Hydrated Flocculated Polymer Composition for Lost-Circulation Sealing
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Solution Overview
Problem
Drilling fluids are often lost to the surrounding formation through natural fractures, cracks, or fractures created during treatments, leading to reduced fluid returns and potential formation fluid influx, which can impact well operations.
Innovation Solution
The use of a hydrated flocculated polymer, produced from a hydratable polymer in an invert emulsion, which is sheared to form globules that accumulate at pore throats to seal fluid loss and anchor solid particulates, forming a filter cake to reduce fluid loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional lost-circulation materials (fibrous, flaky, or granular) are used to control fluid loss, then fluid loss can be controlled to some extent, but the materials require complex formulation and do not provide effective sealing at pore throats
Solution Approach 1:
The patent changes the physical and chemical parameters of the loss control agent by using a polymer with specific molecular weight (10^6 to 10^9 g/mol) and incorporating it into an invert emulsion system. This parameter optimization enables the polymer to effectively seal pore throats while simplifying the overall fluid formulation compared to conventional multi-component mixes of fibrous, flaky, or granular materials.
Solution Approach 2:
The invention creates a composite system by combining polymer with specific molecular weight characteristics into an invert emulsion formulation. This composite approach integrates the sealing capability of the polymer with the delivery mechanism of the emulsion system, providing effective pore throat sealing while reducing the complexity of fluid formulation compared to using separate fibrous, flaky, or granular materials.
2Reliability
If cross-polymerization is used to enhance polymer effectiveness, then fluid loss control improves, but the process becomes more complex and less controllable
Solution Approach 1:
The patent extracts the cross-polymerization step from the field application process and relocates it to the laboratory formulation stage. By pre-forming the polymer with controlled molecular weight (10^6 to 10^9 g/mol) through cross-polymerization before incorporating it into the invert emulsion, the complex process is removed from downhole operations, making the system simpler and more controllable while maintaining effective fluid loss control.
3Reliability
If hydratable polymer is used instead of conventional loss control materials, then effective sealing at pore throats is achieved, but the polymer must be properly hydrated and flocculated
Solution Approach 1:
The patent applies preliminary action by pre-hydrating and pre-flocculating the polymer in the invert emulsion formulation before the fluid reaches the formation. The polymer is prepared with controlled molecular weight and flocculation structure in the laboratory, so that when introduced downhole, it requires minimal additional preparation and can immediately begin sealing pore throats effectively.
Solution Approach 2:
The invert emulsion acts as an intermediary carrier that facilitates the proper hydration and flocculation of the polymer in-situ. The emulsion system provides a controlled environment that enables the polymer to achieve its sealing function without requiring complex direct preparation, thus simplifying the overall process while maintaining effective pore throat sealing.
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 hydrated flocculated polymer effectively reduces fluid loss by sealing pore throats, enhancing fluid-loss control and avoiding the need for cross-polymerization, thus improving well operation efficiency.
Implementation Method 1
a hydrated flocculated polymer produced from a hydratable polymer
Implementation Method 2
a hydrated flocculated polymer produced from a hydratable polymer
Implementation Method 3
which is sheared to form globules
Data Source
AI summary
An invert emulsion is used to form a hydrated flocculated polymer useful in reducing fluid loss in downhole operations. The invert emulsion can be sheared to form the hydrated flocculated polymer, which can be introduced downhole into the fluid loss flow path in a subterranean formation and allowed to accumulate at the pore throat to reduce fluid loss.