Embodiments of the subject matter disclosed herein generally relate to a drilling mud used to aid the drilling of boreholes into the earth, and more particularly, to a magnetic drilling mud having a composition that is stable, economically viable, and suitable for wellbore monitoring.
During drilling a wellbore for oil and gas exploration, a drilling mud is used for multiple purposes. For example, as the drill bit 102 of a drilling system 100 illustrated in
The drilling mud is also used to control the formation pressure around the well. Note that one or more formations 120 may exist around the well that hold oil 122, and a pore water pressure above the formation may be larger than the wellbore pressure, so that the oil may have a pressure larger than the pressure inside the well. Thus, the drilling mud may be pressurized by the pump 112 to be substantially equal to the oil pressure or lower, so that a flow of the pore fluid into the well can be controlled. Also, by controlling the drilling mud pressure, it is possible to maintain the integrity of the well as the increased formation pressure may damage the walls of the well if that formation pressure is not balanced by the drilling mud pressure.
The drilling mud may also be used to seal permeable formations or channels existing in the formation 120 during drilling. The drilling mud may also be used to reduce a friction between the drill pipe 114 or casing and the wellbore 104, cools and cleans the drill bit 102, coats the formation 120 with a thin, low-permeability filter cake, maintains wellbore stability, and minimizes formation damage.
In some applications, it is desired to be able to trace the movement of the drilling mud through the formation 120. For these applications, the presence of a tracer material in the drilling mud allows the operator of the well to measure the fluid movement around the borehole, which is critical for the identification of several important events, such as, e.g., lost circulation, mudcake formation, and cement displacement. The tracer material is typically added to the composition of the drilling mud.
Note that a drilling mud may have various compositions, e.g., can be water based, oil based, synthetic based, may include various chemicals such as polymers, foaming agents, clays, depending on the intended purpose of the drilling mud.
Radioactive tracers have been used for decades to determine the flow rate and flow profiles, to evaluate completion problems and treatment effectiveness etc. Recently, magnetic particles have been used as a high-magnetic susceptibility tracer, as discussed in [1] or as a contrast agent in NMR, as discussed in [2] and [3] for formation characterization.
One such tracer is a magnetic bentonite material. Magnetic bentonite can be prepared with either chemical synthetic methods or by adding iron oxide particles directly into the bentonite slurry. However, the existing methods generate a drilling mud that is not stable, i.e., the materials in the mud precipitate, or the drilling mud is expensive.
Thus, there is a need for a new drilling mud and associated manufacturing method that overcomes the above noted problems.
According to an embodiment, there is a magnetic drilling mud for use in a well and the magnetic drilling mud includes water, bentonite, magnetic micro-particles, and an anionic surfactant that prevents separation of the bentonite and the magnetic micro-particles in the water. The magnetic micro-particles have a diameter less than 100 μm.
According to another embodiment, there is a method for making a magnetic drilling mud for use in a well, and the method includes adding bentonite to water to obtain a mixture, aging the mixture by exposing the mixture to a temperature larger than a room temperature, adding magnetic micro-particles to the mixture, and adding an anionic surfactant that prevents separation of the bentonite and the magnetic micro-particles in the water. The magnetic micro-particles have a diameter less than 100 μm, and the anionic surfactant has a molecular concentration smaller than or equal to a critical micelle concentration of the anionic surfactant.
According to yet another embodiment, there is a method for imagining a wellbore, and the method includes pumping down a magnetic drilling mud into a well, applying a pressure to the magnetic drilling mud to enter into fractures into a formation, moving a magnetic probe inside the well, to record a magnetic field generated by the magnetic drilling mud, and generating an image of the well based on recorded data indicative of the magnetic field generated by the magnetic drilling mud. The magnetic drilling mud includes water, bentonite, magnetic micro-particles, and an anionic surfactant that prevents separation of the bentonite and the magnetic micro-particles in the water, and the magnetic micro-particles have a diameter less than 100 μm.
For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
The following description of the embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following embodiments are discussed, for simplicity, with regard to a stable magnetic drilling mud that includes sodium dodecyl sulfate (SDS) as a stabilizing surfactant. However, the embodiments to be discussed next are not limited to such a surfactant, but may use other anionic surfactants.
Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
According to an embodiment, an economical and stable magnetic drilling mud for wellbore monitoring purpose is introduced. The novel magnetic drilling mud includes inexpensive micro-size Fe3O4 particles having a diameter of about d=100 μm, that are used to magnetize a bentonite slurry. In one application, the diameter of the micro-particles is about 50 μm. A selected anionic surfactant (e.g., SDS) is added to stabilize the Fe3O4-bentonite suspension. The type of surfactant and its concentration are discussed later. The suspension's stability, rheological properties, and magnetic hysteresis, which are discussed later in more detail, indicate that this novel drilling mud is stable, economic, and magnetic.
A method for forming the novel magnetic drilling mud is now discussed with regard to
Fe3O4 micro-particles (not nano- or milli-particles) that are magnetic are added in step 204 and one or more surfactants are added in step 206 into the aged bentonite slurry and all these elements are mixed in step 208 for about 30 minutes in a stand mixer. Step 204 may be performed with other magnetic micro-particles, for example, NbO, NbO2, NiO, Ni2O3, and Mn2O3. The amount of the micro-particles added in step 204 is between 0.1 and 10% of the total mass of the bentonite slurry. The surfactant added in step 206 is SDS. The Fe3O4 micro-particles used in this embodiment have an average diameter around 50 μm and the bentonite used in step 200 is in powder form.
In addition to the SDS surfactant used in step 206, two more surfactants were studied: cetyltrimethyl ammonium bromide (CTAB), and Tween-20 (which is a polyoxyethylene sorbitol ester that belongs to the polysorbate family; it is a nonionic detergent having a molecular weight of 1,225 daltons, assuming 20 ethylene oxide units, 1 sorbitol, and 1 lauric acid as the primary fatty acid).
An X-ray diffraction (XRD) analysis was performed in order to determine the chemical composition of the bentonite powder. Samples of the bentonite powder were passed through 200 mesh size sieves. The bentonite basically consists of sodium montmorillonite (Na,Ca)0.33(Al, Mg)2(Si4O10)(OH)2nH2O) and it was found that the 28 peaks are at 7.511, 28.121, 35.101, 48.021, 52.311 and 76.201. A spectrometer was used to determine the cations available in the bentonite and
Long-term stability of the drilling mud is one of the requirements for a successful mud. Thus, this characteristic of the various magnetic drilling muds manufactured as noted above has been investigated. The Fe3O4 micro-particle is inherently instable in a bentonite slurry due to the high density of the iron oxide (ρ=5.17 g/cm3). In addition, the existing magnetic muds use a high-cost sub-micron magnetic particles to achieve the stability. In this regard,
where ρs and ρr are the density of the solid particle and the fluid respectively, d is the diameter of the particles, and μ is the viscosity of the fluid.
It is noted that the micro-size particles (i.e., particles having a size in the micrometer range) have a much higher terminal velocity compared to the sub-micro-size particles (i.e., nano-particles having a size less than 1 micrometer) even at a high viscosity. In this regard,
Based on these observations, the stability of various suspensions stabilized with the three types of surfactants having a molar concentration of 8 mM, and including 5% by mass Fe3O4 particles, and 2% by mass bentonite, have been studied as illustrated in
The influence of the concentration of the SDS on the suspension's stability has also been investigated. In this regard,
This concentration range is close to the critical micelle concentration (CMC) of the SDS surfactant (8.2 mM at 25° C.). Note that in colloidal and surface chemistry, the critical micelle concentration (CMC) is defined as the concentration of surfactants above which micelles form and all additional surfactants added to the system go to micelles. Thus, in one embodiment, the molar concentration of the anionic surfactant of the magnetic drilling mud is selected to be the same as the critical micelle concentration of that surfactant. In another embodiment, the molar concentration of the anionic surfactant of the magnetic drilling mud is selected to be in a range smaller than the critical micelle concentration. In still another embodiment, the molar concentration of the anionic surfactant of the magnetic drilling mud is selected to be between half the CMC and one CMC. Note that a high bentonite mass concentration can improve the stability of the suspension due to its large viscosity.
Rheology is another property of a drilling fluid. The rheology is the science of deformation and flow within a material. The viscosity of the bentonite suspension is sensitive to the presence of additives and contaminants. The influence of the Fe3O4 micro-particles and the SDS surfactant on the rheological behaviors of the bentonite slurries under different temperatures has been investigated.
The addition of the Fe3O4 particles and the SDS surfactant has a similar influence on the viscosity of the 2% and 3% bentonite slurries. With the addition of 1% Fe3O4 particles, a significant decrease in the viscosity of the suspension (line 802) is observed when compared to the raw bentonite (line 800). However, with the coexistence of the SDS surfactant and the Fe3O4 micro-particles, the viscosity of the suspensions (lines 804 and 806) increases with the increased concentration of Fe3O4 micro-particles. The sample with the 5% Fe3O4 and 8 mM SDS (line 806) almost doubles the viscosity of the bentonite slurry. The inventors have found this unexpected result of increased viscosity for the novel drilling mud in spite of the increased amount of magnetic particles, which is believed to be due to a synergistic effect between the bentonite-Fe3O4-SDS components of this novel drilling mud.
The rheological characteristics of the drilling mud are also affected by the temperature. For example, the temperature alters the rheological characteristics of a clay paste through a combination of competing effects: increased platelet Brownian motion and hindered bond formation, increased Debye-Huckel length and inter-particle repulsions, faster aggregation towards minimum potential energy configuration, and decreased fluid viscosity [4]. For example, the viscosity of water decreases from 1 cP to 0.3 cP when the temperature increases from 20° C. to 90° C. The viscosity of a drilling mud having a composition of 3% bentonite, 5% Fe3O4 particles, and 8 mM SDS decreases monotonically with an increase in the temperature as illustrated in
The novel magnetic drilling mud has been found to exhibit typical ferromagnetic behavior. In this regard,
The surface charge properties of the drilling mud have also been investigated. When an iron oxide surface comes in contact with water, a hydroxylated surface could form. The surface electrical charge of the iron oxide surface is dependent on the protonation/deprotonation of the hydroxyl groups when the pH of the solution changes. The point of zero charge (PZC) of the Fe3O4 micro-particles is around pH 7.9. These properties of the Fe3O4 micro-particles affect the interaction between the various components of the drilling mud in various ways.
For the bentonite-Tween20-Fe3O4 system, as a nonionic surfactant, the Tween20 is not able to interact with either the bentonite platelet or the Fe3O4 micro-particles, which results in the poor suspension stability of this composition.
For the bentonite-CTAB-Fe3O4 system, the hydrophilic head of the cationic surfactant CTAB can bind onto the negatively charged bentonite platelets and the Fe3O4 micro-particles via electrostatic interactions. The hydroxyl groups on the Fe3O4 micro-particles' surface can also form hydrogen bonds with the CTAB molecules, which likely enhanced the interaction between the Fe3O4 and CTAB. This seems likely to be the tail-tail interaction between the CTAB coated bentonite platelets and the Fe3O4 micro-particles, which contributes to the stabilization of this suspension. Also, the CTAB surfactant may serve as bridges between the bentonite and the Fe3O4 micro-particles
For the bentonite-SDS-Fe3O4 system, there are several possible interaction mechanisms between the negatively charged bentonite platelets and the anionic surfactant SDS. The ion exchange can take place between OH− ions on the bentonite surfaces and the anionic part of the surfactant CH3(CH2)11OSO3−. Hydrogen bonds can form between the bentonite platelets and the surfactant molecules. In addition, it is possible that the Ca2+ cation establishes electrostatic bridges between the anionic part of the surfactant and the surface of the bentonite particles.
Therefore, surfactants with hydroxyl, carboxyl, sulfate, sulfonate, phosphate, phosphonate groups are expected to be capable to bond to the hydroxyl groups of the Fe3O4 micro-particle and subsequently modify their surface in an advantageous way for the drilling mud, as discussed above with regard to the SDS based drilling mud.
The novel SDS-based drilling mud is an economical and stable ferromagnetic drilling fluid for wellbore monitoring purpose. The micro-size iron oxide (Fe3O4) particles are used to magnetize the bentonite suspension and the surfactant is used to stabilize the suspension. The anionic surfactant SDS improves the stability of the suspension to the most degree among the tested surfactants (Tween 20, CTAB, and SDS). The surfactant concentration that best maintains the stability of the magnetic drilling mud is between 4˜8 mM, which is close to the CMC of the SDS.
The magnetic drilling fluid 606 exhibits a typical ferromagnetic behavior. The saturation and residual magnetizations depend on the mass concentration of Fe3O4 particles, as illustrated in
For example, as illustrated in
The same system can be used to identify the lost circulation material in the well. The magnetic drilling mud 606 is pumped down the wellbore as a lost circulation material to seal unwanted fractures. Once the magnetic drilling mud reaches a thief zone (a zone where the mud leaks out of the casing), a strong magnetic field may be applied with the magnetic probe 1130 to attract the magnetic particles from the mud at the leaking area and separate them from the suspension. The ferromagnetic particles will accumulate at the entrance of the thief zone to form a solid plug. Once formed, the solid plug will inhibit further fluid flow into the thief zone. Other applications of the novel magnetic drilling mud may be envisioned.
In an embodiment, illustrated in
In one application, the anionic surfactant is sodium dodecyl sulfate (SDS). The SDS has a molar concentration between 4 and 8 mM. The magnetic micro-particles are Fe3O4. The Fe3O4 micro-particles have a diameter of 50 μm. In this application, a concentration of the Fe3O4 micro-particles is less than 10% of a total volume.
The disclosed embodiments provide a magnetic drilling mud that is stable. It should be understood that this description is not intended to limit the invention. On the contrary, the embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.
Although the features and elements of the present embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein.
This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.
This application claims priority to U.S. Provisional Patent Application No. 62/835,749, filed on Apr. 18, 2019, entitled “MAGNETIC WATER BASED DRILLING MUD,” and U.S. Provisional Patent Application No. 62/842,561, filed on May 3, 2019, entitled “MAGNETIC WATER BASED DRILLING MUD,” the disclosures of which are incorporated herein by reference in their entirety.
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/IB2020/051276 | 2/14/2020 | WO | 00 |
Number | Date | Country | |
---|---|---|---|
62842561 | May 2019 | US | |
62835749 | Apr 2019 | US |