Resin-Based LCM Compositions for High-Pressure Well Sealing
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Solution Overview
Problem
Conventional lost circulation materials (LCMs) are ineffective in high-pressure formations and high-injectivity zones, leading to fluid loss during drilling and cementing operations, resulting in increased costs and downtime due to the inability to effectively seal lost circulation zones.
Innovation Solution
The development of LCM compositions comprising a resin, an emulsifier, a crosslinker, a cementitious and/or weighting agent, a retarder, a dispersant, and a silicon-based defoamer, which have a controlled thickening time to form a stable barrier that prevents fluid loss by reaching a Bearden consistency of 100 Bc within 3 to 6 hours, allowing injection through a drill bit to seal lost circulation zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional lost circulation materials are used, then the materials can be easily injected, but they are ineffective in high-pressure formations and high-injectivity zones, leading to fluid loss
Solution Approach 1:
The patent uses a composite material system consisting of resin, emulsifier, crosslinker, and cementitious/weighting agents. This composite formulation creates an LCM composition that can effectively seal lost circulation zones in high-pressure formations while maintaining injectability. The combination of these materials provides both the sealing effectiveness and the rheological properties needed for successful injection and placement.
2Productivity
If the LCM composition thickens too quickly, then it forms a seal faster, but it becomes difficult to inject through the drill bit
Solution Approach 1:
The patent controls the thickening behavior by adjusting formulation parameters including the type and amount of resin, emulsifier concentration, crosslinker dosage, and water-to-cement ratio. These parameter changes allow the LCM composition to maintain proper rheology for injection through the drill bit while still achieving adequate thickening and sealing within the required time frame. The retarder component specifically manages the thickening rate to balance injectability with sealing speed.
3Stress or pressure
If the LCM composition is too dense, then it provides better weighting and sealing pressure, but it requires more energy to inject and may not reach the lost circulation zone effectively
Solution Approach 1:
The patent incorporates weighting agents at controlled concentrations (typically 5-20% by weight of cement) to provide localized density enhancement where needed for sealing pressure, while maintaining overall composition density that allows effective injection. This local quality approach ensures sufficient sealing pressure at the lost circulation zone without requiring excessive injection energy throughout the entire fluid column.
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 LCM compositions provide a stable and effective seal in high-pressure formations and high-injectivity zones, reducing fluid loss and maintaining stability, thus reducing operational costs and downtime by forming a durable barrier that prevents fluid penetration into the formation.
Implementation Method 1
LCM compositions may include a resin; an emulsifier selected from the group consisting of ethoxylated phenol, sodium salt of modified tall oil fatty amide, carboxylic acid terminated fatty polyamide, modified amidoamine, tall oil fatty acid, oxidized tall oil fatty amidoamine, ether carboxylic acid, and combinations thereof
Implementation Method 2
The LCM compositions may have a thickening time of from about 3 hours than about 6 hours by reaching a Bearden consistency of 100 Bc
Implementation Method 3
a crosslinker
Implementation Method 4
a cementitious and/or weighting agent
Implementation Method 5
a dispersant
Implementation Method 6
a silicon-based defoamer
Data Source
AI summary
Lost circulation material (LCM) compositions may include a resin; an emulsifier selected from the group consisting of ethoxylated phenol, sodium salt of modified tall oil fatty amide, carboxylic acid terminated fatty polyamide, modified amidoamine, tall oil fatty acid, oxidized tall oil fatty amidoamine, ether carboxylic acid, and combinations thereof; a crosslinker, a cementitious and/or weighting agent; a retarder; a dispersant; and a silicon-based defoamer. The LCM compositions may have a thickening time of from about 3 hours than about 6 hours by reaching a Bearden consistency of 100 Bc. Methods of eliminating or reducing lost circulation in a lost circulation zone from a well may include introducing these LCM compositions into the well.