Research on Preparation and Performance of Nickel-Based Dendritic Foam Metal as Sand Control Media

Summary Mechanical sand control is a commonly used method for protecting oil- and gaswell equipment. The filter medium in the screen pipe filters sand, reducing clogging and equipment wear, thereby improving oil recovery efficiency and system stability. However, under long-term cyclic stress and the impact of gravel collisions, the sand control medium in these screen pipes is prone to wear fatigue and cracking, leading to a shortened lifespan. In this paper, we propose a new method for the preparation of nickel-based dendritic foam metal (NDFM) for sand control in oil and gas wells based on pulsed jet electrodeposition technology. We prepared an NDFM with a honeycomb pore channel structure and studied it for its corrosion resistance, anti-erosion properties, and anticlogging performance. The results showed that compared with existing metal woven mesh and conventional foam metal, the NDFM had corrosion weight loss and primary erosion layer weight loss of only 34.1% and 46.5% of those for metal woven mesh and 80.1% and 76.7% of those for conventional foam metal, respectively. Furthermore, its oil recovery efficiency increased by 78% and 14.9% compared with metal woven mesh and conventional foam metal, respectively. A mathematical model for the seepage of NDFM during the erosion process was established. Through simulations of the oil/water emulsion in the actual seepage and erosion processes, our analysis showed that the special 3D spatial structure and unique microconical honeycomb flow channels of the NDFM enable rapid fluid flow while forming a dendritic flow retardation zone. This results in improved seepage performance, reducing primary erosion wear and extending the service life of the sand control medium.