Sand Control with Ceramics
Reliable sand control

Sand control is a constant challenge in oil or gas production, Carbon Capture and Storage and alternative energy applications: Especially in sandstone reservoirs, it is essential to filter sand as effectively as possible to ensure stable and uninterrupted production.
Challenges of Sand Control
In reservoirs with low geological strength, or higher oil and gas reservoir depletion, there is an increased risk of sand particles entering the borehole during oil and gas production. These particles can impair production performance and cause damage to equipment. Conventional metallic sand filters are often inadequate in such scenarios, as they can quickly erode and corrode due to abrasive particles. Ceramic material silicon carbide (SiC) is engineered to replace the traditional metallic filter media as a durable, robust, and reliable alternative.
Advantages for Oil and Gas Production
Ceramic filter systems are up to ten times harder than metal filters. With the special material properties of SiC, they resist the usual abrasive wear and corrosion. The service life of ceramic filters is significantly extended compared to metal filters. Effective sand control maximizes flow capacity, leading to sustainably improved productivity of the borehole, promoted by the new ceramic engineered design.
SiC sand filters can also be used under various borehole conditions, including vertical, inclined, and horizontal wells. They have proved successful in environments with a high proportion of fine particles. The design promotes the formation of a natural sand pack around the ceramic sand filter without impairing productivity, this solution is an economical alternative to conventional gravel packs.
Easy Installation
Advantages also lie in the uncomplicated installation and easy handling of ceramic sand filters: Sand filtration can be deployed via wireline/slickline, coiled tubing, or conventional rig systems, significantly simplifying and accelerating planning and logistics, especially at offshore locations.
Scientific Validation
Numerous tests, including particle size analyses and erosion tests, bending and erosion tests demonstrate the outstanding performance of the ceramic material in this specific application. The use of ceramics as a replacement for metallic material has been proven through tests in accordance with ISO and API standards.
A wide range of erosion tests has been conducted on ceramic sand screens and successfully tested in actual field applications. The results show that silicon carbide is superior to traditional materials such as stainless steel and hard metal, especially in aggressive chemical environments and at high flow rates.
Application Example: Dvalin Gas Field
A practical example of the successful use of 3M™ Ceramic Sand Screens made of SiC is the Dvalin gas field development in the Norwegian Sea. This field is characterized by high temperatures of up to 160°C and high pressure (SIWHP 620 bar). The expected sand production and high flow rate could lead to severe damage to production facilities without effective countermeasures.
After extensive examinations and tests, the latest generation of ceramic sand filters were specified. All wells within the project were equipped with the robust and erosion-resistant sand screen systems made of SiC, leading to sand-free production and outstanding productivity.
Properties of Silicon Carbide
Silicon carbide (SiC) is a technical ceramic material characterized by the following features and advantages:
- Exceptional Hardness: SiC is nearly as hard as diamond and about ten times harder than stainless steel. This property gives the material high wear resistance, even under extreme conditions.
- High Temperature Resistance: SiC retains its strength and hardness even at high temperatures, making it ideal for applications in hot environments.
- Chemical Resistance: The material is resistant to a variety of chemicals, including hot sulfuric acid and aggressive completion fluids, ensuring the longevity of the ceramic even in corrosive environments.
Conclusion
Silicon carbide sand filters offer an advanced solution to the challenges of sand control in oil and gas production, Carbon Capture and Storage and alternative energy. This leads to more efficient and cost-effective oil and gas production, even under extremely challenging conditions.