Multi-modal Lost Circulation Material Particle Distribution
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Solution Overview
Problem
Traditional lost circulation materials are often too large to pass through equipment components or too small to effectively reduce lost circulation during subterranean drilling operations, leading to inefficiencies in plugging loss zones and complicating their preparation, delivery, and disposal.
Innovation Solution
The use of multi-modal lost circulation materials with a particle size distribution ranging from 20 to 50 microns for d10, 55 to 90 microns for d50, and 240 to 340 microns for d90, which includes a combination of graphitic material, ground marble, and ground fibrous cellulosic materials, allowing for improved plugging efficiency and easier retention within drilling fluid systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lost circulation materials are used with larger particle sizes, then plugging effectiveness in loss zones is improved, but the materials cannot pass through equipment components like shaker screens
Solution Approach 1:
The lost circulation material is segmented into multiple particle size ranges (first, second, and third ranges) that can pass through different equipment components. This segmentation allows the material to be effectively processed by standard drilling equipment while maintaining plugging capability through the combined action of multiple particle sizes in the loss zones.
2Ease of operation
If lost circulation materials are made smaller to pass through equipment, then ease of handling is improved, but plugging effectiveness in loss zones is reduced
Solution Approach 1:
The invention merges multiple particle size ranges into a single composite lost circulation material formulation. The first particle size range (2-10 mesh) provides passability through equipment, the second range (14-30 mesh) provides intermediate functionality, and the third range (35-50 mesh) contributes to plugging effectiveness. The combined action of these merged particle sizes resolves the contradiction between handling ease and plugging effectiveness.
3Ease of manufacture
If a single particle size is used for lost circulation material, then material preparation is simplified, but both plugging effectiveness and equipment compatibility cannot be simultaneously optimized
Solution Approach 1:
The lost circulation material is formulated as a composite material containing particles in three different size ranges with specific weight percentages (40-70% first range, 10-40% second range, 10-40% third range). This composite approach allows the material to exhibit multiple functions simultaneously: passability through equipment, effective distribution in drilling fluid, and plugging effectiveness in loss zones, thereby optimizing overall performance while maintaining reasonable preparation simplicity.
Data Source
AI summary
Methods and compositions for treating subterranean formations with fluids containing lost circulation materials are provided. In one embodiment, the methods introducing a treatment fluid that includes a base fluid and a lost circulation material into a wellbore penetrating at least a portion of a subterranean formation, wherein the lost circulation material includes a plurality of particles having a multi-modal particle size distribution comprising a d10 value ranging from about 20 to about 50 microns, a d50 value ranging from about 55 to about 90 microns, and d90 value ranging from about 240 to about 340 microns.