On Material Challenges in Customizing Current Oilfield Submersible Pumps for Metal and Mineral In-Situ Leaching/Recovery (C2026-00034)

Manuel Marya

Adapting oilfield submersible pumps for in-situ metal and mineral extraction (solution mining) presents significant engineering challenges, particularly in material selection, design optimization, and the transition from large-scale oilfield manufacturing to smaller, specialized production. These extraction methods using well constructions recover valuable resources by leaching them directly from subsurface deposits but also expose subsurface equipment to highly corrosive fluids and abrasive particulates. This environment demands robust, purpose-built systems such as centrifugal or progressive cavity pumps, re-engineered for extreme environments. This study evaluates the performance of key pump components, including rotating shafts, stages, and housings, under highly acidic wellbore environments, with a focus on corrosion resistance and mechanical durability. It identifies critical areas for advancement, including corrosion and wear resistant alloys and coatings, high-performance non-metallic seals, and protective liners. The study also emphasizes the need for rapid adaptation of existing designs to support flexible, small-scale manufacturing. By outlining the core requirements for submersible pumps in solution mining, this paper supports the development of more durable, efficient, and sustainable systems for cost-effective resource recovery. Laboratory test results using common lixiviants illustrate the material challenges, particularly for traditional oilfield metals, many of which require substitutions including with materials originally conceived for ultra-corrosive oilfield wells.