Crosslinked Polymer Granules for Lost Circulation Control

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Solution Overview

Problem

Conventional lost circulation materials are ineffective in certain drilling operations due to lack of mechanical and thermal stability at high temperatures and pressures, leading to decreased drilling efficiency and mud loss in hydrocarbon wells.

Innovation Solution

The use of crosslinked polymer granules as a lost circulation material, which are mechanically and thermally stable, and can be selectively buoyant to effectively restrict fluid flow through leakage pathways in hydrocarbon wells, including positively, neutrally, or negatively buoyant fractions tailored for specific drilling conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional lost circulation materials are used, then they can provide some circulation control, but they lack mechanical and thermal stability at high temperatures and pressures, leading to effectiveness deterioration

Engineering Contradiction:

Improveeffectiveness of lost circulation materialVSAvoidhigh temperature stability

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent applies parameter changes by modifying the chemical composition and crosslinking degree of polymer granules to achieve thermal stability at high temperatures. The crosslinked polymer structure maintains its physical properties under high temperature and pressure conditions, resolving the contradiction between effectiveness and temperature stability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials by combining crosslinked polymer granules with specific density characteristics into a controlled composition. This composite approach enhances both mechanical stability and thermal resistance while maintaining the desired density properties for effective lost circulation control.

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If crosslinked polymer granules with specific density are used, then they can selectively reach leakage pathways, but this requires precise control of material properties

Engineering Contradiction:

Improveselective reaching of leakage pathwaysVSAvoiddensity control precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by precisely controlling the density parameter of crosslinked polymer granules. By adjusting the crosslinking degree and polymer composition, the granules achieve specific density values that enable selective buoyancy control, allowing them to reach leakage pathways effectively while maintaining manufacturability.

Inventive Principle:

Principle #35Parameter changes

3Loss of substance

If lost circulation material is provided to restrict fluid flow, then mud loss decreases, but pumping costs increase due to reduced return stream flow rate

Engineering Contradiction:

Improvemud lossVSAvoidpumping costs

Core Design Contradiction:

Loss of substanceVSUse of energy by moving object

Solution Approach 1:

The patent applies parameter changes by optimizing the density parameter of lost circulation material to match or exceed drilling mud density. This ensures the material remains suspended and effectively blocks leakage pathways without significantly impeding return stream flow, thereby reducing mud loss while minimizing impact on pumping energy requirements.

Inventive Principle:

Principle #35Parameter changes

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 crosslinked polymer granules significantly reduce pumping costs and enhance the effectiveness of lost circulation material by selectively reaching and blocking leakage pathways, improving drilling efficiency and reducing mud loss.

Implementation Method 1

The lost circulation material may include a plurality of crosslinked polymer granules, and a characteristic dimension of each crosslinked polymer granule is at least 20 micrometers and at most 1 millimeter. Each crosslinked polymer granule may contain a highly crosslinked polymeric material... selectively buoyant to effectively restrict fluid flow through leakage pathways

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Data Source

PatentUS11345842B2Hydrocarbon wells including crosslinked polymer granules as lost circulation material and methods of drilling the hydrocarbon wells

Publication Date: 2022.05.31 EXXONMOBIL UPSTREAM RESEARCH COMPANY(US)

AI summary

Hydrocarbon wells including crosslinked polymer granules as lost circulation material and methods of drilling the hydrocarbon wells. The hydrocarbon wells include a wellbore that extends within a subsurface region, a drilling rig, a drilling mud supply system, a lost circulation detection structure, and a lost circulation material supply system that includes a lost circulation material. The lost circulation material includes a plurality of crosslinked polymer granules, and a characteristic dimension of each crosslinked polymer granule is at least 20 micrometers and at most 1 millimeter. Each crosslinked polymer granule contains a highly crosslinked polymeric material that includes a plurality of polyethylene polymer chains. The methods include rotating a drill string to extend a length of a wellbore and, during the rotating, flowing a drilling mud stream. The methods also include detecting a lost circulation event and, responsive to the detecting, providing a lost circulation material to the wellbore.