Low-Density Petroleum Coke Lost Circulation Materials
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Solution Overview
Problem
Traditional lost circulation materials in wellbore drilling and cementing operations often have high densities, leading to transport difficulties and density alterations, which can result in costly fluid loss and well control issues, due to their high particle densities and requirements for high viscosity fluids and low pump rates.
Innovation Solution
The use of low-density petroleum coke, specifically fluid coke and flexicoke, as lost circulation materials, which have particle densities of less than 1.6 g/cc, allowing for effective suspension and high flow rates, and exhibit high crush strengths, reducing CO2 emissions by utilizing a carbon source that would otherwise contribute to emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional high-density lost circulation materials are used, then fluid loss control is achieved, but transport difficulties and density alterations occur
Solution Approach 1:
The patent changes the density parameter of lost circulation materials from traditional high-density materials (greater than 2.0 g/cc) to low-density petroleum coke materials (less than 1.6 g/cc). This parameter change enables the materials to be effectively suspended in drilling fluids at high pump rates without causing transport difficulties or density alterations, while still providing effective fluid loss control in lost circulation zones.
2Stability of the object's composition
If high viscosity fluids and low pump rates are used with traditional materials, then material suspension is maintained, but productivity decreases
Solution Approach 1:
The patent changes the density parameter of lost circulation materials to be lower (less than 1.6 g/cc) than traditional materials. This enables the materials to remain suspended in drilling fluids even at high pump rates, eliminating the need to reduce productivity through low pump rates while maintaining material suspension and distribution.
3Reliability
If high-density lost circulation materials are used, then fluid loss is controlled, but costly fluid loss and well control issues occur
Solution Approach 1:
The patent changes the density parameter of lost circulation materials from high-density (greater than 2.0 g/cc) to low-density (less than 1.6 g/cc) petroleum coke. This change improves compatibility with drilling fluids, reducing unwanted fluid loss and well control issues while maintaining effective plugging of lost circulation zones.
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 low-density petroleum coke lost circulation materials improve fluid transport and suspension, reduce viscosifier loads, and enhance pumping flexibility, while maintaining mechanical strength, thereby addressing the limitations of traditional materials and reducing environmental impact.
Implementation Method 1
The use of low-density petroleum coke, specifically fluid coke and flexicoke, as lost circulation materials, which have particle densities of less than 1.6 g/cc, allowing for effective suspension and high flow rates
Implementation Method 2
exhibit high crush strengths, reducing CO2 emissions by utilizing a carbon source that would otherwise contribute to emissions
Data Source
AI summary
Lost circulation particles are commonly used in drilling and/or cementing operations to prevent fluid loss to a subterranean formation. Drilling fluids and methods of drilling and/or cementing operations may also use petroleum coke lost circulation particles composed of fluid coke and/or flexicoke material. Such petroleum coke lost circulation particles may have improved transport into wellbores because of their lower density compared to traditional lost circulation material and may produce fewer fines that can interfere with lost circulation efficacy.