Why are cobalt-removing PDC Cutters applied in gas and oil ？
May 23,2025
Discover how cobalt-removed PDC cutters enhance drilling efficiency in extreme conditions. This article explores SUNGOOD TECH’s innovative technology, featuring advanced thermal stability, wear resistance, and cost-saving applications in shale gas and hard rock formations. Learn how cobalt removal extends bit lifespan by 200% and reduces operational costs.
Cobalt-Removed PDC Cutters: Solving Drill Bit Longevity Challenges
The Limitations of Traditional PDC Cutters
Traditional PDC (Polycrystalline Diamond Compact) cutters often fail in high-temperature drilling due to cobalt’s thermal instability. When bottom-hole temperatures exceed 750°C, cobalt binder softens, triggering diamond graphitization and premature wear. SUNGOOD TECH’s cobalt-removed PDC cutters address this issue by selectively eliminating cobalt from the diamond layer (depth: ~0.2mm), achieving thermal stability up to 820°C while maintaining cutting efficiency.
Technological Breakthrough: From Lab to Field
SUNGOOD TECH’s process integrates three innovations:
- Gradient Cobalt Removal
Eco-friendly acid solutions precision-strip surface cobalt at 20–25°C, preserving the diamond core structure. - Nano-Interface Reinforcement
A tungsten carbide transition layer deposited via HPHT sintering (5GPa, 1500°C) boosts impact resistance by 40%. - Crystal Alignment Technology
Magnetic-assisted sintering aligns diamond crystals along the cutting direction, achieving 15,000-meter wear resistance (granite) – double conventional PDC performance.
Real-World Performance
1. Shale Gas Horizontal Wells
In Sichuan Basin projects, SUNGOOD’s cutters enabled 180m/day penetration rates (311mm drill bits), reducing bit replacement frequency by 30% through anti-sticking edge design (Ra 0.8μm).
2. Ultra-Hard Formations
In Xinjiang’s HRC 72 rock formations, single bits drilled 800m continuously – 45% longer than industry standards.
3. High-Temperature Reservoirs
In South China Sea deepwater blocks (128°C), SUNGOOD cutters showed 0.35% volume loss after 48 hours vs. 2.1% for standard PDC.
Cost-Efficiency Analysis
Metric | Traditional PDC | SUNGOOD Cobalt-Free |
|---|---|---|
Bit Cost | $3,500 | $4,200 (+20%) |
Bits per 1,000m | 6–8 | 3–4 |
Total Cost/km | 21,000–28,000 | 16,800–21,000 |
Source: SUNGOOD TECH 2023 Field Reports |
Industry Impact
Certified with API 17D and patented thermal barrier technology (US2023178235A1), SUNGOOD’s PDC cutters enable “three-high” drilling (high RPM, high pressure, long life). This innovation is reshaping deepwater drilling and extended-reach horizontal applications.
Call for Discussion:
Can cobalt-free PDC technology solve deep-sea drilling challenges? Share your insights below.
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