Encapsulated Lost Circulation Materials with Shape-Memory Foam

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Solution Overview

Problem

Conventional Lost Circulation Materials (LCMs) face challenges in reliable delivery due to adsorption on pipes and casings and unwanted reactions, leading to inefficiencies in sealing off lost circulation zones during well operations.

Innovation Solution

Encapsulated LCMs comprising a compressed shape-memory polymer foam core and a disintegrating agent, such as a phase change material or gas-producing material, within a protective shell, which is triggered to release the foam to fill voids or fractures, reducing fluid loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional LCMs are directly pumped into the target application area, then the sealing function can be achieved, but losses occur due to adsorption on pipe surfaces and unwanted reactions with environmental components

Engineering Contradiction:

Improvedelivery reliabilityVSAvoidLCM loss

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

A protective shell acts as an intermediary between the LCM core and the environment (pipes, casings, formation). The shell prevents adsorption and unwanted reactions during transport, allowing the LCM to reach the target zone without premature activation or loss. Once at the target, the shell disintegrates to release the active LCM material.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The LCM system is divided into two functional segments: a protective shell for transport and an active core for sealing. This segmentation allows the LCM to perform different functions at different stages - protection during pumping and sealing at the target zone - thereby improving delivery reliability and reducing losses.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the LCM is delivered to the target location, then the sealing function can be performed, but premature expansion or reaction may occur before reaching the desired location

Engineering Contradiction:

Improvesealing effectivenessVSAvoiddowntime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The LCM core is prepared in a compressed, inactive state within the shell before reaching the target zone. The shell maintains this preliminary state during transport, preventing premature expansion or reaction. Only after the LCM reaches the desired location does the shell disintegrate, allowing the sealing action to commence at the optimal time and place.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The LCM undergoes parameter changes (from compressed to expanded state) only after reaching the target zone. The protective shell maintains stable parameters during transport, and the disintegration of the shell triggers the parameter change at the appropriate location, ensuring sealing effectiveness while minimizing downtime.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the LCM expands to fill voids or fractures, then fluid loss is reduced, but the expansion must be controlled to prevent solids from entering fractures

Engineering Contradiction:

Improvefluid loss preventionVSAvoidsolids entry into fractures

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The LCM exhibits different properties at different locations and stages: during transport, it remains compressed and contained within the shell; upon disintegration, it expands locally at the target zone to fill voids and fractures. This localized expansion prevents solids from entering fractures while achieving fluid loss prevention at the specific problem area.

Inventive Principle:

Principle #3Local quality

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 encapsulated approach ensures precise delivery and expansion of the shape-memory polymer foam to effectively seal lost circulation zones, minimizing fluid loss and downtime, while preventing premature expansion and solids entry into fractures.

Implementation Method 1

heating the disintegrating agent to cause the phase change material to expand

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

heating the disintegrating agent to cause the phase change material to expand

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

heating the disintegrating agent to cause the gas-producing material to produce a gas

Methodology Applied

Scientific EffectGas production:

Implementation Method 4

expanding the released shape-memory polymer foam

Methodology Applied

Scientific EffectShape memory effect: Shape Memory Polymer

Data Source

PatentUS12258821B2Encapsulated lost circulation materials based on shape-memory polymer foam

Publication Date: 2025.03.25 BAKER HUGHES OILFIELD OPERATIONS LLC

AI summary

An encapsulated lost circulation material includes: a particulate having a core including a compressed shape-memory polymer foam, and a disintegrating agent, the disintegrating agent including at least one of a phase change material or a gas-producing material; and a shell encapsulating the core. A method of reducing lost circulation includes: introducing into a subsurface a wellbore fluid including the encapsulated lost circulation material; heating the disintegrating agent to cause the phase change material to expand, or to cause the gas-producing material to produce a gas, or a combination thereof to break the shell; and releasing the compressed shape-memory polymer foam from the encapsulated lost circulation material; expanding the released shape-memory polymer foam; and filling a void or fracture of the subsurface with the expanded compressed shape-memory polymer foam to reduce fluid loss.