Downhole Mud Powered Battery

Patent metadata

Field	Value
Publication number	US-2016226080-A1
Application number	US-201615010075-A
Country	US
Kind code	A1
Filing date	Jan 29, 2016
Priority date	Jan 30, 2015
Publication date	Aug 4, 2016
Grant date	—

Abstract

Methods, systems, and devices for powering downhole tools with an electrochemical device are provided. A downhole power system includes an electrochemical device having an anode and a cathode. The power system includes a downhole tool electrically communicating with the electrochemical device to provide electrical power to the downhole tool. The electrochemical device is activated when immersed in a downhole fluid and inactive when not immersed in the downhole fluid, the downhole fluid functioning as an electrolyte.

First claim

1 . A downhole power system, comprising:
an electrochemical device having an anode and a cathode; and a downhole tool electrically communicating with the electrochemical device to provide electrical power to the downhole tool, wherein the electrochemical device is activated when immersed in a downhole fluid and inactive when not immersed in the downhole fluid, the downhole fluid functioning as an electrolyte.

2 . The downhole power system of claim 1 , wherein the anode material comprises at least one of magnesium (Mg) and zinc (Zn).

3 . The downhole power system of claim 2 , wherein the anode comprises a magnesium tube.

4 . The downhole power system of claim 1 , wherein the cathode comprises:
one or more cathode plates bonded to a support grid sheet, thereby forming a cathode assembly, the cathode assembly rolled together to form a scroll shape.

5 . The downhole power system of claim 1 , wherein the cathode material comprises at least one of silver (Ag), silver chloride (AgCl), silver oxide (AgO), copper chloride (CuCl), and lead chloride (PbCl 2 ).

6 . The downhole power system of claim 4 , wherein the cathode plate comprises a silver plated silver chloride sheet.

7 . The downhole power system of claim 6 , wherein the support grid sheet comprises a silver plated copper grid sheet.

8 . The downhole power system of claim 1 , wherein the downhole fluid comprises a drilling fluid having a chlorine (CI) based salt brine.

9 . The downhole power system of claim 1 , wherein the electrochemical device operates at temperatures ranging from −2 to 250° C.

10 . The downhole power system of claim 9 , wherein the operating temperature ranges from 200° C. to 230° C.

11 . A downhole battery, comprising:
a magnesium or zinc based anode; a cathode; and a separator comprising a high temperature resistant material, the separator physically and electrically isolating the anode and cathode; wherein the battery is inactive when not immersed in a downhole fluid and activated when immersed in the downhole fluid, the downhole fluid functioning as an electrolyte.

12 . The downhole battery of claim 11 , wherein the anode comprises a magnesium tube and wherein the downhole battery operates at temperatures ranging from 200 to 230° C.

13 . The downhole battery of claim 11 , wherein the cathode material comprises at least one of silver (Ag), silver chloride (AgCl), silver oxide (AgO), copper chloride (CuCl), and lead chloride (PbCl 2 ).

14 . The downhole battery of claim 13 , wherein the cathode comprises:
a cathode assembly in shape of a scroll, the cathode assembly comprising:
a support grid sheet, the support grid sheet material comprising silver coated copper; and
one or more cathode plates bonded to the support grid sheet, the one or more cathode plates comprising a silver coated silver chloride plate, wherein the support grid sheet and the one or more cathode plates are rolled together to form the scroll shape.

15 . The downhole battery of claim 14 , further comprising:
an anode conductor electrically coupled to the anode; a cathode conductor electrically coupled to the cathode; wherein the separator couples the magnesium tube anode with the cathode assembly at a first end of the downhole battery, the cathode assembly positioned within a cavity formed within the magnesium tube; and wherein the downhole battery comprises an opening to allow the downhole fluid to enter the cavity and activate the downhole battery.

16 . The downhole battery of claim 11 , wherein the high temperature resistant material of the separator comprises at least one of PEEK, polyimide, LCP, PPS, teflon, and other high temperature polymers.

17 . The downhole battery of claim 11 , wherein the downhole fluid comprises at least one of a drilling fluid, a drilling mud, and a chlorine based salt brine.

18 . A method of forming a high temperature downhole fluid activated battery, comprising:
forming a cathode assembly, comprising:
annealing a salt comprising silver chloride (AgCl) to create a high temperature ingot of silver chloride;
forming non-conductive plates of AgCl from the ingot;
coating the plates with silver (Ag);
bonding the plates to a silver plated copper grid sheet; and
rolling the sheet into a spiral or scroll shape;
coupling the cathode assembly to a high temperature resistant separator; coupling the separator and cathode assembly to an anode having a tube shape; and electrically bonding an anode conductor to the anode tube and a cathode conductor to the cathode assembly.

19 . The method of claim 17 , further comprising:
positioning the cathode assembly within a cavity formed within the anode tube, wherein the separator couples the anode tube with the cathode assembly to form a first end of the downhole fluid battery; and wherein the downhole battery comprises an opening to allow the downhole fluid to enter the cavity thereby activating the downhole battery.

20 . The method of claim 18 , wherein the cathode conductor passes through an aperture in the separator.

Assignees

• Schlumberger Technology Corp

Inventors

• Shitikov Vladimir

Classifications

• H01M4/661

  Metal or alloys, e.g. alloy coatings (H01M4/669 take precedence) · CPC title

• H01M4/667

  in the form of layers, e.g. coatings · CPC title

• H01M6/103

  Cells with electrode of only one polarity being folded or wound · CPC title

• H01M4/72

  Grids · CPC title

• H01M4/54

  of silver · CPC title