Deformable Core Composites for Deep Penetration Lost Circulation Control
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Solution Overview
Problem
Existing well treatment methods face challenges in forming effective barriers to prevent the loss of circulation fluids into highly permeable zones during drilling, cementing, and workover operations, as conventional lost circulation materials (LCMs) like cements are ineffective in penetrating deep channels and setting quickly, leading to increased costs and potential formation damage.
Innovation Solution
A well treatment composition featuring a deformable core particulate coated with viscosifying agents, which upon exposure to environmental conditions, increases viscosity and forms a plug or barrier in the wellbore or formation, effectively reducing fluid loss by agglomerating and creating a fluid-impermeable barrier in targeted areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cements are used as lost circulation materials, then the barrier formation is improved, but the penetration depth into low flow rate channels is limited to a few centimeters
Solution Approach 1:
The lost circulation material is divided into multiple size fractions (e.g., 20-40 mesh, 40-60 mesh, 60-80 mesh particles). These segmented particles work cooperatively: larger particles bridge at the entrance while smaller particles penetrate deeper into channels, collectively achieving both barrier formation and deep penetration that neither fraction could accomplish alone.
Solution Approach 2:
The patent changes the particle size parameter by using a distribution of sizes rather than a single size. This parameter change allows the LCM composition to adapt to different channel sizes and flow conditions, enabling penetration to depths of several feet while maintaining effective barrier formation through the combined action of various size fractions.
2Duration of action of moving object
If cements are used in high flow rate channels, then the set time prevents stoppage of loss of circulation, but the barrier plug effectiveness is reduced
Solution Approach 1:
The LCM composition performs preliminary action by rapidly accumulating and plugging high flow rate channels before the cement sets. The non-cement LCM particles bridge and block the channels during the pumping phase, preventing loss of circulation to occur in the first place, rather than relying on cement to set and plug after damage has occurred.
Solution Approach 2:
The patent uses disposable, non-cement LCM particles that perform their plugging function quickly and then remain as permanent mechanical barriers. These particles are sacrificed to plug the channels, eliminating the need for cement setting time and providing immediate loss of circulation control.
3Adaptability or versatility
If multiple components (core particulate, viscosifying agent, crosslinking agent) are shipped separately, then the formulation flexibility is improved, but the platform space and operational complexity increase
Solution Approach 1:
The patent merges multiple components (core particulate, viscosifying agent, and crosslinking agent) into a single pre-coated composite particle. This consolidation eliminates the need for separate storage and handling of multiple components on the platform, reducing space and operational complexity while maintaining the ability to achieve gelation through the integrated design.
Solution Approach 2:
The coated core particulate serves multiple functions simultaneously: the core provides the structural LCM element, the coating provides viscosification, and the crosslinking agent provides gelation. This multi-functional design eliminates the need for separate additives and simplifies the overall system while maintaining formulation effectiveness.
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 allows for deeper penetration and more effective plugging of fluid losses, reducing operational costs and minimizing formation damage by forming a robust, impermeable barrier that reduces fluid influx into the formation, enabling safer and more efficient well treatment operations.
Implementation Method 1
the viscosifying agent (and optionally crosslinking agent, crosslinking delaying agent and other additives) disassociate from the deformable core. The viscosity of the well treatment fluid increases after the fluid is introduced into the wellbore and after the viscosifying agent begins to disassociate from the deformable core
Implementation Method 2
In those instances where crosslinking of the viscosifying agent is desirable, the crosslinking agent and, optionally, a crosslinking delaying agent, may also be coated (as a hardened mass) onto the deformable core
Implementation Method 3
Agglomeration of the deformable core particulates downhole forms a barrier or highly viscous plug in the targeted area of the subterranean formation and/or wellbore
Data Source
AI summary
Loss of wellbore fluids (such as drilling fluids, completion fluids and workover fluids) into the flow passages of a subterranean formation may be reduced or eliminated by introducing into the wellbore in communication with the formation a composition containing a composite of a deformable core having a hardened coating which contains a viscosifying agent and, optionally, a crosslinking agent. The viscosity of the composition increases in-situ as the viscosifying agent, and optional crosslinking agent, disassociate from the deformable core and react. A fluid-impermeable barrier is thereby formed. The composites may also be used in spacers, well cements, workover and completion fluids as their need arises.