Soluble Frac Balls

Soluble Frac Balls (also known as dissolvable frac balls or soluble ball sealers) are fully dissolvable downhole tools engineered for horizontal well multi-stage hydraulic fracturing. In conventional plug-and-perf completions, composite bridge plugs are used for zonal isolation between stages, but these must be drilled out with coiled tubing after fracturing - adding rig time, operational cost, and wellbore risk. Soluble frac balls eliminate this requirement by providing temporary zonal isolation through seating in frac sleeves or ball seats, then dissolving completely in wellbore fluids after stimulation - leaving no debris and restoring full wellbore access for immediate production logging.

The soluble frac ball must withstand downhole temperatures up to 150°C and differential pressures exceeding 70MPa, with a very small stress area when pressurized against the ball seat. This demands exceptional thermal stability, short-circuit resistance, and mechanical strength. Our product range addresses these requirements with two material categories:

• Soluble Metal Frac Balls - manufactured from high-strength soluble magnesium alloy formulations, delivering ≥70MPa pressure rating with controlled dissolution in chloride brine. Available in three application-specific grades: standard (90°C, 3% KCl), low-temperature clear water (43°C, 0.05% KCl), and high-temperature high-pressure (90°C, 3% KCl).

• Soluble Polymer Frac Balls - manufactured from degradable polymer formulations, delivering ≥50MPa pressure rating with dissolution time of 12–48 hours in clear water at 90°C. Lighter weight and cost-effective for moderate pressure applications. We currently provide frac ball products with diameters ranging from 10mm to 120mm, covering common ball seat and sleeve sizes. Custom development is available for specific performance requirements based on customer-provided operating conditions, temperatures, pressures, and dimensions.

1. Eliminates Coiled Tubing Mill-Out

Unlike conventional composite bridge plugs that require drilling and milling with coiled tubing after fracturing, soluble frac balls dissolve completely in wellbore fluids - saving rig time, reducing operational cost, and eliminating wellbore risk associated with mill-out operations. Full wellbore drift diameter is restored for immediate production logging.

2. Two Material Categories for Diverse Applications

• Soluble Metal (Magnesium Alloy) - ≥70MPa pressure rating, three grades for standard/low-temp/HTHP environments, dissolution rate 35–85 mg/hr/cm² in chloride brine

• Soluble Polymer - ≥50MPa pressure rating, 12–48h dissolution time in clear water at 90°C, lighter weight and cost-effective

Both categories are fully dissolvable with zero residual debris.

3. Wide Diameter Range: 10mm – 120mm

Standard diameters cover common ball seat and frac sleeve sizes from small (10mm) to large (120mm). Custom diameters available to match specific wellbore and completion equipment dimensions.

4. High Pressure & Temperature Rating

Soluble metal balls: ≥70MPa pressure rating, operating up to 150°C. Soluble polymer balls: ≥50MPa pressure rating. The small contact stress area against the ball seat demands - and delivers - exceptional mechanical strength and thermal stability under sustained differential pressure.

5. Controlled Dissolution

Metal grades offer precise dissolution rates (35–85 mg/hr/cm²) calibrated to specific temperature and chloride concentration. Polymer grades offer time-based dissolution (12–48 hours). Both can be customized to match your operational timeline - ensuring the ball remains intact during fracturing, then dissolves predictably after the job.

6. Simple Deployment via Ball Drop

No specialized setting tools required - the ball is simply dropped or pumped from surface and seats in the target ball seat or frac sleeve under differential pressure. Compatible with standard ball-drop fracturing systems and plug-and-perf completions.

7. Custom Formulation Development

Custom material formulations, diameters, and dissolution rates can be developed based on customer-provided operating conditions - including temperature, pressure, fluid type, required dissolution time, and ball seat dimensions.

The Soluble Frac Ball operates in three stages:

1. Deployment & Seating Stage

The soluble frac ball is dropped or pumped from surface through the wellbore. It travels down the tubing/casing until it reaches the target ball seat or frac sleeve, where it seats under its own weight and differential pressure. The ball creates a pressure-tight seal against the seat, isolating the lower zone.

2. Fracturing (Pressure Isolation) Stage

With the ball seated, pressure is applied from surface to initiate or continue fracturing of the zone above the ball seat. The ball withstands the full differential pressure (up to 70MPa for metal balls, 50MPa for polymer balls) and downhole temperature (up to 150°C) throughout the fracturing operation - maintaining structural integrity and seal performance. The small contact area between the ball and seat requires high mechanical strength to prevent extrusion or deformation.

3. Dissolution Stage

After fracturing operations are complete, the ball begins to dissolve in the wellbore fluid. For metal balls, the magnesium alloy dissolves at a controlled rate (35–85 mg/hr/cm²) in chloride brine at the specified temperature. For polymer balls, the material degrades over 12–48 hours in clear water at 90°C. Once fully dissolved, no solid debris remains - the dissolution byproducts (soluble metal salts, polymer fragments) are circulated out during flowback, restoring full wellbore drift diameter and enabling immediate production logging without coiled tubing mill-out.

All Soluble Frac Balls are manufactured and tested under strict quality control:

• Raw material inspection - metal alloy composition verification (magnesium/aluminum content), polymer molecular weight testing, and solubility calibration per batch

• Dimensional inspection - ball diameter, sphericity, and surface finish verification (diameter tolerance per drawing, typically ±0.1mm for precision seats)

• Density measurement - specific gravity verification per grade

• Compressive strength testing - uniaxial and ball-seat crush test at rated pressure (70MPa or 50MPa) with no deformation, cracking, or extrusion

• Dissolution testing - dissolution rate (metal) or dissolution time (polymer) verification in standardized fluid at specified temperature and chloride concentration

• Pressure seal testing - ball-to-seat pressure containment test at rated differential pressure with zero leakage

• Packaging inspection - individual or bulk packaging with corrosion inhibitor (metal balls) or desiccant (polymer balls), labeled with material type, diameter, batch number, and manufacture date

We provide:

• 12-month product quality warranty from date of shipment

• Custom material and diameter development

• Technical support for ball seat compatibility, deployment, and dissolution time matching

• Each shipment includes material test report (MTR), pressure test certificate, dissolution test report, and operating manual

• Third-party inspection (BV/SGS/DNV) available on request

• Horizontal Well Multi-Stage Fracturing (Plug-and-Perf)

The primary application - replacing composite bridge plugs for zonal isolation between fracturing stages in horizontal well completions. The ball seats in the frac sleeve or ball seat, provides pressure isolation during stimulation, then dissolves completely - eliminating coiled tubing mill-out and reducing total completion time.

• Shale Gas & Tight Oil Completions

Widely used in unconventional reservoir development where long horizontal wellbores require many isolation stages. The intervention-free design reduces operational cost and risk in high-stage-count wells.

• Ball-Activated Frac Sleeve Systems

Compatible with ball-drop activated sliding sleeve completions - each stage is activated by a progressively larger ball that seats in the corresponding sleeve, opening ports for fracturing. Soluble balls eliminate the need to retrieve or drill out balls after the job.

• Temporary Wellbore Isolation

Provides short-term pressure isolation during well testing, acidizing, or workover operations, then dissolves automatically without intervention - ideal for wells where coiled tubing access is limited or costly.

• Re-Fracturing Operations

Used for temporary isolation during refracturing of existing wells, particularly where previous bridge plug debris or casing restrictions make mechanical plug deployment difficult.

• Offshore & Remote Well Completions

Especially valuable in offshore or remote locations where coiled tubing mobilization is expensive - eliminating mill-out reduces rig spread cost and operational complexity.

Q: What is a soluble frac ball and how does it differ from a composite bridge plug?

A: A soluble frac ball is a fully dissolvable ball that seats in a ball seat or frac sleeve to provide temporary zonal isolation during fracturing. Unlike a composite bridge plug (which must be drilled out with coiled tubing after the job), the soluble ball dissolves completely in wellbore fluid - leaving no debris and eliminating mill-out operations, saving rig time and cost.

Q: What materials are soluble frac balls made from?

A: We offer two categories: (1) Soluble metal balls - high-strength soluble magnesium alloy, ≥70MPa pressure rating, dissolution in chloride brine. (2) Soluble polymer balls - degradable polymer, ≥50MPa pressure rating, dissolution in clear water. Both are fully dissolvable with zero residue.

Q: What sizes are available?

A: Standard diameters range from 10mm to 120mm, covering common ball seat and frac sleeve sizes. Custom diameters can be manufactured for specific equipment dimensions. The ball diameter must match the ball seat ID for proper sealing.

Q: How long does the ball take to dissolve?

A: For metal balls, dissolution is rate-based: 35–85 mg/hr/cm² depending on grade, temperature, and chloride concentration. For polymer balls, dissolution is time-based: 12–48 hours in clear water at 90°C. Custom dissolution rates/times are available. The ball remains intact during fracturing, then dissolves predictably after the job.

Q: What pressure and temperature can the ball withstand?

A: Soluble metal balls: ≥70MPa pressure rating, operating up to 150°C. Soluble polymer balls: ≥50MPa pressure rating. Exact performance depends on grade, temperature, and fluid chemistry. Our technical team can recommend the appropriate grade for your well conditions.

Q: How is the ball deployed?

A: It is simply dropped or pumped from surface - no specialized setting tools required. The ball travels down the wellbore and seats in the target ball seat or frac sleeve under differential pressure. Compatible with standard ball-drop fracturing systems.

Q: How many balls are needed per well?

A: One ball is typically required per fracturing stage or per ball seat. The total number depends on the number of stages in the completion. For multi-stage horizontal wells, a set of progressively sized balls (one per stage) is used. We can provide ball size scheduling based on your completion design.

Q: Is the ball compatible with all fracturing fluids?

A: Metal balls dissolve in chloride brine (KCl/NaCl) - compatibility with specific fluid additives should be verified. Polymer balls dissolve in clear water and most water-based fluids. Our technical team can provide compatibility testing for your specific fluid system.

Q: What is the difference between soluble frac balls and plugging balls?

A: Soluble frac balls are larger (10–120mm), higher pressure (70MPa), and designed to seat in ball seats/frac sleeves for stage isolation (replacing bridge plugs). Plugging balls are smaller (9–26mm), moderate pressure (40–50MPa), and designed to seal perforation holes for diversion within a stage. Both are fully degradable but serve different functions.

Q: What is the MOQ and delivery time?

A: MOQ is 10 pieces for standard products (precision balls are typically ordered in stage sets). Delivery time is 7–15 working days for standard sizes/materials and 15–30 working days for custom formulations. We ship from Shanghai or Ningbo port.

Q: How should the balls be stored?

A: Metal balls: store in original sealed packaging with corrosion inhibitor, in a dry environment below 25°C, away from moisture and salt air. Polymer balls: store in sealed packaging with desiccant, below 25°C, RH <60%. Shelf life is 12 months from manufacture under recommended conditions.

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