Consumable downhole tools

Abstract

A method of removing a downhole tool from a wellbore comprising contacting the tool with a heat source wherein the tool comprises at least one load-bearing component comprising a thermally degradable material. A method of reducing the structural integrity of a downhole tool comprising fabricating the load-bearing components of the tool from a thermally degradable material. A method of removing a downhole tool comprising mechanically milling and/or drilling the tool from a wellbore wherein the tool comprises at least one load bearing component comprising a phenolic resin wherein the phenolic resin comprises a rosole, a novalac or combinations thereof.

1 . A method of removing a downhole tool from a wellbore comprising contacting the tool with a heat source wherein the tool comprises at least one load-bearing component comprising a thermally degradable material. 
   
   
       2 . The method of  claim 1  wherein the thermally degradable material comprises a thermoplastic material, a phenolic material, a composite material, or combinations thereof. 
   
   
       3 . The method of  claim 2  wherein the thermoplastic material comprises polyalphaolefins, polyaryletherketones, polybutenes, nylons or polyamides, polycarbonates, thermoplastic polyesters, styrenic copolymers, thermoplastic elastomers, aromatic polyamides, cellulosics, ethylene vinyl acetate, fluoroplastics, polyacetals, polyethylenes, polypropylenes, polymethylpentene, polyphenylene oxide, polystyrene or combinations thereof. 
   
   
       4 . The method of  claim 1  wherein the load-bearing components are acid-resistant. 
   
   
       5 . The method of  claim 1  wherein the heat source comprises a torch with a fuel load that produces heat and oxygen when burned. 
   
   
       6 . The method of  claim 5  wherein the torch further comprises a torch body with a plurality of nozzles distributed along its length. 
   
   
       7 . The method of  claim 5  wherein the fuel load comprises a flammable, non-explosive solid. 
   
   
       8 . The method of  claim 5  wherein the fuel load comprises thermite. 
   
   
       9 . The method of  claim 5  wherein the torch further comprises a firing mechanism with a heat source to ignite the fuel load. 
   
   
       10 . The method of  claim 9  wherein the firing mechanism further comprises a device to activate the heat source. 
   
   
       11 . The method of  claim 9  wherein the firing mechanism is an electronic igniter. 
   
   
       12 . The method of  claim 1  wherein the tool is a frac plug, 
   
   
       13 . The method of  claim 1  wherein the tool is a bridge plug. 
   
   
       14 . The method of  claim 1  wherein the tool is a packer. 
   
   
       15 . A method of reducing the structural integrity of a downhole tool comprising fabricating the load-bearing components of the tool from a thermally degradable material. 
   
   
       16 . The method of  claim 15  wherein the thermally degradable material comprises a thermoplastic material, a phenolic material, a composite material, or combinations thereof. 
   
   
       17 . The method of  claim 15  wherein the thermoplastic material comprises polyalphaolefins, polyaryletherketones, polybutenes, nylons or polyamides, polycarbonates, thermoplastic polyesters, styrenic copolymers, thermoplastic elastomers, aromatic polyamides, cellulosics, ethylene vinyl acetate, fluoroplastics, polyacetals, polyethylenes, polypropylenes, polymethylpentene, polyphenylene oxide, polystyrene or combinations thereof. 
   
   
       18 . The method of  claim 15  further comprising contacting the load bearing components with a heat source. 
   
   
       19 . The method of  claim 15  wherein the tool comprises a frac plug, a bridge plug or a packer. 
   
   
       20 . A method of removing a downhole tool comprising mechanically milling and/or drilling the tool from a wellbore wherein the tool comprises at least one load bearing component comprising a phenolic resin wherein the phenolic resin comprises a rosole, a novalac or combinations thereof.