Temperature- and Salt-Resistant Micro-Crosslinked Polyampholyte Gel as Fluid-Loss Additive for Water-Based Drilling Fluids

The Application Potential of Artificial Intelligence and Numerical Simulation in the Research and Formulation Design of Drilling Fluid Gel Performance

Drilling fluid is pivotal for efficient drilling. However, the gelation performance of drilling fluids is influenced by various complex factors, and traditional methods are inefficient and costly. Artificial intelligence and numerical simulation technologies have become transformative tools in various disciplines. This work reviews the application of four artificial intelligence techniques-expert systems, artificial neural networks (ANNs), support vector machines (SVMs), and genetic algorithms-and three numerical simulation techniques-computational fluid dynamics (CFD) simulations, molecular dynamics (MD) simulations, and Monte Carlo simulations-in drilling fluid design and performance optimization. It analyzes the current issues in these studies, pointing out that challenges in applying these two technologies to drilling fluid gelation performance research include difficulties in obtaining field data and overly idealized model assumptions. From the literature review, it can be estimated that 52.0% of the papers are related to ANNs. Leakage issues are the primary concern for practitioners studying drilling fluid gelation performance, accounting for over 17% of research in this area. Based on this, and in conjunction with the technical requirements of drilling fluids and the development needs of drilling intelligence theory, three development directions are proposed: (1) Emphasize feature engineering and data preprocessing to explore the application potential of interpretable artificial intelligence. (2) Establish channels for open access to data or large-scale oil and gas field databases. (3) Conduct in-depth numerical simulation research focusing on the microscopic details of the spatial network structure of drilling fluids, reducing or even eliminating data dependence.

Development of Multiple Crosslinked Polymers and Its Application in Synthetic-Based Drilling Fluids

This study addresses the performance challenges of Synthetic-Based Drilling Fluids (SBDF) in deep wells and high-temperature environments by engineering a novel multiple hydrogen-bonded crosslinked polymer, MBAH/nano-SiO2. Synthesized using methyl methacrylate (MMA), butyl methacrylate (BMA), acrylic acid (AA), N-hydroxyethyl acrylamide (HEAA), and nano-silica (nano-SiO2), the polymer improved crosslinking density, thermal properties, particle size distribution, and colloidal stability. The development of a 'weak gel' structure in W/O emulsions improved rheology and electrical stability (ES), with ES values reaching up to 775 V after aging at 180 °C. Moreover, the polymer's amphiphilic structure and the synergistic effect of nano-SiO2 increased emulsion film thickness and strength, further augmenting stability. The high-temperature and high-pressure filtration loss of SBDF was considerably reduced to 7.6 mL, benefiting well wall stability and reservoir damage control. This study provides crucial insights into optimizing multiple hydrogen-bonded crosslinked strategies and polymers in SBDF applications.

Preparation of Low-Molecular-Weight Polyacrylamide as the Delayed Crosslinking Plugging Agent for Drilling Fluid

Deep wells and ultra-deep wells often encounter cracks, karst caves, and other developed strata, which can lead to leakage during drilling. Conventional bridge slurry plugging technology is prone to leaking due to the poor plugging effect of the plugging agent. The gel plugging agent possesses characteristics of flexible plugging and adaptive matching of formation leakage channels. It can fill cracks or caves and enhance the pressure-bearing capacity of the formation. A controllable crosslinking plugging agent based on low-molecular-weight polyacrylamide was studied. Polyacrylamide with different molecular weights is synthesized from acrylamide and an initiator. A crosslinking time-controllable polymer is synthesized from low-molecular-weight polyacrylamide by adding crosslinking agent and retarder. The low-molecular-weight polyacrylamide plugging agent has low viscosity before gelation and good fluidity in the wellbore. After being configured on the ground, it is transported by pipeline and sent underground to reach the thickening condition. The gel solution rapidly solidifies, and its strength improves after high-temperature crosslinking. The synthesis conditions of the polymer were as follows: a monomer concentration of 9%, initiator 3.5%, synthesis temperature of 65 °C, and hydrogen peroxide initiator. The optimal formula of the gel plugging agent is as follows: a polymer concentration of 6%, a crosslinking agent concentration of 1%, and a retarder concentration of 8%. The generated polymer molecular structure contains amide groups. This crosslinking time-controllable plugging agent based on low-molecular-weight polyacrylamide has stable rheology, and its temperature resistance can reach 150 °C. At 150 °C, the gelation time can be controlled by adjusting the concentration of retarder, and the longest can reach 4 h. The plugging efficiency of the gel plugging agent is more than 95%. With the increase in seam width, the pressure of the gel plugging agent gradually decreases.

Development and Application of the Anti-High-Temperature Delayed Crosslinking Polymer as a Gel Plugging Additive for Drilling Fluid

With the gradual deepening of the exploration and development of deep and ultra-deep oil and gas resources, the problem of lost circulation in drilling operations is becoming more and more complex. From field experience, conventional plugging materials cannot fully meet the technical requirements of plugging operations in drilling engineering. In this study, a high-temperature- and salt-resistant polymer HDZ-A was synthesized. A high-temperature and delayed crosslinking polymer gel plugging agent can be prepared by adding a certain concentration of a crosslinking agent and a retarder. In this paper, the optimum synthesis conditions of the HDZ-A were determined with orthogonal experiments using viscoelasticity and viscosity as evaluation criteria for newly developed polymers. The molecular structure, temperature resistance, and relative molecular mass of HDZ-A were determined using infrared spectroscopy, nuclear magnetic resonance spectroscopy, and gel permeation chromatography. In addition, the optimal formula of the gel plugging agent was determined using gel strength as the evaluation standard. The results show that the newly developed gel plugging agent has stable performance after high-temperature crosslinking, and can resist high temperatures of 160 °C during formation. Under conditions of 160 °C, the gelation time can reach 4.5 h, and the plugging efficiency can reach more than 97%. Finally, the field test of the newly developed high-temperature-resistant delayed crosslinking polymer gel plugging agent was carried out in the direct exploration well KT-14X in the Ordos Basin. The field test showed that the plugging effect of the HDZ-A gel plugging agent was remarkable.

Application of a Core-Shell Structure Nano Filtration Control Additive in Salt-Resistant Clay-Free Water-Based Drilling Fluid

When drilling into a reservoir, the drilling fluid containing bentonite is prone to solid phase invasion, causing serious damage to the reservoir, and the conventional API barite suspension stability is poor, which makes it easy to cause sedimentation and blockage. Therefore, in order to avoid accidents, we use ultrafine barite to obtain a good suspension stability. More importantly, the method of modifying zwitterionic polymers on the surface of nano-silica is used to develop a temperature-resistant and salt-resistant fluid loss reducer FATG with a core-shell structure, and it is applied to ultra-fine clay-free water-based drilling fluid (WBDF). The results show that the filtration loss of clay-free drilling fluid containing FATG can be reduced to 8.2 mL, and AV can be reduced to 22 mPa·s. Although the viscosity is reduced, FATG can reduce the filter loss by forming a dense mud cake. The clay-free drilling fluid system obtained by further adding sepiolite can reduce the filtration loss to 3.8 mL. After aging at 220 °C for 15 d, it still has significant salt tolerance, the filtration loss is only 9 mL, the viscosity does not change much, a thinner and denser mud cake is formed, and the viscosity coefficient of the mud cake is smaller. The linear expansion test and permeability recovery evaluation were carried out. The hydration expansion inhibition rate of bentonite can reach 72.5%, and the permeability recovery rate can reach 77.9%, which can meet the long-term drilling fluid circulation work in the actual drilling process. This study can provide guidance for technical research in related fields such as reservoir protection.

Development of a Low-Molecular-Weight Filtrate Reducer with High-Temperature Resistance for Drilling Fluid Gel System

Currently, conventional polymeric filtrate reducers with high-temperature resistance for use in drilling fluids have high molecular weights, which greatly affects the rheological properties. Therefore, to address the challenges in regulating the rheology and filtration performance of high-density drilling fluids at high temperatures, it is essential to develop low-molecular-weight filtrate reducers with high-temperature resistance. In this study, a low-molecular-weight filtrate reducer with high-temperature resistance (LMF) was prepared via free radical polymerization from acrylamide and 2-acrylamido-2-methyl-1-propanesulfonic acid as monomers, tertiary dodecyl mercaptan as a chain transfer agent, and ammonium persulfate as the initiator. LMF was then characterized by infrared spectroscopy, thermogravimetric analysis, and gel permeation chromatography. The obtained filtrate reducer exhibits a weight-average molecular weight (Mw) of 3819 and an initial thermal decomposition temperature of 300.7 °C, indicating good thermal stability. The effects of LMF dosage, temperature, and NaCl dosage on the rheology and filtration performance of mud samples were also investigated, and the mechanism of action was revealed by zeta potential, particle size distribution, scanning electron microscopy, and adsorption measurements. The results reveal that LMF increases the mud sample viscosity and reduces its filtration. For example, the filtration of the mud sample with 2 wt% LMF was 7.2 mL, a reduction of 70% compared to that of a blank mud sample. Further, after aging at 210 °C for 16 h, the filtration of the same sample was 11.6 mL, and that of a mud sample with 2 wt% LMF and 35 wt% NaCl after aging at 180 °C for 16 h was 22 mL. Overall, we have reported a scheme to prepare a low-molecular-weight filtrate reducer with high-temperature resistance and superior filtrate-reducing effects, laying the foundation for the investigation and development of low-molecular-weight filtrate reducers.

Equimolar Polyampholyte Hydrogel Synthesis Strategies with Adaptable Properties

Polyampholyte hydrogels exhibit great antibacterial and antifouling properties, which make them attractive for biomedical applications, such as drug delivery, wound healing, and tissue engineering. They also have potential applications in food safety, wastewater treatment, and desalination. Since they are based on ionic interactions, polyampholytes are known to require lower amounts of chemical cross-linkers as compared with traditional gels. However, the effects of both chemical and physical interactions on the material's performance are yet to be fully understood and were examined in the present work. Here, four series of equimolar polyampholyte hydrogels were synthesized with anionic (acrylamidomethylpropane sulfonic acid sodium salt) and cationic monomers (acrylamidopropyl-trimethylammonium chloride) along with a cross-linker (N,N'-methylenebisacrylamide). The mechanical and rheological properties of the gels were characterized following changes to the initial monomer concentration and crosslinker ratios, which led to gels with different toughness, stretchability, and compressibility. The direct correlation of the cross-linking degree with the initial monomer concentration showed that the chemical crosslinker could be further reduced at a high monomer concentration of 30% by weight, which creates an inter-chain network at a minimal crosslinker concentration of 0.25%. Lastly, N'N-dimethylacrylamide was added, which resulted in an increase in the number of H-bonds in the structure, noticeably raising material performance.

A Thermal-Responsive Zwitterionic Polymer Gel as a Filtrate Reducer for Water-Based Drilling Fluids

It is crucial to address the performance deterioration of water-based drilling fluids (WDFs) in situations of excessive salinity and high temperature while extracting deep oil and gas deposits. The focus of research in the area of drilling fluid has always been on filter reducers that are temperature and salt resistant. In this study, a copolymer gel (PAND) was synthesized using acrylamide, N-isopropyl acrylamide, and 3-dimethyl (methacryloyloxyethyl) ammonium propane sulfonate through free-radical polymerization. The copolymer gel was then studied using FTIR, NMR, TGA, and element analysis. The PAND solution demonstrated temperature and salt stimulus response characteristics on rheology because of the hydrophobic association effect of temperature-sensitive monomers and the anti-polyelectrolyte action of zwitterionic monomers. Even in conditions with high temperatures (180 °C) and high salinities (30 wt% NaCl solution), the water-based drilling fluid with 1 wt% PAND displayed exceptional rheological and filtration properties. Zeta potential and scanning electron microscopy (SEM) were used to investigate the mechanism of filtration reduction. The results indicated that PAND could enhance bentonite particle colloidal stability, prevent bentonite particle aggregation, and form a compact mud cake, all of which are crucial for reducing the filtration volume of water-based drilling fluid. The PAND exhibit excellent potential for application in deep and ultra-deep drilling engineering, and this research may offer new thoughts on the use of zwitterionic polymer gel in the development of smart water-based drilling fluid.

Investigation on Filtration Control of Zwitterionic Polymer AADN in High Temperature High Pressure Water-Based Drilling Fluids

With the exploration and development of high-temperature and high-salt deep oil and gas, more rigorous requirements are warranted for the performance of water-based drilling fluids (WBDFs). In this study, acrylamide, 2-acrylamide-2-methylpropanesulfonic acid, diallyl dimethyl ammonium chloride, and N-vinylpyrrolidone were synthesized by free radical copolymerization in an aqueous solution to form a temperature and salt-resistant zwitterionic polymer gel filtration loss reducer (AADN). The zwitterionic polymer had excellent adsorption and hydration groups, which could effectively combine with bentonite through hydrogen bonds and electrostatic attraction, strengthening the hydration film thickness on the surface of bentonite, and promoting the stable dispersion of drilling fluid. In addition, the reverse polyelectrolyte effect of zwitterionic polymers strengthened the drilling fluid’s ability to resist high-temperature and high-salt. The AADN-based drilling fluid showed excellent rheological and filtration control properties (FLAPI < 8 mL, FLHTHP < 29.6 mL) even after aging at high-temperature (200 °C) and high-salt (20 wt% NaCl) conditions. This study provides a new strategy for simultaneously improving the high-temperature and high-salt tolerance of WBDFs, presenting the potential for application in drilling in high-temperature and high-salt deep formations.

Rheological Investigation of Welding Waste-Derived Graphene Oxide in Water-Based Drilling Fluids

Throughout the world, the construction industry produces significant amounts of by-products and hazardous waste materials. The steel-making industry generates welding waste and dusts that are toxic to the environment and pose many economic challenges. Water-based drilling fluids (WBDF) are able to remove the drill cuttings in a wellbore and maintain the stability of the wellbore to prevent formation damage. To the best of our knowledge, this is the first study that reports the application of welding waste and its derived graphene oxide (GO) as a fluid-loss additive in drilling fluids. In this research, GO was successfully synthesized from welding waste through chemical exfoliation. The examination was confirmed using XRD, FTIR, FESEM and EDX analyses. The synthesized welding waste-derived GO in WBDF is competent in improving rheological properties by increasing plastic viscosity (PV), yield point (YP) and gel strength (GS), while reducing filtrate loss (FL) and mud cake thickness (MCT). This study shows the effect of additives such as welding waste, welding waste-derived GO and commercial GO, and their amount, on the rheological properties of WBDF. Concentrations of these additives were used at 0.01 ppb, 0.1 ppb and 0.5 ppb. Based on the experiment results, raw welding waste and welding waste-derived GO showed better performance compared with commercial GO. Among filtration properties, FL and MCT were reduced by 33.3% and 39.7% with the addition of 0.5 ppb of raw welding-waste additive, while for 0.5 ppb of welding waste-derived GO additive, FL and MCT were reduced by 26.7% and 20.9%, respectively. By recycling industrial welding waste, this research conveys state-of-the-art and low-cost drilling fluids that aid in waste management, and reduce the adverse environmental and commercial ramifications of toxic wastes.

Synthesis of a Low-Molecular-Weight Filtrate Reducer and Its Mechanism for Improving High Temperature Resistance of Water-Based Drilling Fluid Gel System

During the exploitation of deep and ultradeep oil and gas resources, the high-temperature problem of deep reservoirs has become a major challenge for water-based drilling fluids. In this study, a novel high-temperature-resistant filtrate reducer (LDMS) with low molecular weight was synthesized using N, N-dimethylacrylamide; sodium p-styrene sulfonate; and maleic anhydride, which can maintain the performance of a drilling fluid gel system under high temperature. Unlike the conventional high-temperature-resistant polymer filtrate reducer, LDMS does not significantly increase the viscosity and yield point of the drilling fluid gel systems. After aging at 210 °C, the filtrate volume of a drilling fluid with 2 wt% LDMS was only 8.0 mL. The mechanism of LDMS was studied by particle size distribution of a drilling fluid gel system, Zeta potential change, adsorption experiment, change of bentonite interlayer spacing, filter cake scanning electron microscope, and related theoretical analysis. The mechanism study revealed that LDMS could be adsorbed on the surface of bentonite particles in large quantities and intercalated into the interlayer of bentonite. Thus, it can improve the hydration degree of bentonite particles and the colloidal stability of the drilling fluid gel system, maintain the content of fine particles in the drilling fluid gel system, form a compact mud cake, and significantly reduce the filtrate volume of the drilling fluid gel system. Therefore, this work will promote the application of a low-molecular-weight polymer filtrate reducer in high-temperature-resistant water-based drilling fluid gel systems.

Nano-Modified Polymer Gels as Temperature- and Salt-Resistant Fluid-Loss Additive for Water-Based Drilling Fluids

With the continuous exploration and development of oil and gas resources to deep formations, the key treatment agents of water-based drilling fluids face severe challenges from high temperatures and salinity, and the development of high temperature and salt resistance filtration reducers has always been the focus of research in the field of oilfield chemistry. In this study, a nano-silica-modified co-polymer (NS-ANAD) gel was synthesized by using acrylamide, isopropylacrylamide, 2-acrylamide-2-methyl propane sulfonic acid, diallyl dimethyl ammonium chloride, and double-bond-modified inorganic silica particles (KH570-SiO₂) through free radical co-polymerization. The introduction of nanotechnology enhances the polymer’s resistance to high temperature degradation, making it useful as a high-temperature-resistant fluid loss reducer. Moreover, the anions (sulfonates) and cations (quaternary ammonium) enhance the extension of the polymer and the adsorption on the surface of bentonite particles in a saline environment, which in turn improves the salt resistance of the polymer. The drilling fluids containing 2.0 wt% NS-ANAD co-polymer gels still show excellent rheological and filtration performance, even after aging in high temperature (200 °C) and high salinity (saturated salt) environments, showing great potential for application in deep and ultra-deep drilling engineering.

Novel Acrylamide/2-Acrylamide-2-3 Methylpropanesulfonic Acid/Styrene/Maleic Anhydride Polymer-Based CaCO3 Nanoparticles to Improve the Filtration of Water-Based Drilling Fluids at High Temperature

Filtration loss control under high-temperature conditions is a worldwide issue among water-based drilling fluids (WBDFs). A core–shell high-temperature filter reducer (PAASM-CaCO₃) that combines organic macromolecules with inorganic nanomaterials was developed by combining acrylamide (AM), 2-acrylamide-2-methylpropane sulfonic acid (AMPS), styrene (St), and maleic anhydride (MA) as monomers and nano-calcium carbonate (NCC). The molecular structure of PAASM-CaCO₃ was characterized. The average molecular weight of the organic part was 6.98 × 10⁵ and the thermal decomposition temperature was about 300 °C. PAASM-CaCO₃ had a better high-temperature resistance. The rheological properties and filtration performance of drilling fluids treated with PAASM-CaCO₃ were stable before and after aging at 200 °C/16 h, and the effect of filtration control was better than that of commonly used filter reducers. PAASM-CaCO₃ improved colloidal stability and mud cake quality at high temperatures.