Polymer-Sand Nanocomposite for Lost Circulation Control
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Solution Overview
Problem
Traditional lost circulation materials (LCMs) are limited in their ability to effectively curb lost circulation events and stabilize wellbores during hydrocarbon extraction, as they lack chemical and thermal stability, leading to significant drilling fluid losses and potential wellbore instability.
Innovation Solution
A polymer-sand nanocomposite is developed by combining a polymer hydrogel with surface-modified sand particles, which forms a stable and dense filter cake when injected into lost circulation zones, reducing fluid losses and enhancing wellbore stability through the use of a hydrogel polymer, organic cross-linker, and salt, along with surface modifications such as graphene incorporation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lost circulation materials are used, then the material can be easily applied, but the material lacks chemical and thermal stability leading to significant drilling fluid losses
Solution Approach 1:
The patent applies composite materials by combining sand particles with polymer hydrogel and graphene oxide to create a nanocomposite structure. This composite approach provides both chemical and thermal stability while maintaining the ability to curb lost circulation events. The sand provides structural framework, the polymer hydrogel provides flexibility and sealing properties, and the graphene oxide enhances thermal stability and mechanical strength.
Solution Approach 2:
The patent utilizes parameter changes by controlling the molecular weight, functional groups, and concentration of the polymer hydrogel to optimize performance. The polymer's molecular structure and cross-linking density are adjusted to achieve the desired balance between stability and fluid loss prevention capability under specific downhole conditions.
2Reliability
If traditional lost circulation materials are used, then the application process is simple, but the wellbore stability is compromised due to inability to prevent fluid diversion into fractures
Solution Approach 1:
The patent applies preliminary action by pre-modifying sand particles with polymer hydrogel and graphene oxide before injection. This pre-preparation ensures that the nanocomposite has the required chemical and thermal stability properties before it encounters the challenging downhole environment, thereby preventing fluid diversion into fractures and stabilizing the wellbore.
Solution Approach 2:
The nanocomposite structure combining sand, polymer hydrogel, and graphene oxide provides enhanced wellbore stability through improved mechanical properties and resistance to chemical degradation. The composite material formulation allows for tailored performance characteristics to address specific wellbore stability challenges.
3Reliability
If polymer hydrogel and surface-modified sand are combined to form nanocomposite, then chemical and thermal stability is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by pre-modifying sand particles with polymer hydrogel and graphene oxide through controlled chemical processes before final assembly. This pre-preparation of components with specific functional properties streamlines the overall manufacturing process while ensuring the nanocomposite achieves the required chemical and thermal stability.
Solution Approach 2:
The manufacturing process utilizes parameter changes by controlling temperature, pressure, and chemical concentration during the nanocomposite formation. These parameter optimizations balance the complexity of preparation with the achievement of stable, high-performance material properties.
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 polymer-sand nanocomposite effectively reduces drilling fluid losses and stabilizes the wellbore by forming a stable barrier in lost circulation zones, providing both chemical and thermal stability, thus preventing fluid diversion into fractures and maintaining integrity during elevated temperatures.
Implementation Method 1
attachment of an organic cross-linker to the surface of sand particles by preparing a cross-linker solution comprising one or more organic cross-linkers, combining the cross-linker solution and the sand particles to generate a cross-linker modified sand precursor, and heating the cross-linker modified sand precursor to a temperature of 120 to 180° C. for at least 2 hours
Implementation Method 2
preparing a polymer hydrogel by combining a hydrogel polymer, additional organic cross-linker, and a salt
Implementation Method 3
Combining the water reducing properties of the polymer hydrogel with sand having surface modifications forms a stable and dense filter cake which reduces drilling fluid losses into the formation
Implementation Method 4
forms a stable and dense filter cake which reduces drilling fluid losses into the formation
Data Source
AI summary
A method of forming a barrier to overcome lost circulation in a subterranean formation. The method includes injecting a polymer-sand nanocomposite into one or more lost circulation zones in the subterranean formation where the polymer-sand nanocomposite is formed from sand mixed with a polymer hydrogel. Further, the polymer hydrogel includes a hydrogel polymer, an organic cross-linker, and a salt. The sand additionally comprises a surface modification. The associated method of preparing a polymer-sand nanocomposite lost circulation material for utilisation in forming the barrier is provided.