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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,

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Presentation on theme: "NEAR-NET SHAPE INJECTION MOLDING OF FRAC BALLS Presentation by C. Andrew Rosenholm Director of Business Development Bruce Diamond Corp. January 17 th,"— Presentation transcript:

1 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

2 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

3 G10/FR4 BALLS INEFFICIENT METHOD OF MANUFACTURE FROM PLATE TO SPHERE

4 STEP 1: SAW PLATE INTO BARS, THEN CUT INTO SQUARES

5 STEP 2: TURN SQUARE BLANK INTO A SPHERE

6 STEP 3: GRIND TURNED SPHERE INTO BALL

7 56% OF THE MATERIAL IS WASTED!

8

9 INJECTION MOLDED BALLS ARE FORMED TO NEAR-NET-SHAPE PRIOR TO GRINDING – TO NEAR-NET-SHAPE PRIOR TO GRINDING – NO TURNING OR MACHINING NECESSARY! NO TURNING OR MACHINING NECESSARY!

10 INJECTION MOLDING CAN REPLACE COMPOSITE AND THERMOSET MATERIALS FOR A FRACTION OF THE COST!

11 ADVANTAGES OF INJECTION MOLDING: WIDE RANGE OF MECHANICAL AND THERMAL PROPERTIES TO CHOOSE FROMWIDE RANGE OF MECHANICAL AND THERMAL PROPERTIES TO CHOOSE FROM SPECIFIC GRAVITIES RANGE FROM A LITTLE MORE THAN WATER TO AS HEAVY AS LEADSPECIFIC GRAVITIES RANGE FROM A LITTLE MORE THAN WATER TO AS HEAVY AS LEAD

12 WHAT LITTLE WASTE THERE IS CAN BE REGROUND AND REUSEDWHAT LITTLE WASTE THERE IS CAN BE REGROUND AND REUSED MOLDING MACHINE CYCLE TIMES ARE A FRACTION OF THE TIME IT TAKES TO MACHINE COMPOSITEMOLDING MACHINE CYCLE TIMES ARE A FRACTION OF THE TIME IT TAKES TO MACHINE COMPOSITE

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

14 ADDITIONAL FEATURES POSSIBLE WITH INJECTION MOLDING: MULTI-LAYER BALL (THINK GOLF BALL) – MULTI-MATERIALMULTI-LAYER BALL (THINK GOLF BALL) – MULTI-MATERIAL INSERTED RFID CHIPSINSERTED RFID CHIPS INSERTED TRACERSINSERTED TRACERS

15 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

16 CAN THERMOPLASTICS SUBSTITUTE FOR THE HEAVY PHENOLIC BALLS USED WITH PLUG-AND-PERF FRAC PLUGS? INJECTION MOLDED BALLS IN 1.000, AND ARE IN USE THAT PERFORM BETTER THAN PHENOLIC AND COST LESS

17 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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