Resilient Graphitic Carbon for Drilling Fluid Loss Circulation
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Solution Overview
Problem
Existing resilient graphitic carbon materials used in the oil and gas industry for loss circulation control (LCM) do not provide sufficient sealing and porosity, leading to inefficiencies in drilling operations due to limitations in resiliency, density, and morphology.
Innovation Solution
A specially-sourced improved resilient graphitic carbon material with a needle-like morphology, higher resiliency, lower density, and greater degree of graphitization is developed, offering enhanced porosity and sealing capabilities through a continuous fluid bed thermal purification process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional resilient graphitic carbon materials are used as LCM, then basic sealing function is provided, but insufficient sealing and porosity lead to drilling inefficiencies
Solution Approach 1:
The patent applies parameter changes by modifying key physical properties of the graphitic carbon material: increasing porosity to 0.43 cc/gram (from 0.24 cc/gram), increasing resiliency to 138-145% (from 100-130%), and adjusting density to 1.49-1.53 gram/cc (from 1.56-1.62 gram/cc). These parameter changes enable the material to form tighter seals while maintaining drilling efficiency.
Solution Approach 2:
The patent utilizes porous materials by significantly increasing the total pore volume to 0.43 cc/gram. This enhanced porosity allows the graphitic carbon material to better adapt to fracture geometries and form more effective seals through the bridging mechanism, directly addressing the insufficient sealing capability of conventional materials.
2Reliability
If graphitic carbon material with higher density is used, then better sealing is achieved, but resiliency and porosity are reduced
Solution Approach 1:
The patent resolves this contradiction through parameter changes by achieving an optimal balance: density is reduced to 1.49-1.53 gram/cc (from 1.56-1.62 gram/cc), while resiliency is increased to 138-145% (from 100-130%). This inverse relationship between density and resiliency is optimized to provide both effective sealing and elastic recovery capability.
Solution Approach 2:
The patent employs composite material principles by creating a graphitic carbon material with enhanced porosity (0.43 cc/gram) and controlled density (1.49-1.53 gram/cc). This composite structure combines the sealing capability of denser materials with the resiliency of more porous materials, achieving superior overall performance.
3Reliability
If conventional graphitic carbon is used, then basic LCM function is provided, but insufficient porosity leads to inadequate fracture sealing
Solution Approach 1:
The patent directly addresses this contradiction by utilizing porous materials with significantly increased total pore volume to 0.43 cc/gram (from 0.24 cc/gram). This enhanced porosity enables the material to better penetrate and seal fracture networks, directly improving fracture sealing capability.
Solution Approach 2:
The patent applies parameter changes by increasing the porosity parameter from 0.24 cc/gram to 0.43 cc/gram, which directly enhances the material's ability to form effective seals in fractures while maintaining appropriate density and resiliency characteristics.
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 improved material forms a tighter seal, with increased porosity and resiliency, effectively addressing the limitations of previous LCMs by providing superior sealing and drilling efficiency.
Implementation Method 1
The resilient graphite is believed capable of packing tightly under compression in the pores and fractures, to expand or contract without being dislodged or collapsed due to changes in the equivalent circulating density or with an increase in fluid weight. In addition, graphite also worked as solid lubricant to reduce wear of metal components and improve drilling efficiency.
Implementation Method 2
One of the methods to prevent loss event from happening or stop the loss is via addition of granular particles into the drilling fluid, which act as bridging agent to establish the foundation for complete sealing of the fracture or as wellbore strengthening materials that pop the fracture open.
Implementation Method 3
graphite also worked as solid lubricant to reduce wear of metal components and improve drilling efficiency
Data Source
AI summary
A method for controlling the loss of drilling fluid from an oil well borehole into formations penetrated by a drill bit is disclosed by which resilient graphitic carbon particles having a resiliency greater than about 130% rebound after compression to 10,000 psi; a degree of graphitization greater than 85%, as measured by d002 using XRD; an average pore size larger than 0.035 micron; and an aspect ratio smaller than 0.63 are added to the drilling fluid.