Patent Application
20150315886
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Recovery of hydrocarbons often requires performing multi-stage fracture stimulation treatments. Such treatments use repeating steps of zonal treatment and isolation of the treated zone. Major types of such treatments include fracturing operations, high-rate matrix treatments and acid fracturing, matrix acidizing and injection of chelating agents. Another important application of zonal isolation is well drilling in a permeable or fissured formation, which frequently results in losing a significant part of the drilling fluid into the formation. While such losses in permeable formations can be greatly minimized by using various fluid loss agents, preventing fluid loss in fractured formations is still a major problem.
This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. A method is given for reducing the flow of a treatment fluid in a well including a wellbore penetrating a subterranean formation. The method involves preparing a slurry including a high solids content fluid made using a carrier fluid and solids having a multi-model size distribution, injecting the high solids content fluid into the well, placing the high solids content fluid at the location at which fluid flow is to be decreased, and either reducing the volume of the carrier fluid or increasing the viscosity of the carrier fluid.
Embodiments are described with reference to the following figures. The same numbers are used throughout the figures to reference like features and components.
It should be noted that in the development of any actual embodiments, numerous implementation-specific decisions may be made to achieve the developer's specific goals, for example compliance with system- and business-related constraints, which can vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
The description and examples are presented solely for the purpose of illustrating embodiments and should not be construed as a limitation to the scope and applicability. Although some of the following discussion emphasizes fracturing, the fluids and methods may be used in many other well treatments. Embodiments are applicable to wells of any orientation. Embodiments may be described for hydrocarbon production wells, but it is to be understood that embodiments may be used for wells for production of other fluids, for example water or carbon dioxide, or, for example, for injection or storage wells. It should also be understood that throughout this specification, when a concentration or amount range is described as being useful, or suitable, or the like, it is intended that any and every concentration or amount within the range, including the end points, is to be considered as having been stated. Furthermore, each numerical value should be read once as modified by the term “about” (unless already expressly so modified) and then read again as not to be so modified unless otherwise stated in context. For example, “a range of from 1 to 10” is to be read as indicating each and every possible number along the continuum between about 1 and about 10. In other words, when a certain range is expressed, even if only a few specific data points are explicitly identified or referred to within the range, or even when no data points are referred to within the range, it is to be understood that the inventors appreciate and understand that any and all data points within the range are to be considered to have been specified, and that the inventors have possession of the entire range and all points within the range.
This application discloses a method of using a slurry containing a multi-modal mixture of solid particles for isolating or plugging wellbore intervals, fractures, or formation zones during multi-stage fracturing and other treatments (including matrix acidizing and acid fracturing (fracture acidizing) of carbonates, water control, treatment of carbonates with chelating agents, squeezing scale control or other control agents, and any other operations that require setting a plug in a wellbore or in a formation, including during drilling and workover operations). The method can be used to plug or block fluid flow in any flow path, for example wellbores, vugs, natural and manmade fractures, channels, and wormholes. Such a pumpable (“flowable”), mobile, slurry in a carrier fluid is called here a High Solids Content Fluid (HSCF). The method involves pumping the HSCF downhole where either a) the volume of the continuous liquid phase of the slurry is reduced (“dehydration”) so that the solid volume fraction exceeds the packed volume fraction, or b) the viscosity of the continuous liquid phase of the slurry is increased to the point at which the slurry does not flow under the applied fluid pressure; either action can cause the formation of a mechanically stable plug. The plug may be chemically removable or permanent. In each portion of the following discussion, technique a) (volume reduction or “dehydration”), will be emphasized first, followed by technique b) (viscosity increase), although many statements in all discussions apply to both. Whenever we refer to formation of a plug, such formation is understood to be inferred from a reduction in well and/or treatment fluid flow.
A reduction in the volume of the continuous liquid phase may be induced by using many mechanisms, including fluid absorption by absorbing agents, reaction of fluid with some of the solid components of the slurry, fluid leak-off (for example into a manmade or natural fracture or vug), precipitation of part of the continuous phase, and breakdown of a multi-phase fluid. The particle size distribution in multi-modal mixtures of solid particles may be engineered to control the porosity and permeability of the plug created using models based on the ratios of different particle sizes and the distribution. The mixture of solid particles may also include at least one degradable and/or dissolvable and/or removable component, the disappearance of which will increase the plug permeability.
By a multimodal mixture of solid particles we mean mixtures of grains comprising particles of at least two distinct average sizes. Often the particle sizes are discrete and do not overlap as illustrated in
The advantages of using multi-modal mixtures of solids for plug creation by slurry dehydration or slurry fluid viscosity increase include the following
Embodiments include a method of zonal isolation or plugging by dehydrating or increasing the viscosity of the fluid phase of a slurry which comprises a multi-modal mixture of solid particles (HSCF). The method includes:
The slurry is prepared by mixing the multi-modal mixture of solid particles and a carrier fluid. Mixing may be performed on-the-fly during pumping or by preparing the slurry in a batch mixer prior to pumping. For on-the-fly mixing, flow-through blenders may be used. Batch mixing may be performed, for example, using mixers designed for mixing cements or drilling fluids. The sections below provide detailed descriptions of some suitable components of the slurry
The multi-modal mixture of solid particles for preparation of HSCF's contains particles having at least two, and preferably at least three, modes of particle size distribution as shown in
In embodiments, the multi-modal mixture of solid particles may include particles of various types. It may be sand, ceramic and/or glass beads, synthetic proppant, plastics and polymers, carbonates, salts, wax, paraffin, nut shells, and many other materials, including all solids that have been or will be pumped down a well. Some components of the mixture may also be removable, that is degradable, soluble/dissolvable or meltable at downhole conditions so that at some time they disappear from the plug that was initially formed. Non-limiting examples of the removable materials include:
Fluids that may be used for preparing slurries include, but are not limited to, water; brine; gelled water; slick-water; aqueous solutions of at least one polysaccharide, for example guar and its derivatives, alginate and its derivatives, and cellulose and its derivatives; aqueous solution of polyvinyl alcohol; solutions of crosslinked polymers, for example guar and its derivatives, diutans, alginate and its derivatives, cellulose and its derivatives; emulsions; foams; and others. In other embodiments non-aqueous fluids may be used, for example oils; diesel; gelled oils; organic solvents; tributoxy ethanols; alcohols, and others. In yet other embodiments, VES fluids may be used; VES fluid viscosity may be increased by changing the ionic strength, or by changing the pH. The fluids may also include various additives, especially soluble additives to give the fluids special properties. Non-limiting examples include clay stabilizing agents, thermal stability agents, iron control agents, and others. Fluids may also contain at least one type of solid particles having a shape different from the shape of the particles in the multi-modal mixture. Non-limiting examples include fibers (including nanofibers, for example nanocellulose fibers), rods, plate-like particles, and others. These additional solid particles may also be removable and may be made of the same types of materials as the removable portions of the multi-Once prepared, embodiment slurries be pumped downhole using the same pumping equipment as used for fracturing, matrix acidizing, cementing and well drilling. Downhole, the slurry may be injected into the formation or allowed to stay in the wellbore before dehydrating or viscosifying.
Numerous mechanisms may be used to dehydrate a multi-modal particle-containing HSCF slurry; embodiments include:
Absorbing Liquid by Particles
At least one kind of particle in the multi-modal mixture or in the fluid may have fluid absorbing properties. The volume of such particles may increase with fluid absorbtion (that is, the particles are swellable) or may remain unchanged. A fluid containing either type of particles downhole undergoes a reduction in the amount of liquid phase in the slurry, which reduces the fluidity of the mixture and causes plug creation. A beneficial side effect of the swelling is that with the increased size of some of the particles in the slurry there is an additional factor reducing the mobility of the slurry.
Examples of suitable water-swellable materials include but are not limited to crosslinked polysaccharides, for example crosslinked guar and its derivatives, crosslinked alginate and its derivatives, crosslinked or non-crosslinked cellulose and its derivatives; crosslinked polyols, for example polyvinyl alcohols; crosslinked polyacrylamides; water swellable clays, for example bentonite; suitable cement particles; and others. The following may, for example, be used as crosslinking agents: salts of metals, for example Ca, Mg, Ti, Zr, Fe, Al, Ni, Cr, and Cu; boric acid and its derivatives; di- and polyaldehydes, for example glutaric aldehyde, and others. Certain polymers may also be crosslinked by exposure to radiation. Water swellable elastomer compositions may also be used for slurry dehydration. Typical methods of making such compositions include incorporation of water-swellable polymer material in an elastomeric matrix, with optional vulcanization at the end of the process; examples are given in U.S. Pat. No. 6,358,580; U.S. Pat. No. 4,590,227; and WO 2009/021849. Non-limiting examples of particles that may absorb fluid without a significant volume change include zeolites, glass membranes, salts which are able to form crystalline hydrates, highly crosslinked polymers, and others. An embodiment utilizing dehydrating a slurry containing a tri-modal mixture of solid particles in which one size is swellable is illustrated in Example 1 below.
Causing precipitation of a portion of the continuous phase may be achieved by reaction of at least one soluble component in the continuous phase with another component that is initially part of the solid particles of the slurry. Some non-limiting examples of chemical reactions that result in creating insoluble precipitates include: reactions of low-molecular weight chemicals, for example salts, forming insoluble salts, or insoluble complexes of polymeric components; for example:
Additional embodiments of systems whose dehydration is brought about by precipitation of part of the continuous phase are described in Examples 3 and 4 below.
In some embodiments, it may be desirable to delay the formation of insoluble precipitates; in such cases, some components of the slurry that may give insoluble precipitates in reaction with soluble components may be in encapsulated form or in a form that enables gradual release of the components into the continuous phase. For example, grains of such components may be coated with substantially insoluble or slightly soluble coatings. These components may then enter the continuous phase by shear destruction of capsules, by diffusion through the coating, or by at least partial dissolution of the coating. Alternatively, such coatings may be destroyed by chemical agents. These mechanisms allow control of the time of formation of the insoluble precipitates, and therefore enable control over the placement the plug. Example 5 below shows an embodiment using a coated component for controlling the formation of insoluble precipitates.
Using Water-Reactive Chemicals
In other embodiments, water based slurries are effectively dehydrated by addition of water-reactive agents. Examples of such agents include, but are not limited to, oxides, for example MgO, CaO, and others; cements; and active metals, for example Al and Mg. In one embodiment, MgO reacts with water, giving practically insoluble magnesium hydroxide Mg(OH)2. It should be noted that the volume of the reactive particles in this reaction increases by a factor of about four, which may be an additional factor in reducing the fluidity of the slurry.
Fluid Leak-Off
Fluid leak of into the formation is another mechanism of slurry dehydration. In this case the slurry is injected into the fracture, and the fluid leaks off either into the formation or into the fracture. The remaining solids form a plug; the permeability depends upon the composition of the original multi-modal mixture.
Destabilizing a Multiphase Carrier Fluid
Destabilization of multi-phase carrier fluids may result in a significant reduction in the fluidity of the system. Emulsions are examples of such multiphase systems that may be destabilized, for example by addition of surfactants, addition of solvents, changing the salinity and increasing the temperature. Destabilizing a water-bitumen emulsion, such as those used in road construction, by adding ethoxybutanol results in precipitation of bitumen and a significant reduction of the fluidity of the mixture. The same happens with commercially available PLA emulsion as illustrated below in Example 6.
The prepared slurry can be pumped downhole using the same pumping equipment as used for fracturing, matrix acidizing, cementing and well drilling. Downhole, the slurry may be injected into the formation or left in the wellbore before creation of the plug. Any systems used to delay viscosification of fluids being pumped downhole (for example to reduce hydraulic horsepower requirements) may be used. The carrier fluid of the slurry is mixed with a chemical agent that will result in increasing the viscosity of the fluid downhole. Some non-limiting examples of such agents are salts of borate or transitions metals, for example Ti, and Zr, for polysaccharide-based carrier fluids or solutions of polyols; and salts of transition metals, for example Zr, and Cr for polyamide based carrier fluids. Increasing the viscosity of the carrier fluids can be delayed using chemical delaying agents (for example sugars and their derivatives for the reactions of polysaccharides with borate salts). Alternatively, the mixture may be activated by shear in perforations if the agent responsible for increasing the fluid viscosity is coated and the coating is destroyed by shear. In yet other embodiments, VES (viscoelastic surfactant) fluids may be used; VES fluid viscosities may be increased by changing the ionic strength, or by changing the pH. For example, many VES fluid systems have low viscosity in acid but much higher viscosity as the pH is increased; reaction of such a carrier fluid with a source of base, for example with a carbonate formation, can set a plug. Some examples of systems suitable for plug generation by viscosity are shown in examples 7 and 8.
If zonal isolation is intended to be temporary, the conductivity of the plug may be increased after the plug is no longer needed. For this several mechanisms may be used; examples include:
Degradation.
Some components of the original multimodal mixture may be made of degradable materials. Examples of such materials are described above in the discussion of the preparation of the slurry. Bottomhole temperature increases speed-up degradation processes and eventually degradable materials disappear. When the degradable particles are smaller than non-degradable particles, the degradation may result in an increase in permeability of the plug without complete removal of the plug; this is valuable if the plug is propping up a manmade fracture that the operator wants held open. If the plug is in a natural fracture, vug, or wormhole, then it may not be necessary to prop it open and any or all of the particles introduced may be degradable. If the plug is in the wellbore or a perforation, it may be important to ensure that the plug is completely removable by using degradable particles that are larger than any non-degradable particles or by using all degradable particles.
Dissolution and/or Chemical Destruction.
This mechanism is similar to the degradation mechanism except that a special dissolution agent may be injected into the plug to cause at least partial dissolution. Examples of materials that can be used are also described above in the discussion of the preparation of the slurry. Chemical destruction is also a useful mechanism for removing residues of the used carrier fluid. For example, when fluid crosslinking is used as a dehydration mechanism, the crosslinked fluid may be destroyed by decrosslinking agents or by destructors of polymer chains. It is well known that crosslinked guar can be effectively destroyed by oxidizers, for example NH4S2O8, NaBO3, and others. Alginate crosslinked with calcium can be destroyed by acid, for example citric acid, or by the same oxidizing agents. Note that acid may be produced inside the plug if polyesters (for example PLA) are used as part of the original multimodal mixture. Many polymers can be destroyed by enzymes. One embodiment is decrosslinking of alginate complexed with Ca2+ by lactic acid formed by hydrolyzing PLA.
Melting.
If some components of the original multi-modal mixture are meltable, then temperature recovery will cause their removal from the plug. Examples of materials that potentially can be used in that way are described above in the discussion of the preparation of the slurry
Any elements of the disclosed embodiments may be replaced by any one of numerous equivalent alternatives, only some of which are disclosed in the specification.
Alginate/Ca2+ complex particles were prepared by incubating 2000 ml of a 2% alginate solution in an oven at a temperature between 50° C. and 80° C. with 133 ml of a 1% solution of CaCl2 for 24 hours. The complex formed was then washed with deionized water and put back into the oven at 50 to 80° C. for further drying. The solid mass obtained was then milled and the particles having sizes between 0.43 mm and 0.84 mm were selected. 10 g of the swellable 0.43 to 0.84 mm size alginate/Ca2+ complex particles were added to the slurry composition given in Table 1. Further swelling of the alginate/Ca2+ particles turned the slurry to a solid-like substance.
An alginate/Ca2+ complex was prepared by mixing 20 ml of a 2% alginate solution with 2 ml of a 10% CaCl2 solution. As a result of gel syneresis, after 1 hour 5.3 g of alginate/Ca2+ complex and 14.7 ml of non-gelled water was obtained.
A slurry was prepared with the multi-modal composition and fluid described in Table 2. When 0.5 ml of a 10% solution of CaCl2 was added, formation of an insoluble complex having a high water content resulted in a significant reduction in the fluidity of the slurry.
A slurry containing the tri-modal mixture of solid particles and the alginate solution described in Table 3 was prepared.
The apparatus used is shown in
An alginate/Ca2+ complex was prepared by mixing 20 ml of a 2% alginate solution with 1 g of commercially available encapsulated CaCl2 grains having a size of from about 1 to 2 mm (NutriCAB™, 80% CaCl2, available from Soda Feed Ingredients S.A.R.L., Monaco). The commercially available NutriCAB™ grains had been washed several times with deionized water to remove possible traces of free CaCl2 and then dried on a glass vacuum filter. Mixing of the alginate solution with the encapsulated CaCl2 grains provided a slurry having a uniform distribution of particles and high fluidity. Ten minutes after the mixing, the properties of the slurry remained unchanged. To cause release of CaCl2 into the continuous phase, some of the CaCl2 grains were crushed with a spatula, which resulted in formation of a rigid mass containing the alginate/Ca2+ complex and water.
The fluidity of an HSCF slurry was significantly reduced by destabilizing a PLA emulsion used as a carrier fluid for a tri-modal solid particle mixture. The emulsion used was LANDY™ PL-1000 produced by Miyoshi Oil & Fat Co., Ltd. The emulsion contains fine PLA droplets suspended in an aqueous solution having a mass content of approximately 40%. The composition of the mixture is given in Table 4 below:
After addition of 2 ml of a 1:1 volume:volume mixture of organic solvents (butoxyethanol and DBE-2 (dibasic ester-2 (which is 24% dimethyl adipate and 75% dimethyl glutarate) available from Invista)) there was a significant reduction in the fluidity of the slurry.
A sample of particles of the alginate/Ca2+ complex of Example 2 was divided into two equal 20 g portions. These portions were each placed in 100 ml SHOTT bottles with screw lids with 50 ml of deionized water. 0.5 g of 1.0 to 0.4 mm (18/40 mesh) PLA was added to one bottle. The bottles were heated in an oven at 104° C. (219° F.) for 10 days. Upon removal from the oven, the liquids in both bottles had a brown color. No solids remained in the bottle that had contained PLA particles. The alginate/Ca2+ complex in the bottle without PLA appeared to have a volume similar to that before heating.
The fluidity of a High Solids Content Fluid was significantly increased by crosslinking of the continuous phase. The composition of the mixture is given in Table 5 below:
Addition of the crosslinker caused the slurry to form a solid.
This example shows the advantages of both high solids content, which is possible with suitable multimodal distributions of particles, and generation of a high viscosity in the continuous phase to making a high strength plug. To illustrate the benefits of using HSCF's for seal generation, the performance of plugs formed from fluids of various compositions have been evaluated. The plugs formed from HSCF's containing particles having three sizes showed the highest stability to displacement with hydraulic pressure in these experiments.
The laboratory setup shown in
Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/RU2011/000971 | 12/9/2011 | WO | 00 | 12/11/2014 |
