Conical Scrap Tire LCMs for Severe Wellbore Loss Zones
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Solution Overview
Problem
Conventional lost circulation materials (LCMs) are ineffective in severe loss zones with fractures of conical, ovular, elliptical, circular, semi-circular, pseudo-cylindrical, or triangular shapes, as they are not engineered to effectively seal these fractures, leading to continued drilling fluid loss during wellbore drilling.
Innovation Solution
Engineered LCMs with conical, capsule, spherical, or ovoid shapes, made from granular scrap tire particles bound by a polymer adhesive, which can be compressed and wedged into fractures to form a seal, reducing or eliminating fluid loss in severe loss zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional LCMs (individual rubber particles) are introduced into severe loss zones, then the materials are easy to access and simple to introduce, but they are easily dislodged from fractures and fail to effectively seal them, leading to continued fluid loss
Solution Approach 1:
The LCM is segmented into multiple functional components: a rigid core structure (conical, spherical, or ovoid shape) made from composite materials, and an elastic outer layer made from rubber particles. This segmentation allows the rigid core to provide structural integrity and fracture plugging capability while the elastic layer provides sealing effectiveness, resolving the contradiction between reliability and complexity.
Solution Approach 2:
The LCM uses composite materials combining rigid structural elements (such as metal, plastic, or ceramic cores) with elastic rubber particles. This composite structure enables the LCM to maintain its shape for effective fracture plugging while providing the elasticity needed for reliable sealing, thus improving sealing effectiveness without excessive complexity.
2Reliability
If conventional LCMs are used, then the material cost is low and materials are readily available, but they do not form a shape capable of being compressed and wedged into fractures, resulting in ineffective sealing
Solution Approach 1:
The LCM is pre-formed into specific geometric shapes (conical, spherical, or ovoid) with predetermined mechanical properties before introduction into the wellbore. This preliminary shaping allows the LCM to be immediately effective upon contact with fractures, eliminating the need for complex in-situ formation processes and maintaining ease of manufacture while achieving reliable sealing.
Solution Approach 2:
The LCM manufacturing process controls key parameters such as rubber particle size distribution (0.5-5mm), core material composition, and elastic layer thickness to optimize both sealing capability and manufacturability. By standardizing these parameters, the invention achieves reliable fracture sealing without excessive manufacturing complexity.
3Reliability
If small LCMs are introduced to combat severe losses, then the materials are easy to access and inexpensive, but they are easily dislodged from the wellbore fractures and allow further fluid loss instead of packing the fractures
Solution Approach 1:
The composite structure combines a rigid core with an elastic rubber particle layer, creating an LCM that has both the structural strength to resist dislodgment and the sealing capability to prevent fluid loss. The rigid core provides mechanical strength while the elastic layer provides sealing, resolving the contradiction between strength and reliability.
Solution Approach 2:
The LCM employs curved geometric shapes (spherical or ovoid) that are mechanically superior for withstanding wellbore pressures and forces. These curved shapes distribute stress more effectively than angular shapes, increasing structural strength and preventing dislodgment while maintaining the ability to seal fractures effectively.
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 engineered LCMs effectively seal fractures of various shapes, reducing or eliminating drilling fluid loss by forming a resilient, elastic seal that maintains under pressure, thereby allowing continued drilling operations without fluid loss.
Implementation Method 1
a polymer adhesive that is dispersed between the granular scrap tire particles and binds the granular scrap tire particles together
Implementation Method 2
These LCMs are resilient and are capable of being compressed and wedged into fractures, blocking the severe loss zone and remediating severe losses
Implementation Method 3
capable of being compressed and wedged into fractures
Data Source
AI summary
A method and drilling fluid additive for reducing severe fluid losses in a well, comprising a combination of granular scrap tire particles and polymer adhesive molded into a cone shape. Once in the severe loss zone, a plurality of LCMs wedge into the formation fractures and seal off the severe loss zone.