Patent No. EP4242284 (titled "Two-Material P&A Plug") was filed by Conocophillips on Apr 9, 2018. The application was issued on Jul 16, 2025.
A method for well plug and abandonment (P&A) involves deploying a cast-in-place plug comprising two materials to create a rock-to-rock seal. The plug consists of an expansion metal, preferably a bismuth-based eutectic alloy, positioned below an adhesion resin. The expansion metal is melted downhole and expands upon solidification to seal the annulus and wellbore, serving as a structural base for the subsequent resin layer. This dual-material configuration provides redundant sealing mechanisms, resulting in greater structural integrity under wellbore conditions than a rock-to-rock plug of equal length composed of either material alone. This approach allows for shorter plug lengths, reducing the need for extensive section milling or perforation and decreasing overall P&A costs and time.

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