Dissolvable Frac Plug | API 11D1 | 10,000 PSI | Magnesium Alloy | No Mill-Out

The Dissolvable Frac Plug is a next-generation temporary zonal isolation tool engineered for multi-stage hydraulic fracturing and well re-completion operations. Unlike conventional composite or cast iron frac plugs that require time-consuming and high-risk milling or coiled tubing interventions after stimulation, this fully dissolvable design breaks down completely in downhole fluids - including brine, freshwater, and low-concentration KCl solutions - leaving no debris behind and ensuring a full-diameter wellbore for unobstructed oil and gas flow, with zero post-frac intervention required. Constructed from high-strength magnesium-aluminum alloy structural components with polylactic acid (PLA) and advanced polymer sealing elements, the plug features a metal-to-metal expandable dissolvable backup system, thermoplastic elastomer sealing elements, and a bidirectional slip anchoring design that provides stable casing engagement during high-pressure stimulation. The minimalist design has 60% fewer parts than conventional products, reducing the total material volume to be dissolved and ensuring consistent, thorough degradation across the entire plug assembly. Rated to 10,000 PSI (68.95 MPa) differential pressure with a temperature range of 25°C to 120°C (77°F to 248°F), the plug provides reliable isolation during stimulation and predictable dissolution tailored to specific well conditions - with dissolution time customizable from 7 days at higher temperatures to 18 days at lower temperatures, based on wellbore temperature and fluid chloride concentration. Whether operating in shale gas formations, tight oil reservoirs, onshore fields, or offshore completions, this plug provides dependable zonal isolation during fracturing and predictable, controllable dissolution afterward. The compact, lightweight design enables fast pump-down deployment at rates up to 19 barrels per minute via wireline, tubing string, or coiled tubing, and the large inner diameter maximizes flowback efficiency after fracturing - accelerating well cleanup and production startup. By eliminating post-frac milling, debris removal, and intervention operations, the dissolvable frac plug saves rig time, reduces labor costs, minimizes casing damage risk, and reduces water consumption during pump-down - delivering significant total completion cost savings for operators worldwide.

1. Fully Dissolvable, Debris-Free Construction with 60% Fewer Parts

Constructed from 100% dissolvable materials - high-strength magnesium-aluminum alloy for structural components, polylactic acid (PLA), and advanced polymers for sealing and non-structural parts - the plug dissolves completely in brine (including low-concentration KCl solutions as low as 1% chloride) and even freshwater, eliminating milling, coiled tubing operations, and debris-related slowdowns entirely. The minimalist design has 60% fewer parts than conventional frac plugs, reducing the total volume of material requiring dissolution and ensuring consistent, thorough degradation across the entire assembly with no residual components left in the wellbore. Dissolution rate exceeds 99%, restoring full drift diameter for unobstructed production.

2. Reliable Zonal Isolation with Metal-to-Metal Dissolvable Backup

Equipped with a metal-to-metal expandable dissolvable backup system and high-performance thermoplastic elastomer sealing elements, the plug delivers dependable temporary isolation during fracturing. It withstands differential pressures up to 10,000 PSI (68.95 MPa) and temperatures from 25°C to 120°C (77°F to 248°F), ensuring no slippage or pressure leakage during stimulation operations. The bidirectional slip design provides stable anchoring against pressure from both directions, and the dissolvable backup rings prevent elastomer extrusion under high pressure while still degrading completely during the dissolution phase.

3. Customizable Dissolution Time with Predictable Performance

The dissolution rate is precisely adjustable based on wellbore temperature, fluid salinity (Cl⁻ concentration), and specific operational timeline. Standard dissolution time ranges from 7 days at higher temperatures and higher chloride concentrations to 18 days at lower temperatures and lower salinity - with custom formulations available to match your exact fracturing schedule and production startup timeline. The magnesium-aluminum alloy electrolyte composition is tailored for each order, ensuring the plug maintains full structural integrity during the active fracturing period and dissolves predictably afterward, with no risk of premature degradation.

4. Enhanced Operational Efficiency with Large ID and Fast Pump-Down

The compact and lightweight design enables fast pump-down rates up to 19 barrels per minute, reducing deployment time and water consumption compared to heavier conventional plugs. The large inner diameter (ID) maximizes flowback efficiency after fracturing, accelerating well cleanup and reducing the time to first production. Deployment is flexible via wireline, tubing string, or coiled tubing - compatible with standard setting equipment - and the anti-preset design ensures reliable, accurate depth placement in deviated and horizontal wellbores.

5. Significant Cost and Risk Reduction

By eliminating post-frac milling, debris removal, and coiled tubing intervention operations, the dissolvable frac plug saves rig time, reduces labor costs, and minimizes the risk of casing damage associated with drill-out operations. Operators have reported total project savings up to $515,000 compared to composite plug completions requiring mill-out, along with reduced water consumption during pump-down operations and faster production startup. The intervention-free design also eliminates HSE risks associated with coiled tubing operations and milling debris handling.

6. Versatile Application Across Well Types and Environments

Suitable for onshore and offshore wells, vertical, deviated, and horizontal completions, as well as single and multi-zone fracturing operations. The plug performs exceptionally well in unconventional reservoirs including shale gas and tight oil - where over 42% of projects now utilize dissolvable plugs to eliminate mill-out operations - and adapts to complex downhole environments. The ability to dissolve in both high-salinity brine and low-concentration KCl/freshwater makes it compatible with a wide range of completion fluid systems worldwide.

The Dissolvable Frac Plug operates in four phases - deployment, isolation and fracturing, dissolution, and production - to streamline the completion process:

Phase 1: Deployment and Setting

The plug is installed at specific intervals in the wellbore using wireline, tubing string, or coiled tubing, with pump-down rates up to 19 barrels per minute. The anti-preset design ensures the plug travels safely to target depth without premature activation, even in deviated and horizontal sections. Once on depth, the setting tool activates the bidirectional slip system - both upper and lower slips expand and anchor to the casing wall, while the sealing elements compress against the casing ID to form a pressure-tight seal. The metal-to-metal dissolvable backup rings expand to prevent elastomer extrusion. After setting, the setting tool releases and is retrieved.

Phase 2: Isolation and Fracturing

Once set, the bidirectional slip design ensures stable anchoring against pressure from both directions, while the thermoplastic elastomer seals and metal backup rings create a tight, reliable isolation barrier. High-pressure fracturing fluid is pumped through perforations above the plug to create fractures in the target formation, with the plug containing differential pressure up to 10,000 PSI. The large inner diameter allows efficient fluid circulation and treatment placement. The magnesium-aluminum alloy structure maintains full mechanical integrity during this phase - dissolution is engineered to remain minimal until stimulation is complete.

Phase 3: Dissolution

After fracturing operations are complete and the well is put on flowback, the plug is exposed to wellbore fluids at downhole temperature. The magnesium-aluminum alloy undergoes controlled electrochemical reaction with chloride ions in the fluid, while PLA and polymer components undergo hydrolysis - both processes gradually breaking down the plug into soluble salts and fine particulates. Dissolution is accelerated by higher temperatures and higher Cl⁻ concentrations, and slowed by lower temperatures and lower salinity. The 60% fewer-parts design ensures all components dissolve uniformly, with dissolution rate exceeding 99% and no residual debris. Standard dissolution completes in 7–18 days depending on well conditions.

Phase 4: Production

Once fully dissolved, the wellbore is completely clear of obstructions, restoring full drift diameter and allowing oil and gas to flow freely to the surface. No additional cleanup, milling, or coiled tubing intervention is required - reducing downtime and accelerating production startup compared to conventional composite or cast iron plugs that require drill-out.

Every Dissolvable Frac Plug is manufactured under an ISO 9001:2015 certified quality management system and designed in accordance with API 11D1 specifications for downhole packers and bridge plugs. Our quality assurance process covers the full product lifecycle:

Raw Material Control

Magnesium-aluminum alloy billets are sourced from approved suppliers and accompanied by material test reports (MTR) verifying chemical composition, electrolyte content, tensile strength, and hardness. Each batch undergoes spectroscopic composition analysis and dissolution rate verification testing. PLA and polymer sealing materials are tested for molecular weight, tensile strength, and hydrolysis performance. Thermoplastic elastomer seals are tested for hardness, compression set, and fluid compatibility before release to production.

In-Process Manufacturing Control

All components are machined on precision lathes and machining centers with documented process parameters. Critical dimensions - outer diameter, inner diameter, seal groove dimensions, slip tooth geometry, and backup ring fit - are inspected at first-article, in-process, and final inspection stages using calibrated micrometers, bore gauges, and coordinate measuring machines. The bidirectional slip assembly is tested for uniform expansion and release force.

Performance Testing (100% of production)

• Hydrostatic Pressure Seal Test: Each plug is assembled and tested at rated differential pressure (10,000 PSI) with zero visible leakage as the pass criterion

• Setting Function Test: Sample plugs from each production lot are set in test casing to verify bidirectional slip expansion, seal compression, and anti-preset function

• Dissolution Verification Test: Representative samples from each alloy batch are immersed in controlled-temperature chloride solution to confirm dissolution rate matches the ordered specification

• Dimensional Inspection: 100% verification of critical mating dimensions against engineering drawings

• Structural Integrity Test: Compression and tensile testing of alloy components to verify mechanical strength meets specification

Warranty and Support

We provide an 18-month warranty from the date of shipment against manufacturing defects in materials and workmanship. Our engineering team provides 24-hour online technical support for product selection, dissolution rate customization, running procedures, and field troubleshooting.

1. Shale Gas and Tight Oil Multi-Stage Fracturing

The core application scenario - suitable for large-scale multi-stage fracturing of horizontal shale gas and tight oil wells, helping operators improve reservoir stimulation efficiency and reduce completion costs. Over 42% of shale gas projects now utilize dissolvable frac plugs due to their ability to eliminate mill-out operations entirely, and horizontal wells dominate the application segment with over 80% market share. The fast pump-down capability (up to 19 bbl/min) and large inner diameter are particularly valuable in long-lateral shale wells where efficient deployment and flowback directly impact well economics.

2. Horizontal, Deviated, and Vertical Well

Completions Compatible with horizontal, deviated, and vertical wellbores, adapting to different wellbore trajectories and conditions. The anti-preset design and bidirectional slip system ensure reliable setting and sealing in high-angle and horizontal sections where conventional plugs may experience slippage or premature setting. The lightweight construction facilitates deployment in extended-reach laterals.

3. Onshore and Offshore Operations

Stable performance in both onshore and offshore environments, with offshore application adoption growing significantly in recent years. The intervention-free design is particularly valuable offshore where rig time and coiled tubing costs are substantially higher than onshore - eliminating post-frac mill-out operations delivers disproportionate cost savings on offshore platforms. The compact design also reduces deck space and handling requirements.

4. Low-Salinity and Freshwater Completion Environments

Unlike many dissolvable plugs that require high-salinity brine to achieve reliable degradation, this plug is engineered to dissolve effectively in low-concentration KCl solutions (as low as 1% chloride) and even freshwater - making it compatible with a wide range of completion fluid systems worldwide, including regions where high-salinity brine is not readily available or where freshwater-based fracturing fluids are used. The customizable dissolution formulation can be matched to the specific fluid chemistry and temperature of any well.

Q: What is the difference between a dissolvable frac plug and a composite frac plug?

A: A dissolvable frac plug is made from materials - magnesium-aluminum alloy, PLA, and polymers - that degrade completely in wellbore fluids after fracturing, requiring no mill-out or coiled tubing intervention. A composite frac plug is made from non-metallic composite materials that must be drilled out after use (typically 10–30 minutes per plug). Dissolvable plugs eliminate post-frac intervention costs entirely but are more expensive per unit; composite plugs are lower cost but require mill-out. The choice depends on well economics: dissolvable plugs are preferred for extended-reach and offshore wells where intervention costs are high, while composite plugs are economical for standard wells where drill-out is manageable.

Q: How long does the Dissolvable Frac Plug take to dissolve?

A: Standard dissolution time ranges from 7 to 18 days, depending on downhole temperature and fluid chloride concentration - higher temperatures and higher salinity accelerate dissolution, while lower temperatures and lower salinity slow it. For example, at 90°C in 2% KCl solution, dissolution typically completes in approximately 10–14 days. The dissolution rate is fully customizable by adjusting the magnesium-aluminum alloy electrolyte formulation to match your specific well conditions and operational timeline. We provide dissolution performance predictions based on your well data.

Q: In what types of fluid will the plug dissolve?

A: The plug dissolves in brine solutions (1%+ chloride concentration), low-concentration KCl solutions, and freshwater. Unlike some dissolvable plugs that require high-salinity brine, this plug is engineered for effective degradation across a broad range of fluid chemistries. The dissolution rate will vary based on chloride concentration and temperature - we recommend providing your completion fluid composition and well temperature so our engineers can recommend the optimal alloy formulation.

Q: What is the maximum pressure and temperature rating?

A: The rated differential pressure is up to 10,000 PSI (68.95 MPa / 689.5 bar). The standard operating temperature range is 25°C to 120°C (77°F to 248°F). For higher-temperature wells, custom alloy and elastomer formulations may be available - contact our engineering team with your specific well conditions.

Q: What casing sizes and deployment methods are available?

A: Standard sizes cover 3.5" (88.9mm) to 5.5" (139.7mm) casing, with custom sizes available on request. The plug can be deployed via wireline, tubing string, or coiled tubing, with pump-down rates up to 19 barrels per minute. It is compatible with standard setting equipment - contact us for specific setting tool compatibility details for your casing size.

Q: Does the plug leave any residue after dissolution?

A: No. The entire plug - including magnesium-aluminum alloy structural components, PLA and polymer sealing elements, bidirectional slips, and dissolvable backup rings - is manufactured from 100% dissolvable materials. Dissolution rate exceeds 99%, and all degradation products are soluble salts or fine particulates that flow back with produced fluids. No mill-out, debris cleanout, or intervention is required, and full wellbore drift diameter is restored.

Q: What is the MOQ, delivery time, and sample policy?

A: The MOQ is 1 piece for standard models. Custom dissolution formulations require a minimum order quantity depending on the formulation - contact us for details. Standard products ship within 7–15 working days after deposit; custom sizes or formulations require 20–30 working days. We ship from Shanghai or Ningbo port. Sample evaluation units may be available for qualified projects - contact our sales team. Payment terms include T/T (30% deposit, 70% before shipment), L/C at sight, and Western Union.

Q: What certifications do you provide?

A: The plug is designed and manufactured to API 11D1 specifications, and our facility is ISO 9001:2015 certified. Each shipment includes material test reports (MTR), pressure test certificates, and dissolution test reports. CE/PED certification and third-party inspection (BV, SGS, DNV) are available on request to meet import requirements of different countries.

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