Low-density ceramic floats for use in a downhole environment
Provided is a float for use with a fluid flow control device, a fluid flow control device, a method for manufacturing a fluid flow control device, and a well system. The float, in one aspect, includes a ceramic base material having one or more cavities therein, the ceramic base material and the one or more cavities creating a net density for the float that is between a first density of a desired fluid and a second density of an undesired fluid, such that the float may control fluid flow through a flow control device when encountering the desired fluid or the undesired fluid.
1 . A float for use with a fluid flow control device, comprising:
a non-foam ceramic base material having one or more cavities therein, the non-foam ceramic base material and the one or more cavities creating a net density for the float that is between a first density of a desired fluid and a second density of an undesired fluid, such that the float may control fluid flow through a flow control device when encountering the desired fluid or the undesired fluid, wherein the non-foam ceramic base material and the one or more cavities create the net density for the float that is above the first density of the desired fluid and below the second density of the undesired fluid, and further wherein the one or more cavities are:
four or more substantially equally spaced cavities; or
four or more gradiently spaced cavities positioned to alter a center of gravity of the float; or
four or more substantially equally sized cavities.
2 . The float as recited in claim 1 , further including a fluid impermeable exterior surrounding the non-foam ceramic base material having the plurality of cavities therein.
3 . The float as recited in claim 2 , wherein the fluid impermeable exterior forms a hermetic seal around the non-foam ceramic base material having the plurality of cavities therein.
4 . The float as recited in claim 1 , wherein the non-foam ceramic base material having the plurality of cavities therein is located within one or more openings in a non-ceramic base material.
5 . The float as recited in claim 1 , wherein the non-foam ceramic base material having the one or more cavities therein is formed using an additive manufacturing process.
6 . A fluid flow control device, comprising:
an inlet port;
an outlet port;
a float positioned between the inlet port and the outlet port, the float movable between an open position that allows fluid flow through the outlet port and a closed position that restricts fluid flow through the outlet port, the float including:
a non-foam ceramic base material having one or more cavities therein, the ceramic base material and the one or more cavities creating a net density for the float that is between a first density of a desired fluid and a second density of an undesired fluid, such that the float may control fluid flow through the fluid flow control device when encountering the desired fluid or the undesired fluid, wherein the non-foam ceramic base material and the one or more cavities create the net density for the float that is above the first density of the desired fluid and below the second density of the undesired fluid, and further wherein the one or more cavities are:
four or more substantially equally spaced cavities; or
four or more gradiently spaced cavities positioned to alter a center of gravity of the float; or
four or more substantially equally sized cavities.
7 . The fluid flow control device as recited in claim 6 , further including a fluid impermeable exterior surrounding the non-foam ceramic base material having the plurality of cavities therein.
8 . The fluid flow control device as recited in claim 6 , wherein the non-foam ceramic base material having the plurality of cavities therein is located within one or more openings in a non-ceramic base material.
9 . The fluid flow control device as recited in claim 6 , wherein the non-foam ceramic base material having the one or more cavities therein is formed using an additive manufacturing process.
10 . A method for manufacturing a fluid flow control device, comprising:
providing a float, the float including:
a non-foam ceramic base material having one or more cavities therein, the ceramic base material and the one or more cavities creating a net density for the float that is between a first density of a desired fluid and a second density of an undesired fluid, such that the float may control fluid flow through a flow control device when encountering the desired fluid or the undesired fluid, wherein the non-foam ceramic base material and the one or more cavities create the net density for the float that is above the first density of the desired fluid and below the second density of the undesired fluid, and further wherein the one or more cavities are:
four or more substantially equally spaced cavities; or
four or more gradiently spaced cavities positioned to alter a center of gravity of the float; or
four or more substantially equally sized cavities; and
positioning the float between an inlet port and an outlet port of the flow control device, the float movable between an open position that allows fluid flow through the outlet port and a closed position that restricts fluid flow through the outlet port.
11 . The method as recited in claim 10 , wherein providing a float includes forming at least a portion of the float using an additive manufacturing process.
12 . The method as recited in claim 11 , wherein forming at least a portion of a float using an additive manufacturing process includes tailoring the net density for the float above the first density of the desired fluid and below the second density of the undesired fluid.
13 . A well system, comprising:
a wellbore formed through a subterranean formation;
a tubing string positioned within the wellbore;
a fluid flow control device coupled to the tubing string, the fluid flow control device including:
an inlet port operable to receive fluid from the subterranean formation;
an outlet port operable to pass the fluid to the tubing string; and
a float positioned between the inlet port and the outlet port, the float movable between an open position that allows fluid flow through the outlet port to the tubing string and a closed position that restricts fluid flow through the outlet port to the tubing string, the float including:
a non-foam ceramic base material having one or more cavities therein, the ceramic base material and the one or more cavities creating a net density for the float that is between a first density of a desired fluid and a second density of an undesired fluid, such that the float may control fluid flow through the flow control device when encountering the desired fluid or the undesired fluid, wherein the non-foam ceramic base material and the one or more cavities create the net density for the float that is above the first density of the desired fluid and below the second density of the undesired fluid, and further wherein the one or more cavities are:
four or more substantially equally spaced cavities; or
four or more gradiently spaced cavities positioned to alter a center of gravity of the float; or
four or more substantially equally sized cavities.