Gel-Based Lost Circulation Material for Drilling Mud
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Solution Overview
Problem
Conventional gel-based Lost Circulation Materials (LCMs) face challenges in effectively controlling severe mud losses due to poor thermal stability, chemical stability, low gel stiffness modulus, and low yield strength, which limits their ability to seal fractures and vugs in high permeability formations, and require complex preparation and placement procedures, leading to delayed treatment and increased fluid loss.
Innovation Solution
A method and composition that convert drilling mud into a gel-based LCM during continuous drilling by adding a binder to the drilling mud, which includes volcanic ash, a viscosifier, a fluid loss additive, a pH buffer, and a de-foamer, to achieve a target gel characteristic that enhances the gel's stiffness modulus and yield strength, allowing for effective sealing of lost circulation zones without the need for specialized preparation or placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional gel-based LCMs are used to control lost circulation, then some fluid loss control is achieved, but the gel stiffness modulus and yield strength are insufficient to seal severe lost circulation zones
Solution Approach 1:
The patent combines multiple materials to create a composite LCM system: gel-based materials provide the gel network structure, granular materials (such as hollow glass microspheres, sand, or ceramic beads) provide structural support and stiffness, and fibrous materials provide reinforcement. This composite approach achieves both high gel stiffness modulus and yield strength necessary to seal severe lost circulation zones while maintaining the ability to pump and place the material effectively.
2Reliability
If conventional gel-based LCMs are used, then some lost circulation control is achieved, but complex preparation and placement procedures are required, leading to delayed treatment
Solution Approach 1:
The patent merges multiple functional components into a single integrated LCM composition that can be prepared and placed using standard drilling procedures. The composite material system combines gel precursors, granular materials, and fibrous materials in a single slurry that maintains pumpability and sets in situ, eliminating the need for separate preparation steps for different materials and reducing placement complexity.
Solution Approach 2:
The LCM composition is designed to self-adjust and self-set in the lost circulation zone. The gel precursors automatically react and form the gel network upon contact with formation water or under downhole conditions, while the granular and fibrous materials self-arrange to provide structural support. This self-service capability eliminates the need for complex monitoring and adjustment procedures during placement.
3Loss of substance
If conventional LCMs are used to combat lost circulation, then fluid loss is reduced, but the volume of LCM required is large, increasing costs
Solution Approach 1:
The gel-based component of the LCM forms a flexible gel network that can conform to and seal irregular fracture surfaces and vugular zones with thin films of gel material. This gel network acts as a sealing membrane that blocks fluid loss pathways efficiently, requiring much smaller volumes compared to conventional particulate LCMs that need to physically fill and pack the void spaces.
Solution Approach 2:
The composite structure combines the volume-reducing gel network with lightweight granular materials (such as hollow glass microspheres) that provide structural support without adding significant weight or volume. This composite approach achieves effective lost circulation control with minimal LCM volume by leveraging the sealing efficiency of the gel and the structural support of the granular phase.
4Stability of the object's composition
If conventional gel-based LCMs are used, then some gel characteristics are achieved, but thermal stability and chemical stability are poor, limiting effectiveness in severe lost circulation zones
Solution Approach 1:
The patent incorporates thermally stable and chemically stable granular materials (such as ceramic beads, sand, or hollow glass microspheres) into the gel-based LCM system. These inorganic granular materials maintain their structural integrity and stability under high temperature and harsh chemical conditions, providing a stable framework that supports the gel network and maintains lost circulation control effectiveness in severe lost circulation zones where conventional gel-only systems would fail.
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 method and composition provide a flexible stiff gel network that effectively reduces mud loss by creating a robust gel-based LCM with improved yield strength and gel stiffness modulus, capable of sealing severe lost circulation zones quickly and efficiently, reducing the volume of LCM required and meeting environmental regulations.
Implementation Method 1
converting a drilling mud into a gel-based LCM composition during continuous drilling
Implementation Method 2
a viscosifier, to achieve a target gel characteristic that enhances the gel's stiffness modulus and yield strength
Implementation Method 3
a fluid loss additive, to achieve a target gel characteristic that enhances the gel's stiffness modulus and yield strength
Data Source
AI summary
A method of conversion of a water-based mud to a gel-based LCM quickly to control lost circulation in a lost circulation zone in a wellbore during continuous drilling with a drilling mud, the drilling mud comprises a volcanic ash, water, a de-foamer, a pH buffer, and a polymer. The method comprises the steps of entering the lost circulation zone, determining a lost circulation volumetric flow rate, metering a first amount of a binder into the drilling mud to create a binder containing mud, pumping the binder containing drilling mud into the wellbore, and suspending metering of the first amount of the binder to the drilling mud after a pre-defined regulating period of time effective to permit the binder containing drilling mud to create a gel-based LCM operable to alter the lost circulation zone.