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

Abstract Adapting oilfield submersible pumps for in-situ leaching (ISL) or recovery (ISR) of metals and minerals presents engineering challenges, particularly in material selection, design optimization, and manufacturing due to large-scale oilfields to small and specialized production. ISL/ISR utilizes well technologies to recover valuable resources by leaching them from subsurface deposits and inherently expose the 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 wear performance. It identifies critical areas for advancement, including corrosion and wear resistant alloys and coatings, protective liners, non-metallic seals. 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 materials originally conceived for ultra-corrosive oilfield wells.