Shape Memory Polymer Lost Circulation Additive

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Solution Overview

Problem

Conventional lost circulation materials (LCMs) are ineffective in severe loss zones due to their inability to adhere and expand within fractures, leading to continued fluid loss during wellbore drilling in permeable geological formations.

Innovation Solution

Introducing shape memory polymers or alloys into the wellbore that can lodge within fractures and expand to form a barrier, effectively sealing the fractures and reducing fluid loss by changing temperature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional LCMs are introduced into severe loss zones, then they are easy to access and inexpensive, but they cannot effectively block fractures due to inability to adhere and expand

Engineering Contradiction:

Improveavailability and cost of LCMsVSAvoideffectiveness in blocking fractures

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The LCMs utilize shape memory materials that change their physical parameters (shape, volume) in response to temperature changes. When exposed to downhole temperatures, the materials transition from a deformed state to a recovered state, expanding to block fractures effectively while maintaining cost-effectiveness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention employs composite LCMs incorporating shape memory polymers, shape memory alloys, or elastomeric alloys with adhered particles. These composite structures combine the benefits of conventional materials with shape memory properties, enabling both ease of deployment and reliable fracture blocking through temperature-triggered expansion and adhesion

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If small LCMs are used to combat severe losses, then they can be easily introduced into the wellbore, but they are dislodged from fractures and allow further fluid loss

Engineering Contradiction:

Improveease of introduction into wellboreVSAvoidability to remain lodged in fractures

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The LCMs are introduced in a deformed, compressed state that allows easy transport through the wellbore. Upon exposure to downhole temperatures, they undergo parameter changes (shape recovery, expansion) that enable them to lodge securely in fractures and resist dislodgment

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces purely mechanical interlocking mechanisms with thermally-activated shape memory mechanisms. The temperature-driven phase transition and shape recovery provide a more reliable lodging mechanism that adapts to the downhole environment, preventing dislodgment that occurs with conventional mechanical-only LCMs

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If conventional LCMs are used without adhesion properties, then they are simple in design, but they cannot form effective barriers in severe loss zones

Engineering Contradiction:

Improvesimplicity of LCM designVSAvoidability to form barrier in fractures

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The invention creates composite LCMs where shape memory materials are adhered to a core structure or to each other. This composite approach maintains relative design simplicity while adding the critical adhesion and expansion properties needed to form effective barriers in severe loss zones

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The LCMs are designed with differentiated properties: a core structure providing structural integrity and adhesion, and an outer shape memory layer providing temperature-responsive expansion. This local quality differentiation enables effective barrier formation while maintaining overall design efficiency

Inventive Principle:

Principle #3Local quality

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 use of shape memory materials allows for the formation of a robust seal within fractures, significantly reducing or eliminating fluid loss in severe loss zones, thereby enhancing drilling efficiency and reducing operational challenges.

Implementation Method 1

The fluid loss control additive comprises a shape memory polymer, a shape memory alloy, or both. The fluid loss control additive is capable of being wedged into the fractures in a compressed form and expanding within the fractures

Methodology Applied

Scientific EffectShape memory: Shape Memory Polymer

Implementation Method 2

allowing the fluid loss control additive to expand within the fractures, thereby forming a barrier between the wellbore and the subsurface formation

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS11414971B2Methods and materials for reducing lost circulation in a wellbore

Publication Date: 2022.08.16 SAUDI ARABIAN OIL CO

AI summary

A method of reducing lost circulation in a wellbore includes introducing a fluid including a fluid loss control additive comprising shape memory polymer, shape memory alloy, or both into the wellbore. The method further includes allowing the fluid loss control additive to lodge within fractures within a subsurface formation in the wellbore. The method further includes allowing the fluid loss control additive to expand within the fractures, thereby forming a barrier between the wellbore and the subsurface formation to reduce lost circulation in the wellbore.