METHOD

OF MANUFACTURE

slide9
INJECTION MOLDED BALLS ARE FORMED

TO NEAR-NET-SHAPE PRIOR TO GRINDING –

NO TURNING OR MACHINING NECESSARY!

slide10
INJECTION MOLDING CAN REPLACE

COMPOSITE AND THERMOSET

MATERIALS FOR A FRACTION

OF THE COST!

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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
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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
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A UNIQUE QUALITY OF INJECTION MOLDED BALLS IS NON-DIRECTIONALITY, I.E.: THERE IS NO “WEAK” ORIENTATION TO THE BALL
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ADDITIONAL FEATURES POSSIBLE
  • WITH INJECTION MOLDING:
  • MULTI-LAYER BALL (THINK GOLF BALL) – MULTI-MATERIAL
  • INSERTED RFID CHIPS
  • INSERTED TRACERS
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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

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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

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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.

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Brought to you by:

www.brucediamondcorp.com/frac

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