Pre-processed Fiber Flocks for Wellbore Fracture Bridging

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Solution Overview

Problem

Current methods for wellbore treatment face challenges such as low bridging ability of diverting slurries, high material requirements, poor stability of diverting agents, and limitations in downhole delivery, particularly in controlling lost circulation and achieving effective zonal isolation in fractured or permeable formations.

Innovation Solution

A slurry comprising a base fluid and pre-processed fiber flocks, which form a mechanically stable 3D fiber network that can bridge wider fractures with reduced material volume, acting as zonal isolation agents, fluid diverters, or carriers for chemical additives, and are removable or degradable to minimize formation damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional particulate diverting materials are used, then treatment diversion can be achieved, but the bridging ability is reduced due to dilution with wellbore fluid and a relatively large amount of material is required

Engineering Contradiction:

Improveamount of diverting materialVSAvoidbridging ability

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The fiber flocks are pre-processed into a 3D network structure before being introduced into the wellbore. This preliminary formation of a mechanically stable network allows the diverting material to maintain its bridging ability without requiring large quantities, as the structure is already optimized for fracture bridging before deployment

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention uses fiber flocks with a 3D network structure as a composite diverting material that combines the benefits of structural stability and efficient bridging. This composite structure maintains integrity during pumping and effectively bridges fractures with reduced material volume compared to conventional particulates

Inventive Principle:

Principle #40Composite materials

2Reliability

If conventional particulate diverting materials are used, then treatment diversion can be achieved, but poor stability of diverting agents is encountered during pumping and subsequent treatment stages

Engineering Contradiction:

Improvestability of diverting agentVSAvoidtreatment efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The 3D fiber network structure is pre-formed before deployment, establishing mechanical stability in advance. This preliminary structuring ensures the diverting agent maintains its integrity during pumping and subsequent treatment stages, eliminating the need for large quantities of material and improving overall treatment efficiency

Inventive Principle:

Principle #10Preliminary action

3Object-affected harmful factors

If bentonite is used to control lost circulation, then fluid loss is controlled, but viscosity increases and fluid flow into surrounding rock is slowed

Engineering Contradiction:

Improvefluid lossVSAvoidfluid flow resistance

Core Design Contradiction:

Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The fiber flocks are divided into individual flock structures that can bridge fractures independently. This segmentation allows multiple small units to work together to control fluid loss without requiring high concentrations that would increase viscosity and impede fluid flow, unlike bentonite which requires high concentrations to achieve similar effects

Inventive Principle:

Principle #1Segmentation

4Object-affected harmful factors

If polymer additives are used to increase viscosity and control fluid loss, then fluid loss is controlled, but the cost increases compared to particulates

Engineering Contradiction:

Improvefluid lossVSAvoidcost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The fiber flocks are designed as cost-effective diverting materials that can be used in lower concentrations than polymers while achieving comparable fluid loss control. The materials are optimized for single-use deployment in wellbore treatments, providing an economical alternative to expensive polymer additives

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 pre-processed fiber flocks enable effective zonal isolation and fluid diversion with reduced material usage, minimizing wellbore plugging risks and formation damage, and facilitate controlled release of additives, improving treatment efficiency and post-treatment cleanup.

Implementation Method 1

a pre-processed fiber flock comprising a plurality of fibers aggregated together at points of fiber contact to form a mechanically stable 3D fiber network

Methodology Applied

Scientific EffectNetwork effect: