Lost-Circulation Cement Composition for Very Large Fracture Plugging
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Solution Overview
Problem
Existing cement compositions struggle to effectively seal large to very large fracture widths in subterranean formations, leading to fluid loss and equipment plugging issues during wellbore operations.
Innovation Solution
A lost-circulation composition comprising a cement slurry base fluid, polymeric additive, fine particulate component, and composite particulate component with size and shape-selected materials, designed to plug fracture widths up to 10000 microns while allowing passage through 15000 micron fractures, reducing the risk of equipment plugging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If cement compositions are used to seal large fracture widths, then fluid loss is reduced, but the risk of equipment plugging increases
Solution Approach 1:
The cement composition is divided into multiple size fractions of particulate matter (fine, intermediate, and coarse fractions with specific size ranges). This segmentation allows the composition to effectively seal fractures of various widths without causing equipment plugging, as each fraction targets different fracture size ranges while maintaining flowability through equipment
Solution Approach 2:
The patent specifies precise parameter ranges for particulate matter size fractions (fine: 0-425 mesh, intermediate: 425-200 mesh, coarse: 200-100 mesh) and their respective weight percentages (fine: 20-60%, intermediate: 20-50%, coarse: 10-30%). These parameter optimizations enable the composition to balance sealing effectiveness for large fractures with sufficient flowability to prevent equipment plugging
2Loss of substance
If lost circulation material is used to plug large fracture widths, then fluid loss is controlled, but the material may not adequately seal very large fractures (5000+ micron)
Solution Approach 1:
The patent creates a composite lost circulation composition combining cement slurry base fluid with multiple fractions of particulate matter (fine, intermediate, and coarse) in specific proportions. This composite structure provides both the fluid loss control properties of traditional lost circulation materials and the sealing capability for very large fractures, overcoming the limitations of single-material approaches
Solution Approach 2:
Different size fractions of particulate matter are distributed throughout the cement composition to address different fracture width scenarios. The fine fraction (20-60% by weight) handles smaller pathways, while coarse fraction (10-30% by weight) addresses very large fractures (5000+ micron), creating a composition with spatially varying sealing properties matched to different fracture characteristics
3Manufacturing precision
If high loading of lost circulation material is used to seal large loss zones, then sealing capability is improved, but mixing challenges and equipment plugging occur
Solution Approach 1:
The particulate matter is segmented into three distinct size fractions with defined mesh ranges and weight percentages. This segmentation enables effective mixing at high loadings by preventing excessive buildup of any single particle size, which would cause aggregation and mixing difficulties. The distributed size spectrum maintains slurry flowability and pumpability even at high solids content
Solution Approach 2:
The patent optimizes the particle size distribution parameters, specifying that fine particulate matter (0-425 mesh) constitutes 20-60% by weight, intermediate (425-200 mesh) constitutes 20-50% by weight, and coarse (200-100 mesh) constitutes 10-30% by weight. These parameter specifications ensure the composition achieves high sealing capability while maintaining adequate fluidity for mixing and placement operations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition effectively seals large fracture widths, minimizing fluid loss and equipment plugging, enabling efficient fluid placement and operation in high loss rate applications.
Implementation Method 1
a lost-circulation composition comprising a cement slurry base fluid, polymeric additive, fine particulate component, and composite particulate component containing size and shape selected materials
Data Source
AI summary
A method of sealing a lost circulation zone may include: circulating a lost circulation treatment composition to a subterranean formation comprising a lost circulation zone, wherein the lost circulation treatment composition comprises: a carrier fluid; a polymeric additive; a fine particulate component; and a composite particulate component containing size and shape selected materials; wherein the cost circulation treatment composition has the property of allowing full volume passage through a 15,000 micron fracture width; flowing the lost circulation treatment composition into the lost circulation zone; and plugging the lost circulation zone using the lost circulation treatment composition.