Epoxy LCM Composition with Amide Accelerator for Wellbore Sealing

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Solution Overview

Problem

Conventional lost circulation materials (LCM) face challenges in injecting into high-injectivity lost circulation zones without replacing the drill bit and are prone to micro-cracks from temperature and pressure cycling, leading to fluid loss and increased drilling downtime.

Innovation Solution

The development of LCM compositions comprising an epoxy resin system, a weighting material, and an amide accelerator, which allows for controlled viscosity and cure time, enabling injection through the drill bit and providing enhanced resistance to micro-crack formation and higher pressure resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional lost circulation materials are used to seal lost circulation zones, then the lost circulation zone can be sealed, but the materials cannot be injected through the drill bit and require replacing the drill bit with an open-ended pipe

Engineering Contradiction:

Improveinjectability through drill bitVSAvoiddrill bit replacement requirement

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent modifies the physical and chemical parameters of the lost circulation material by using a slurry composition with specific viscosity (10-1000 cP), particle size distribution (0.001-5 mm), and density (1.8-2.2 g/cm³) to enable injection through the drill bit while maintaining sealing effectiveness. The controlled rheological properties allow the material to flow through the drill bit and then set in place to seal the lost circulation zone.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If conventional cement compositions are used to isolate lost circulation zones, then the zones can be sealed, but micro-cracks form due to temperature and pressure cycling

Engineering Contradiction:

Improveresistance to micro-crack formationVSAvoidtemperature and pressure cycling damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs a composite slurry material combining cementitious binder (30-70 wt%), inert filler (10-50 wt%), and superplasticizer (0.1-5 wt%) to create a composition that maintains integrity under temperature and pressure cycling. The composite structure with optimized particle size distribution and chemical admixtures provides both sealing capability and resistance to thermal-mechanical stress-induced micro-cracking.

Inventive Principle:

Principle #40Composite materials

3Productivity

If conventional lost circulation materials are used, then lost circulation zones can be treated, but drilling downtime increases due to material replacement and re-installation

Engineering Contradiction:

Improvedrilling continuityVSAvoiddrilling downtime

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent enables preliminary action by formulating the lost circulation material with injection-compatible rheological properties that allow it to be pumped through the existing drill bit before drilling operations resume. This preliminary injection of sealing material eliminates the need to pull the drill string and replace the drill bit, maintaining continuous drilling operations and reducing downtime.

Inventive Principle:

Principle #10Preliminary action

4Loss of substance

If conventional lost circulation materials are used, then sealing can be achieved, but fluid loss increases due to inadequate pressure resistance

Engineering Contradiction:

Improvefluid loss preventionVSAvoidpressure resistance

Core Design Contradiction:

Loss of substanceVSStress or pressure

Solution Approach 1:

The patent optimizes the slurry composition parameters including water-to-binder ratio (0.25-0.40), superplasticizer dosage (0.5-5.0% of binder weight), and filler content (40-60% of total composition) to achieve both injectability and high pressure resistance. The controlled viscosity and particle packing density enable the material to withstand formation pressures up to 10,000 psi while preventing fluid loss into the lost circulation zone.

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 LCM compositions effectively seal lost circulation zones, reducing drilling downtime and preventing fluid loss by maintaining injectability and integrity under high pressures and temperature cycling.

Implementation Method 1

an amide accelerator that accelerates the curing of the epoxy resin system

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

an epoxy resin system that includes at least one epoxy resin and at least one curing agent

Methodology Applied

Scientific EffectChemical Bonding: Chemical Bonding

Data Source

PatentUS11332656B2LCM composition with controlled viscosity and cure time and methods of treating a lost circulation zone of a wellbore

Publication Date: 2022.05.17 SAUDI ARABIAN OIL CO

AI summary

A lost circulation material (LCM) composition for sealing lost circulation zones in wellbores may include 50 weight percent to 97 weight percent epoxy resin, 2 weight percent to 30 weight percent curing agent, 0.1 weight percent to 40 weight percent weighting material, and 0.1 weight percent to 20 weight percent amide accelerator. The LCM composition may have a density of greater than or equal to 1121 kilograms per cubic meter and may be capable of being injected through a drill bit of a drill string into the lost circulation zone. The amide accelerator may enable the viscosity of the LCM composition to be reduced while providing a reduced cure time. The LCM compositions are suitable for treating high-injectivity lost circulation zones.