Shape Memory Polymer Lost Circulation Material Plugs Fractures
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Solution Overview
Problem
Conventional lost circulation materials are ineffective for plugging large fractures during drilling due to size limitations of particles that can be circulated through drilling equipment, leading to significant economic losses and operational challenges in industries like oil and gas, geothermal, and carbon dioxide storage.
Innovation Solution
A shape memory polymer-based lost circulation material comprising multiple members with temporary and permanent shapes, capable of self-assembly to form a jamming structure upon external triggers like temperature changes, allowing for the plugging of large fractures by transforming from a small temporary shape to a larger permanent shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional lost circulation materials are used to plug fractures, then the materials can be circulated through drilling equipment, but the materials cannot effectively plug large fractures due to size limitations
Solution Approach 1:
The lost circulation material utilizes shape memory polymer members that can dynamically change their shape in response to temperature changes. The members are injected in a relaxed temporary shape that can pass through drilling equipment, then transform to an expanded permanent shape at the fracture site to effectively plug large fractures, thus resolving the contradiction between particle size and plugging effectiveness
Solution Approach 2:
The invention changes the physical state parameter of the lost circulation material by using temperature-responsive shape memory polymers. The material transitions from a compact temporary shape at lower temperatures (suitable for circulation) to an expanded permanent shape at higher temperatures (effective for plugging), allowing the same material to satisfy both size constraints and plugging requirements
2Reliability
If large particles are used to plug large fractures, then plugging effectiveness improves, but the particles cannot be circulated through conventional drilling equipment
Solution Approach 1:
The shape memory polymer members dynamically adjust their size during the drilling operation. They are injected in a compact temporary shape that easily circulates through drilling equipment, then automatically expand to large permanent shapes at the fracture site to provide effective plugging, eliminating the need to choose between circulation ease and plugging effectiveness
Solution Approach 2:
The lost circulation material is prepared in advance in a compressed temporary shape that facilitates easy circulation through drilling equipment. This preliminary compact state allows the material to reach the fracture site without blocking equipment, after which it transforms to its functional expanded state for plugging
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 solution effectively seals large fractures, sustaining high differential pressures and reducing the economic burden of lost circulation issues by enabling the use of small particles that expand to plug larger openings, thus maintaining well integrity and reducing drilling costs.
Implementation Method 1
each member having a temporary shape and a permanent shape. The members may be programmed to form a temporary shape that is small enough to be used with conventional drilling equipment and may further transform to corresponding permanent shapes to plug fractures
Implementation Method 2
the external trigger is a temperature above the glass transition temperature of the plurality of shape memory polymer members
Implementation Method 3
the shape memory polymer-based lost circulation material can utilize self-assembly to form a bridge to plug fractures formed during drilling
Data Source
AI summary
Embodiments relate to a lost circulation material comprising a plurality of shape memory polymer members, each member having a temporary shape and a permanent shape. The members may be programmed to form a temporary shape that is small enough to be used with conventional drilling equipment and may further transform to corresponding permanent shapes to plug fractures. Specifically, the shape memory polymer-based lost circulation material can utilize self-assembly to plug fractures formed during drilling. Embodiments of the lost circulation material can be particularly useful for plugging large fractures. Permanent shapes present different topologies including granular, fibers, and two-dimensional networks/lattices in which can mechanically interlock and form a three-dimensional plug large enough to seal large width fractures.