Classifications

• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
  • C09K8/02—Well-drilling compositions
  • C09K8/03—Specific additives for general use in well-drilling compositions
  • C09K8/035—Organic additives
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
  • C09K8/02—Well-drilling compositions
  • C09K8/04—Aqueous well-drilling compositions
  • C09K8/06—Clay-free compositions
  • C09K8/12—Clay-free compositions containing synthetic organic macromolecular compounds or their precursors

Definitions

• This disclosure relates to drilling compositions, for example, compositions used for drilling natural resource wells.
• Wells may be drilled to extract natural resources such as oil, gas, or water.
• a wellbore is surrounded by a formation, for example, shale or clay, which may influence the stability of the wellbore.
• the formation may exert pressure on the wellbore, or fluids from the formation may enter the wellbore.
• a formation may include permeable regions, and fluids introduced into the wellbore may enter the permeable regions, resulting in fluid loss. Such fluid loss may affect drilling efficiency, may entail replacement of drilling fluids, and affect the stability of the formation.
• Drilling compositions for example, drilling fluids or drilling muds, may be used to facilitate the drilling of wellbores. Drilling fluid or mud may be distributed and circulated along a wellbore to provide functions such as cooling and lubrication of drilling equipment, or to remove cuttings and clear the borehole. In addition to performing these functions, drilling compositions may also assist in promoting formation stability.
• Drilling compositions may form emulsions, for example, an oil-in-water emulsion from a water-based drilling composition. There remains a need for water-based drilling compositions exhibiting sufficient emulsion stability, for example, reducing or avoiding separation.
• this disclosure describes water-based drilling mud compositions.
• the drilling mud compositions may be used in wellbore drilling processes, for example, to form oil wells.
• sodium asphalt sulfonate (SAS), an asphalt salt may be used to promote the formation of an oil-in-water emulsion.
• latex particles may be dispersed in the composition to promote stability of the emulsion. It has been discovered that dispersed latex exhibits synergistic effects when combined with SAS, for example more than additive effects, and this combination promotes emulsion stability. For example, adding insoluble latex and SAS to water-based drilling mud compositions provides relatively higher stability, lubricity, lower fluid loss, and better sealing of shale micro-fractures and formation stability.
• this disclosure describes a water-based drilling mud composition
• a water-based drilling mud composition including an aqueous carrier, an asphalt sulfonate salt, and insoluble latex particles.
• the insoluble latex particles promote stabilization of an emulsion formed in response to introduction of an oil phase in the composition.
• this disclosure describes a water-based drilling mud composition including an oil-in-water emulsion.
• the emulsion may include an aqueous carrier, an oil phase dispersed as droplets in the aqueous carrier, an asphalt sulfonate salt, and dispersed insoluble latex particles.
• the dispersed insoluble latex particles may be present in an oil-water interface between the oil phase and an aqueous phase of the aqueous carrier.
• the insoluble latex particles can have a population-averaged particle size in a range of less than or about 0.150 micrometers.
• FIG. 1 is a chart illustrating lowered high temperature high pressure (HTHP) fluid loss at 250 °F for a water-based drilling mud composition including both sodium asphalt sulfonate (SAS) and powdered latex relative to compositions that do not include one or both of SAS or latex.
• HTHP lowered high temperature high pressure
• FIG. 2 is a chart illustrating lowered permeability plugging test (PPT) fluid loss at 250 °F for water-based drilling mud compositions including both SAS and powdered latex and having a greater concentration by mass of SAS than that of powdered latex relative to compositions that do not include one or both of SAS or latex.
• PPT lowered permeability plugging test
• FIG. 3 is a chart illustrating lowered PPT fluid loss at 325 °F for water-based drilling mud compositions including both SAS and powdered latex and having a greater concentration by mass of SAS than that of powdered latex relative to compositions that do not include one or both of SAS or latex.
• FIG. 4 is a chart illustrating PPT fluid loss at 325 °F for water-based drilling mud compositions including both SAS and powdered latex and having a greater concentration by mass of SAS than that of powdered latex relative to compositions that do not include one or both of SAS or latex.
• FIG. 5 is a chart illustrating lowered PPT fluid loss over time for water-based drilling mud compositions including both SAS and powdered latex and having a greater concentration by mass of SAS than that of powdered latex relative to compositions that do not include SAS or latex at different temperatures (250 °F, 275 °F, and 300 °F).
• FIG. 6 is a chart illustrating lowered PPT fluid loss at 275 °F for water-based drilling mud compositions including both SAS and different types of powdered latex and having a greater concentration by mass of SAS than that of powdered latex relative to compositions that do not include SAS.
• FIG. 7 is a chart illustrating lowered PPT fluid loss at 275 °F oil-based drilling mud compositions including both SAS and powdered latex and having SAS in a concentration by mass that is greater than or equal to that of powdered latex relative to compositions that do not include one or both of SAS or latex.
• FIG. 8 is a chart illustrating lowered PPT fluid loss at 300 °F for oil-based drilling mud compositions including both SAS and powdered latex and having SAS in a concentration by mass that is equal to that of powdered latex relative to compositions that do not include one or both of SAS or latex.
• FIG. 9 is a chart illustrating lowered PPT fluid loss at 300 °F for oil-based drilling mud compositions including both SAS and latex and having SAS in a concentration by mass that is equal to that of powdered latex relative to compositions that do not include one or both of SAS or latex.
• FIG. 10 is a chart illustrating lowered PPT fluid loss and spurt loss at 275 °F for water-based drilling mud compositions including both SAS and powdered latex and having SAS in a concentration by mass that is greater than that of powdered latex relative to compositions including other additives.
• FIG. 11 is a chart illustrating lowered PPT fluid loss and spurt loss at 300 °F for oil- based drilling mud compositions including both SAS and powdered latex and having SAS in a concentration by mass that is greater than that of powdered latex relative to compositions including other additives.
• FIG. 12 is a chart illustrating API and HTHP filtrate volumes at 375 °F for water- based drilling mud compositions including both SAS and powdered latex and having SAS in a concentration by mass that is greater than that of powdered latex relative to compositions that do not include one or both of SAS or latex.
• FIG. 13 is a chart illustrating variation in coefficient of friction with torque for oil- based drilling mud compositions including a solid lubricant.
• FIG. 14 is a chart illustrating variation in coefficient of friction with Stribeck number for oil-based drilling mud compositions excluding and including a solid lubricant.
• FIG. 15 is a chart illustrating variation in coefficient of friction with Stribeck number for oil-based drilling mud compositions excluding and including a solid lubricant and a particulate friction reducing material.
• FIG. 16 is a chart illustrating variation in coefficient of friction with Stribeck number for oil-based drilling mud compositions excluding and including a solid lubricant and an organophilic clay.
• FIG. 17 is a chart illustrating coefficient of friction with time for a base oil-based drilling mud composition.
• FIG. 18 is a chart illustrating coefficient of friction with time for a base oil-based drilling mud composition including a solid lubricant.
• FIG. 19 is a chart illustrating variation of coefficient of friction with Stribeck number for oil-based drilling mud compositions excluding lubricant, including a solid lubricant, and including two different liquid lubricants.
• FIG. 20 is a chart illustrating variation of upweight and downweight along a horizontal section with depth.
• FIG. 21 is a chart illustrating coefficient of friction for sample water-based drilling compositions in which latex is absent or present.
• compositions and methods are described in terms of “comprising” various components or steps, the compositions and methods can also “consist essentially of’ or “consist of’ the various components or steps, unless stated otherwise.
• Values or ranges may be expressed herein as “about”, from “about” one particular value, and/or to “about” another particular value. When such values or ranges are expressed, other embodiments disclosed include the specific value recited, from the one particular value, and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that there are a number of values disclosed therein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself.
• use of the term “about” means ⁇ 20% of the stated value, ⁇ 15% of the stated value, ⁇ 10% of the stated value, ⁇ 5% of the stated value, ⁇ 3% of the stated value, or ⁇ 1% of the stated value.
• Applicant reserves the right to proviso out or exclude any individual members of any such group of values or ranges, including any sub-ranges or combinations of sub-ranges within the group, that can be claimed according to a range or in any similar manner, if for any reason Applicant chooses to claim less than the full measure of the disclosure, for example, to account for a reference that Applicant may be unaware of at the time of the filing of the application.
• Applicant reserves the right to proviso out or exclude any individual substituents, analogs, compounds, ligands, structures, or groups thereof, or any members of a claimed group, if for any reason Applicant chooses to claim less than the full measure of the disclosure, for example, to account for a reference that Applicant may be unaware of at the time of the filing of the application.
• latex refers to an emulsion of one or more polymers in a solvent such as water.
• soldered latex refers to a latex powder formed by drying or dehydrating latex.
• dispersed latex refers to a dispersed form of latex formed by redispersing agglomerated powdered latex into significantly smaller latex particles, for example, dispersed particles having a population-averaged particle size of 1 micrometers or less.
• asphalt sulfonate refers to a sulfonated asphalt formed by treating asphalt with a sulfonating agent.
• SAS sodium asphalt sulfonate
• substituted when used to describe a group, for example, when referring to a substituted analog of a particular group, is intended to describe the compound or group wherein any non-hydrogen moiety formally replaces hydrogen in that group or compound and is intended to be non-limiting.
• a compound or group can also be referred to herein as “unsubstituted” or by equivalent terms such as “non-substituted,” which refers to the original group or compound.
• “Substituted” is intended to be non-limiting and include inorganic substituents or organic substituents as specified and as understood by one of ordinary skill in the art.
• the present disclosure generally relates to drilling compositions, for example, compositions used for drilling natural resource wells.
• the drilling compositions include powdered latex, and at least one salt of asphalt sulfonate, for example, sodium asphalt sulfonate (SAS).
• SAS sodium asphalt sulfonate
• Latex is an emulsion of one or more polymers in water or an aqueous medium and may be natural or synthetic.
• latex includes an emulsion of a synthetic copolymer.
• latex may include an emulsion of a styrene-butadiene copolymer in an aqueous medium.
• Natural or synthetic latex may include dispersed polymeric particles. The properties of latex may depend, inter alia, on the extent of crosslinking in the polymer.
• Powdered latex may be formed from latex, for example, by drying, dewatering, or dehydrating latex to separate or remove water from the emulsion to leave dispersed particles or agglomerates of one or more polymers.
• Powdered latex may thus include a powder of polymeric particles separated from an aqueous medium of latex, for example, by drying.
• the drying may include spray drying.
• the properties of powdered latex may be controlled by controlling the properties of the latex from which the powdered latex is prepared. For example, the extent of crosslinking, concentration, solvent density, rate of drying, or other parameters may ultimately determine the properties of powdered latex. Powdered latex is dispersible or soluble in water-based and oil-based carriers, and is suitable for use in drilling mud compositions, for example, water- based drilling mud compositions and oil-based drilling mud compositions.
• the powdered latex may include at least one of a styrene butadiene copolymer or a vinyl acetate ethylene copolymer. In some aspects, the powdered latex consists of or consists essentially of styrene butadiene copolymer. In some aspects, the powdered latex consists of or consists essentially of vinyl acetate ethylene copolymer.
• the powdered latex may have any suitable population-averaged particle size and particle size distribution. For example, the powdered latex may have a population-averaged particle size in a range from about 0.150 micrometers to about 150 micrometers.
• the powdered latex has a population-averaged particle size in a range from about 70 micrometers to about 100 micrometers, or in a range from about in a range from about 80 micrometers to about 90 micrometers. In some aspects, the population-averaged particle size can be about 85 micrometers. The population-averaged particle size may be a D50 size measured by laser diffraction.
• the methods which may be used for determining the particle size distribution (PSD) of the powdered latex materials for use in accordance with the present disclosure include any of the standard methods for determining the particle size distributions of particulate materials in a particular size range (e.g., from 0.1 to 200 pm), including but not limited to gravitational liquid sedimentation methods as described in ISO 13317, and sieving/sedimentation methods such as described in ISO 1 1277, as well as by spectral, acoustic, and laser diffraction methods, as appropriate, as well as combinations thereof.
• Asphalt refers to hydrocarbon materials including bitumen components, for example, one or more of naphthene aromatics, polar aromatics, saturated hydrocarbons, or asphaltenes. Asphalt may be obtained from natural sources or may be obtained by refining petroleum by one or more of distillation, precipitation, cracking, oxidation or other operations. Asphalt may include one or more of asphaltenes, maltenes, blown asphalt, straight residual oils, distillation residues, still bottoms, cracking residues, asphaltic bitumens, or combinations thereof.
• Asphalts vary significantly in composition and physical properties depending on the crude oil source and the refinery process.
• the asphalt may be oxidized to increase the softening point. It is water insoluble.
• Polymer modified asphalts are petroleum asphalts that have been blended with synthetic polymers such as SBS, EVA, or rubber to improve their performance in certain applications, especially paving.
• Asphalt sulfonate (also known as sulfonated asphalt) can be formed by sulfonating an asphalt with a sulfonation agent.
• Sulfonation agents may include one or more of fuming sulfuric acid, chlorosulfonic acid, concentrated sulfuric acid, or sulfur trioxide.
• Asphalt sulfonate may be prepared by forming a mixture of asphalt and a solvent and exposing the mixture to sulfonation agent.
• the solvent may include hexane.
• the resulting product may be neutralized to form a salt, followed by separation from the solvent.
• the neutralization may be performed using a basic compound, for example, sodium hydroxide or potassium hydroxide.
• Asphalt sulfonate may have different properties and include a mixture or combination of materials based on the parameters of the sulfonation process, for example, the degree of sulfonation or the type of sulfonating agent utilized.
• sodium asphalt sulfonate refers to a sodium salt of asphalt sulfonate. While the disclosure refers to SAS, in examples, SAS may be combined with or replaced by one or more different salts of asphalt sulfonate, for example, a potassium salt, a calcium salt, a lithium salt, or another suitable salt of asphalt sulfonate. Unlike asphalt, which is neither anionic nor water soluble, sodium asphalt sulfonate may be anionic and water soluble, for example, at least 70%, or at least 80% water soluble.
• sodium asphalt sulfonate may be produced by reacting asphalt (thinned with heptane) with sulfur trioxide to form the sulfonic acid. The acid may be neutralized with caustic (50% NaOH) to form the sodium salt. This product is water soluble and no longer exhibits the softening point or other characteristics of asphalt.
• Soltex® Drilling Specialties Company, The Woodlands, Texas is an example of a sodium asphalt sulfonate. It does not exhibit the typical properties of asphalt, does not melt, and does not have a softening point, in contrast with asphalt and other natural bitumen products that do soften and melt.
• Drilling compositions including both powdered latex and SAS may exhibit one or more of lower fluid loss relative to compositions that do not include one or both of powdered latex or SAS.
• the fluid loss may be determined by high-temperature high-pressure (HTHP) fluid loss tests, permeability plugging (PPT) tests, or spurt loss, according to protocols established by the American Petroleum Institute (API).
• Drilling compositions including both powdered latex and SAS may provide beher lubrication, for example, lower coefficient of friction, relative to compositions that do not include one or both of latex or SAS. Drilling compositions according to the disclosure may also promote formation stability and removal of cuhings.
• synergistic effects resulting from combining powder latex and SAS apply to drilling mud compositions including oil-based carriers or water-based carriers. Without being bound by theory, a chemical coupling or network formation may result by combining powdered latex and SAS, which may result in synergy.
• compositions including both powdered latex and SAS, and having a greater concentration by mass of SAS than that of powdered latex may exhibit lower fluid loss, higher lubrication, and higher formation stability relative to compositions including other relative concentrations of SAS and powdered latex.
• a drilling mud composition includes a first concentration of powdered latex, and a second concentration of SAS.
• the second concentration of SAS can be greater than or equal to the first concentration of latex.
• the second concentration of SAS can be greater than the first concentration of latex.
• the second concentration of SAS can be greater than the first concentration of latex by a predetermined threshold, for example, by at least 0.1 pounds per barrel (lbm/bbl), by at least 0.25 lbm/bbl, by at least 0.5 lbm/bbl, by at least 1.0 lbm/bbl, by at least 1.5 lbm/bbl, by at least 2 lbm/bbl, by at least 2.5 lbm/bbl, by at least 3 lbm/bbl, by at least 3.5 lbm/bbl, by at least 4 lbm/bbl, or by at least 5 lbm/bbl.
• the second concentration of SAS can be substantially the same as the first concentration of latex.
• the second concentration of SAS can be lower than the first concentration of latex.
• a drilling mud composition includes a first concentration of powdered latex and a second concentration of SAS, where the second concentration of SAS is greater than or equal to the first concentration of latex.
• the powdered latex and SAS may be dispersed or solubilized in a carrier, for example, a water-based carrier or an oil-based carrier, to form a drilling mud composition.
• a carrier for example, a water-based carrier or an oil-based carrier
• an additive composition to be added to a drilling mud composition or to a carrier composition may include powdered latex and SAS according to the disclosure.
• the additive composition may also include one or more additives, for example, one or more of asphalt, Gilsonite® (or uintahite), lignite, or any other suitable drilling composition additive.
• the drilling mud composition includes a water-based carrier and a second concentration of SAS that is greater than or equal to a first concentration of powdered latex.
• the second concentration of SAS in the drilling mud composition can be greater than the first concentration of latex.
• Drilling mud compositions including a water-based carrier according to such aspects may exhibit lower fluid loss than compositions that do not include one or both of powdered latex or SAS.
• the drilling mud composition has an average high temperature high pressure (HTHP) fluid loss at 250 °F and at 500 pounds per square inch (psi) of less than or about 20 mL when tested according to American Petroleum Institute (API) test 13B-1.
• the drilling mud composition can have an average HTHP fluid loss at 250 °F and at 500 psi of less than or about 18 mL, or less than or about 15 mL, or less than or about 12 mL.
• the drilling mud composition has an average permeability plugging test (PPT) loss at 250 °F with a 12 micrometer filtration disc of less than or about 18.0 mL when tested according to API test 13B-1. In some such aspects, the drilling mud composition has an average PPT less of less than or about 16 mL, or less than or about 15 mL, or less than or about 12 mL.
• PPT permeability plugging test
• Drilling mud compositions including a water-based carrier may exhibit higher lubrication than compositions that do not include one or both of powdered latex or SAS.
• the drilling mud composition has a coefficient of friction of less than or about 0.40 at 250 lb-ft torque.
• the drilling mud composition can have a coefficient of friction of less than or about 0.35, or less than or about 0.30, or less than or about 0.25.
• Drilling mud compositions including a water-based carrier according to the disclosure may exhibit rheological properties (for example, one or more of plastic viscosity, yield point, or gel strength) suitable for drilling.
• a drilling mud composition according to some such aspects has a plastic viscosity at 120 °F in a range of from about 10 cP to about 30 cP when tested according to American Petroleum Institute (API) test 13B-1.
• API American Petroleum Institute
• the drilling mud composition has a plastic viscosity in a range of from about 10 cP to about 15 cP, or from about 10 cP to about 20 cP, or from 15 cP to about 20 cP, or from about 15 cP to about 30 cP, or from about 20 cP to about 30 cP.
• the drilling mud composition has a yield point at 120 °F in a range of from about 10 lb/100 ft 2 to about 45 lb/100 ft 2 when tested according to American Petroleum Institute (API) test 13B-1.
• API American Petroleum Institute
• the drilling mud composition has a yield point at 120 °F in a range of from about 10 lb/100 ft 2 to about 20 lb/100 ft 2 , or from about 20 lb/100 ft 2 to about 45 lb/100 ft 2 , or from about 10 lb/100 ft 2 to about 30 lb/100 ft 2 , or from about 15 lb/100 ft 2 to about 20 lb/100 ft 2 , or from about 15 lb/100 ft 2 to about 30 lb/100 ft 2 , or from about 30 lb/100 ft 2 to about 45 lb/100 ft 2 .
• the drilling mud composition has a 10-second gel strength at 120 °F in a range from about 2.0 lb/100 ft 2 to about 6.5 lb/100 ft 2 when tested according to American Petroleum Institute (API) test 13B-1.
• the drilling mud composition has a 10-second gel strength at 120 °F in a range from about 2.5 lb/100 ft 2 to about 6.5 lb/100 ft 2 , or from about 2.0 to about 3.0 lb/100 ft 2 , or from about 5.0 to about 6.5 lb/100 ft 2 , or from about 5.5 to about 6.5 lb/100 ft 2 .
• the drilling mud composition has a 10-minute gel strength at 120 °F in a range from about 2 lb/100 ft 2 to about 12 lb/100 ft 2 when tested according to American Petroleum Institute (API) test 13B-1.
• API American Petroleum Institute
• the drilling mud composition has a 10-minute gel strength at 120 °F in a range from about 2 lb/100 ft 2 to about 5 lb/100 ft 2 , or from about 2 lb/100 ft 2 to about 10 lb/100 ft 2 , or from about 3 lb/100 ft 2 to about 10 lb/100 ft 2 , or from about 5 lb/100 ft 2 to about 10 lb/100 ft 2 , or from about 5 lb/100 ft 2 to about 12 lb/100 ft 2 .
• Drilling mud compositions including a water-based carrier may include any suitable first concentration of powdered latex and second concentration of SAS.
• the second concentration of SAS can be greater than or equal to the first concentration of powdered latex.
• the first concentration of powdered latex is at least 1 pounds per barrel (lbm/bbl)
• the second concentration of SAS is at least 2 lbm/bbl.
• the first concentration of powdered latex can be in a range from about 1.5 to about 2.5 lbm/bbl
• the second concentration of SAS can be in a range from about 2.5 to about 3.5 lbm/bbl.
• the first concentration of powdered latex can be about 2 lbm/bbl, and the second concentration of SAS can be about 3 lbm/bbl. In some such aspects, the first concentration of powdered latex can be about 1.5 lbm/bbl, and wherein the second concentration of SAS can be about 4.5 lbm/bbl. In some such aspects, the first concentration of powdered latex can be about 1.2 lbm/bbl, and wherein the second concentration of SAS can be about 4.8 lbm/bbl. In some such aspects, the first concentration of powdered latex can be about 1.8 lbm/bbl, and wherein the second concentration of SAS can be about 4.2 lbm/bbl.
• Drilling mud compositions including water-based carriers according to the disclosure may be formed using any suitable technique.
• a technique includes dispersing a first predetermined amount of powdered latex and a second predetermined amount of SAS in a water-based carrier to form a water-based mud.
• the water-based mud may include any drilling composition according to the disclosure including a water-based carrier.
• the drilling mud composition includes an oil-based carrier and a second concentration of SAS that is greater than or equal to a first concentration of powdered latex.
• the second concentration of SAS in the drilling mud composition can be greater than the first concentration of latex.
• Drilling mud compositions including an oil-based carrier may exhibit lower fluid loss than compositions that do not include one or both of powdered latex or SAS.
• the drilling mud composition including an oil-based carrier has an average permeability plugging test (PPT) fluid loss at 300 °F with a 55 micrometer filtration disc of less than or about 1.06 mL when tested according to American Petroleum Institute (API) test 13B-2.
• PPT average permeability plugging test
• the drilling mud composition including an oil-based carrier has an average PPT fluid loss at 275 °F of less than or about 3.3 mL, or less than or about 3.0 mL, or less than or about 2.5 mL. In some such aspects, the drilling mud composition including an oil-based carrier has an average PPT fluid loss at 300 °F with a 40 micrometer filtration disc of less than or about 3.3 mL, or less than or about 3.15 mL, or less than or about 3.00 mL.
• Drilling mud compositions including an oil-based carrier according to such aspects may exhibit higher lubrication than compositions that do not include one or both of powdered latex or SAS.
• Drilling mud compositions including an oil-based carrier according to the disclosure may exhibit rheological properties suitable for drilling.
• a drilling mud composition according to some such aspects has a plastic viscosity at 120 °F in a range of from about 10 cP to about 30 cP when tested according to API test 13B-2.
• a drilling mud composition may have a plastic viscosity in a range of from about 10 cP to about 15 cP, or in a range of from about 12 cP to about 20 cP, or in a range of from about 15 cP to about 20 cP, or in a range of from about 15 cP to about 25 cP, or in a range of from about 15 cP to about 30 cP.
• the drilling mud composition has a yield point at 120 °F in a range of from about 5 lb/ 100 ft2 to about 12 lb/100 ft2 when tested according to API test 13B-2. In some such aspects, the drilling mud composition has a yield point at 120 °F in a range of from about 5 lb/ 100 ft2 to about 10 lb/100 ft2, or from about 5 lb/ 100 ft2 to about 8 lb/100 ft2, or from about 8 lb/100 ft2 to about 12 lb/100 ft2, or from about 5 lb/100 ft2 to about 6 lb/100 ft2.
• the drilling mud composition has a 10-second gel strength at 120 °F in a range from about 2 lb/ 100 ft 2 to about 12 lb/100 ft 2 when tested according to API test 13B-2. In some such aspects, the drilling mud composition has a 10-second gel strength at 120 °F in a range from about 2 lb/100 ft 2 to about 11 lb/100 ft 2 , or in a range from about 2 lb/100 ft 2 to about 10 lb/100 ft 2 , or in a range from about 5 lb/100 ft 2 to about 12 lb/100 ft 2 , or in a range from about 2 lb/100 ft 2 to about 5 lb/100 ft 2 .
• the drilling mud composition has a 10-minute gel strength at 120 °F in a range from about 2 lb/100 ft 2 to about 40 lb/100 ft 2 when tested according to API test 13B-2. In some such aspects, the drilling mud composition has a 10-minute gel strength at 120 °F in a range from about 2 lb/100 ft 2 to about 10 lb/100 ft 2 , or from about 2 lb/100 ft 2 to about 20 lb/100 ft 2 , or from about 10 lb/100 ft 2 to about 30 lb/100 ft 2 , or from about 10 lb/100 ft 2 to about 20 lb/100 ft 2 , or from about 20 lb/100 ft 2 to about 30 lb/100 ft 2 , or from about 10 lb/100 ft 2 to about 40 lb/100 ft 2 .
• Drilling mud compositions including an oil-based carrier may include any suitable first concentration of powdered latex and second concentration of SAS.
• the second concentration of SAS can be greater than or equal to the first concentration of powdered latex.
• the first concentration of powdered latex can be at least about 1 pounds per barrel (lbm/bbl)
• the second concentration of SAS can be at least about 1 lbm/bbl.
• the first concentration of powdered latex can be at least about 2 lbm/bbl
• the second concentration of SAS can be at least about 2 lbm/bbl.
• the first concentration of powdered latex can be at least about 1 lbm/bbl
• the second concentration of SAS can be at least about 2 lbm/bbl.
• the first concentration of powdered latex can be at least about 1 lbm/bbl
• the second concentration of SAS can be at least about 3 lbm/bbl.
• the first concentration of powdered latex can be at least about 1 lbm/bbl
• the second concentration of SAS can be at least about 4 lbm/bbl.
• the first concentration of powdered latex can be at least about 1.5 lbm/bbl
• the second concentration of SAS can be at least about 2.5 lbm/bbl.
• the first concentration of powdered latex can be at least about 1.2 lbm/bbl
• the second concentration of SAS can be at least about 4.8 lbm/bbl.
• the first concentration of powdered latex can be at least about 1.5 lbm/bbl
• the second concentration of SAS can be at least about 4.5 lbm/bbl.
• the first concentration of powdered latex can be about 1 lbm/bbl, and the second concentration of SAS can be about 3 lbm/bbl. In some such aspects, the first concentration of powdered latex can be about 1.2 lbm/bbl, and the second concentration of SAS can be about 4.8 lbm/bbl. In some such aspects, the first concentration of powdered latex can be about 1.5 lbm/bbl, and the second concentration of SAS can be about 4.5 lbm/bbl. In some such aspects, the first concentration of powdered latex can be about 1.8 lbm/bbl, and the second concentration of SAS can be about 4.2 lbm/bbl. In some such aspects, the first concentration of powdered latex can be about 2 lbm/bbl, and the second concentration of SAS can be about 3 lbm/bbl.
• the first concentration of powdered latex can be in a range from about 1.5 to about 2.5 lbm/bbl
• the second concentration of SAS can be in a range from about 1.5 to about 2.5 lbm/bbl
• the first concentration of powdered latex can be about 2 lbm/bbl
• the second concentration of SAS can be about 2 lbm/bbl
• Drilling mud compositions including oil-based carriers according to the disclosure may be formed using any suitable technique.
• a technique includes dispersing a first predetermined amount of powdered latex and a second predetermined amount of SAS in an oil-based carrier to form an oil-based mud.
• the oil-based mud may include any drilling composition according to the disclosure including an oil-based carrier.
• Drilling mud compositions according to the disclosure may include a drilling mud composition that is ready for use or may refer a drilling mud additive composition to be added to a carrier or drilling mud prior to use.
• drilling mud additive compositions may include a blend of powdered latex and SAS.
• such drilling mud additive compositions may include blends of powdered latex and SAS such that adding a predetermined amount of drilling mud additive compositions to a carrier results in a drilling mud composition including concentrations of powdered latex and SAS according to the disclosure.
• drilling mud additive compositions may include a solid lubricant composition.
• the drilling mud additive composition or solid lubricant composition may include SAS and powdered latex.
• the drilling mud additive composition or solid lubricant composition solid lubricant composition consists essentially of SAS and powdered latex.
• the drilling mud additive composition or solid lubricant composition consists of SAS and powdered latex.
• Drilling mud additive compositions may include SAS and powdered latex as a 50/50 SAS-latex blend, a 60/40 SAS-latex blend, a 70/30 SAS-latex blend, an 80/20 SAS-latex blend, or a 90/10 SAS-latex blend.
• the ratio refers to the relative concentrations of SAS and latex, and the blends may optionally include other components or additives.
• Drilling compositions according to the disclosure may provide one or more of better fluid loss control, plugging test performance, formation stability, and lubricity, and may reduce logistic and material handling at a wellsite.
• drilling compositions according to the disclosure can be used as water-based drilling compositions that form stable oil-in-water emulsions.
• Emulsion stability may be improved by the addition of dispersed latex.
• Invert emulsions water- or brine-in-oil emulsions, often described as oil-based mud
• Invert emulsions have been used in the drilling industry. These emulsions are relatively expensive but are relatively stable and provide good wellbore stability.
• Direct emulsions water-in-oil emulsions
• the direct emulsions currently used are primarily formulated using conventional non-ionic or ionic surfactants.
• the surfactants form stable oil in water emulsions but are expensive due to the requirement that they be compatible with field brines. This requirement also results in the use of relatively high concentrations to form the emulsion in the brines normally used in these drilling fluids.
• the emulsions are difficult to break making it difficult to recover the oil for reuse further increasing the expense.
• Sodium asphalt sulfonate can be used to produce a usable emulsion. However, the emulsion can be difficult to create in the field.
• High-shear mix equipment in combination with agents such as sulfonated asphalt salts can produce an acceptable oil-in-water emulsion. It was surprisingly found that the emulsion can be further stabilized by the use of polymers, such as latex particles, to increase the viscosity of the aqueous phase. Fine drill solids further improve the stability of the emulsion.
• the sulfonated asphalt salt may form a type of Pickering emulsion, and adding insoluble latex particles of a sufficiently small size may increase the stability of the oil in water emulsion and improve the ability to generate the emulsion under field conditions.
• dispersed insoluble latex particles may be present in an oil-water interface between the oil phase and an aqueous phase of an aqueous carrier, and stabilize the oil-water interface. The latex particles may help fill interstices or gaps between particles of the sulfonated asphalt salt.
• this disclosure describes water-based drilling mud compositions.
• the drilling mud compositions may be used in wellbore drilling processes, for example, to form oil wells.
• sodium asphalt sulfonate (SAS), an asphalt salt may be used to promote the formation of an oil-in-water emulsion.
• latex particles may be dispersed in the composition to promote stability of the emulsion. It has been discovered that dispersed latex exhibits synergistic effects when combined with SAS, for example more than additive effects, and this combination promotes emulsion stability. For example, adding insoluble latex and SAS to water-based drilling mud compositions provides relatively higher stability, lubricity, lower fluid loss, and beher sealing of shale micro-fractures and formation stability.
• this disclosure describes a water-based drilling mud composition
• a water-based drilling mud composition including an aqueous carrier, an asphalt sulfonate salt, and insoluble latex particles.
• the insoluble latex particles promote stabilization of an emulsion formed in response to introduction of an oil phase in the composition.
• this disclosure describes a water-based drilling mud composition including an oil-in-water emulsion.
• the emulsion may include an aqueous carrier, an oil phase dispersed as droplets in the aqueous carrier, an asphalt sulfonate salt, and dispersed insoluble latex particles.
• the dispersed insoluble latex particles may be present in an oil-water interface between the oil phase and an aqueous phase of the aqueous carrier.
• the insoluble latex particles can have a population-averaged particle size in a range of less than or about 0.150 micrometers.
• compositions according to the present disclosure may also provide comparable or better drilling properties such as fluid loss control, clay/shale stability, and lubricity.
• Conventional direct emulsions have as a relaxed fluid loss control.
• Direct emulsions according to the present disclosure can provide a tight fluid loss control with commensurate subsequent impact on wellbore stability.
• Conventional direct emulsion have been designed for low density applications.
• Direct emulsions according to the present disclosure may be formulated with medium and high densities.
• Direct emulsions according to the present disclosure may provide such additional properties or benefits with less components, for example, with fewer additives.
• direct emulsions according to the present disclosure may provide relatively more complete and simpler oil-in water emulsion.
• direct emulsions according to the present disclosure may provide more versatile systems able to handle more complex water-based mud formulations for a broad application of the direct emulsions.
• using direct emulsions according to the present disclosure allows an adjustment of the density of the drilling fluid significantly below that of saturated brines in certain field conditions. For example a 10 lbs/gallon brine can be emulsified with diesel to build a 8.5 lb/gallon drilling fluid.
• water-based drilling mud composition includes an aqueous carrier, an asphalt sulfonate salt, and insoluble latex particles.
• the aqueous carrier may include water, brine, or any other suitable carrier.
• the insoluble latex particles may promote stabilization of an emulsion formed in response to introduction of an oil phase in the composition.
• the insoluble latex particles can promote stabilization of the emulsion by stabilizing an oil-water interface between the oil phase and an aqueous phase of the aqueous carrier.
• the insoluble latex particles have a population-averaged particle size effective to promote stabilization of the emulsion by stabilizing the oil-water interface.
• the insoluble latex particles may have a population-averaged particle size effective to occupy the oil-water interface.
• the size of the insoluble latex particles may be different from the size of latex particles initially introduced into the composition.
• latex may be introduced in the form of larger or agglomerated dry latex powdered particles, and may be redispersed in the carrier to form the insoluble latex particles.
• the size of the dispersed latex particles may be significantly smaller than the size of the dry latex powdered particles.
• the insoluble latex particles have a population-averaged particle size in a range of less than 1 micrometers. In some such aspects, the insoluble latex particles have a population-averaged particle size in a range of less than 0.500 micrometers. In some such aspects, the insoluble latex particles have a population-averaged particle size in a range of less than 0.200 micrometers.
• the insoluble latex particles have a population-averaged particle size in a range of less than or about 0.150 micrometers.
• the insoluble latex particles may have a population-averaged particle size of about 0.150 micrometers.
• water-based drilling mud compositions may include an oil-in-water emulsion.
• the oil-in-water emulsion may include the aqueous carrier, an oil phase dispersed as droplets in the aqueous carrier, the asphalt sulfonate salt, and
• the insoluble latex particles may include diesel or any other emulsifiable oil suitable for use in drilling operations.
• the insoluble latex particles are present in an oil-water interface between the oil phase and an aqueous phase of the aqueous carrier.
• the insoluble latex particles may promote stabilization of the emulsion by stabilizing the oil-water interface.
• the insoluble latex particles may have a population-averaged particle size effective to promote stabilization of the emulsion by stabilizing the oil-water interface.
• the insoluble latex particles have a population-averaged particle size in a range of less than or about 0.150 micrometers.
• the latex particles may be formed of any suitable polymer material capable of forming a latex.
• the insoluble latex particles include particles of at least one of a styrene butadiene copolymer, a polyvinyl alcohol, a polyvinyl acetate, or a vinyl acetate ethylene copolymer.
• the insoluble latex particles consist of particles of a styrene butadiene copolymer.
• the latex particles may include a carboxylated styrene-butadiene copolymer, for example, Lipaton® SB 20W20 or SP 29Y141 (Synthomer, Roebuck, South Carolina).
• the insoluble latex particles may be introduced as fine dry dispersed particles, or as larger agglomerates that may be redispersed or reduced in size.
• the insoluble latex particles are formed by dispersing a powdered dry latex in the composition.
• the powdered dry latex particles have an agglomerated population- averaged particle size in a range from 70 micrometers to 100 micrometers.
• the dispersion or mixing may promote separation of the agglomerated particles, to release or produce insoluble particles of significantly smaller sizes, such a population-averaged size of less than 1 micrometers, or less than 0.500 micrometers, or less than 0.200 micrometers, or less than 0.150 micrometers, or about 0.150 micrometers.
• the concentration of the latex particles may be sufficient to stabilize the emulsion, for example, by providing at least a minimum number of particles associated with each suspended oil-phase droplet.
• the insoluble latex particles are present in a concentration of at least 0.1 lbs per barrel (lbm/bbl) of the composition. In some such aspects, the insoluble latex particles are present in a concentration of at least 0.2 lbm/bbl of the composition. In some such aspects, the insoluble latex particles are present in a concentration of at least 0.5 lbm/bbl of the composition.
• the concentration of the latex particles may be lower than an upper bound, for example, lower than a concentration that hinders emulsion stability, or a concentration that may promote separation of droplets.
• the insoluble latex particles are present in a concentration of less than 3.0 lbm/bbl of the composition. In some such aspects, the insoluble latex particles are present in a concentration of less than 1.5 lbm/bbl of the composition.
• the insoluble latex particles are present in a concentration in a range from 0.1 lbm/bbl to 3.0 lbm/bbl. In some such aspects, the insoluble latex particles are present in a concentration in a range from 0.1 lbm/bbl to 3.0 lbm/bbl. In some such aspects, the insoluble latex particles are present in a concentration in a range from 0.2 lbm/bbl to 3.0 lbm/bbl. In some aspects, the insoluble latex particles are present in a concentration in a range from 0.5 lbm/bbl to 1.5 lbm/bbl.
• the concentration of latex particles may be varied depending on the nature of aqueous and hydrocarbon phases, as well on the characteristics of any drill solids or other constituents that may be present in the drilling composition, for example, corrosion inhibitors, lubricants, oxygen scavengers, or other additives.
• the asphalt sulfonate may include a wide range of molecular weight species, related to the molecular weight distribution of an asphalt feedstock used to prepare the asphalt sulfonate.
• the sulfonated asphalt may be present as both soluble and colloidal sized particles in the drilling fluid.
• the asphalt sulfonate salt may be dispersed or dissolved in one or both phases, or may be substantially present in the aqueous phase.
• the asphalt sulfonate salt is present in the aqueous carrier, at least to a measurable extent or concentration. In some aspects, a majority, or substantially all, or essentially all, or an entirety of the asphalt sulfonate salt is present in the aqueous carrier.
• the asphalt sulfonate salt may be present in a concentration that is sufficient to stabilize the emulsion. In some aspects, the asphalt sulfonate salt is present in a concentration of at least 0.5 lbm/bbl, or at least 1 lbm/bbl of the composition. In some aspects, the asphalt sulfonate salt is present in a concentration of at least 4 lbm/bbl of the composition.
• An upper bound of a concentration of the asphalt sulfonate salt may be based on the concentration at which surfaces of the individual oil droplets are essentially saturated with asphalt sulfonate.
• the asphalt sulfonate salt is present in a concentration of less than 15 lbm/bbl. In some such aspects, the asphalt sulfonate salt is present in a concentration of less than 6 lbm/bbl of the composition. In some aspects the asphalt sulfonate salt is present in a concentration in a range from 1 lbm/bbl to 15 lbm/bbl. In some such aspects, the asphalt sulfonate salt is present in a concentration in a range from 4 lbm/bbl to 6 lbm/bbl.
• the asphalt sulfonate salt may include one or both of sodium asphalt sulfonate or potassium asphalt sulfonate.
• the asphalt sulfonate salt consists essentially of, or consists of, sodium asphalt sulfonate.
• Providing a combination of insoluble latex particles and asphalt sulfonate salt may promote stability of oil-in-water emulsions, and stability may be determined in terms of a period for which the emulsion does not exhibit changes in droplet size, dispersion, or separation.
• emulsions according to the disclosure are stable for at least 12 hours. In some aspects, the emulsion is stable for at least 1 day. In some aspects, the emulsion is stable for at least 3 days.
• Stability may be determined in response to exposure to elevated temperatures.
• the drilling mud composition does not exhibit oil separation, in response to hot- rolling for 16 hours at a temperature of 107 °C (225 °F).
• drilling mud compositions according to the present disclosure may exhibit suitable or acceptable drilling properties.
• drilling mud compositions according to the present disclosure may exhibit a fluid loss of less than 3 mL over 30 minutes at 100 lbs per square inch (API fluid loss).
• API fluid loss is less than 2.5 mL.
• the fluid loss may be 2.2 mL.
• Drilling mud compositions according to the present disclosure may also exhibit suitable, acceptable, or improved coefficient of friction compared to compositions that do not include latex or asphalt sulfonate salt.
• drilling mud compositions according to the present disclosure may exhibit a coefficient of friction of less than 0.25 at 38 ° C (100 °F).
• Drilling mud compositions according to the present disclosure may include further agents or components.
• a composition further may further include a xanthan gum.
• a composition further includes a polyanionic cellulose polymer.
• Water-based drilling mud compositions may be formed according to any suitable techniques.
• a technique includes emulsifying a precursor composition to form a water-based drilling mud composition according to the present disclosure.
• the precursor composition may include an aqueous carrier, a powdered dry latex, and an asphalt sulfonate salt.
• the emulsifying comprises subjecting the precursor composition to a high shear in a wellbore formation or in a mixer.
• the precursor composition may be sheared outside a formation, and then introduced into the formation.
• the precursory composition may be sheared within the formation, for example, by recirculation through a pump and/or a mixer.
• the emulsifying comprises subjecting the precursor composition to mixing at at least 3000 rotations per minute (rpm) in the mixer.
• the oil phase may be introduced before or during the mixing.
• the mixing and/or emulsification may be performed as a batch process, or as a continuous process.
• the technique may further include adding an oil-based composition to the precursor composition during the emulsifying.
• the precursor composition further includes the oil-based composition, for example, before mixing or emulsification is initiated.
• the present disclosure provides water-based drilling compositions (for example, oil- in-water emulsions) that exhibit improved stability, and techniques for forming such compositions, and techniques for drilling a formation using such compositions.
• water-based drilling compositions for example, oil- in-water emulsions
• HTHP high temperature high pressure
• PPT permeability plugging test
• ASB-1 a blend of SAS and XP-211 styrene butadiene copolymer latex, also known as AxilatTM PSB 150 (Synthomer, Roebuck, South Carolina).
• a base mud composition included 7.0 pounds per barrel (lbm/bbl) of bentonite, 2 lbm/bbl of polyanionic cellulose, 0.75 lbm/bbl of a biopolymer, 10 lbm/bbl of Rev DustTM Inert Particulate (Milwhite, Inc., Brownsville, Texas), 0.5 lbm/bbl of caustic soda, and 2 lbm/bbl of sodium sulfite.
• the base composition had a density of 8.6 lbm/gal.
• FIG. 1 is a chart illustrating lowered high temperature high pressure (HTHP) fluid loss at 250 °F for a water-based drilling mud composition including both sodium asphalt sulfonate (SAS) and powdered latex relative to compositions that do not include one or both of SAS or latex.
• Sample D1 exhibited a reduction in HTHP loss of 28% relative to sample Bl, and 30% relative to sample Cl.
• CoF coefficient of friction
• Sample D1 (60/40 SAS-latex) exhibited a CoF that was generally lower than samples B1 (SAS) and Cl (latex), for example, at a torque of 250 in-lb.
• the properties of water-based drilling mud compositions including different concentrations of powdered latex and sodium asphalt sulfonate (SAS) were evaluated.
• the base mud composition included 7.0 lbm/bbl of bentonite, 2 lbm/bbl of poly anionic cellulose, 0.75 lbm/bbl of a biopolymer, 10 lbm/bbl of Rev DustTM Inert Particulate (Milwhite, Inc.,
• the base composition had a density of 9.0 lbm/gal.
• FIG. 2 is a chart illustrating the lowered permeability plugging test (PPT) fluid loss at 250 °F for water-based drilling mud compositions including both SAS and powdered latex and having a greater concentration of SAS than that of powdered latex relative to compositions that do not include one or both of SAS or latex.
• Sample F2 75/25 SAS-latex
• Sample F2 exhibited a reduction in PPT loss relative to both samples B2 (SAS) and C2 (latex) and also relative to samples D2 (25/75 SAS-latex) and E2 (50/50 SAS-latex).
• EXAMPLE 3 The properties of water-based drilling mud compositions including different concentrations of powdered latex and sodium asphalt sulfonate (SAS) were evaluated.
• the base mud composition included 7.0 lbm/bbl of bentonite, 2 lbm/bbl of poly anionic cellulose, 0.75 lbm/bbl of a biopolymer, 10 lbm/bbl of Rev DustTM Inert Particulate (Milwhite, Inc., Brownsville, Texas), 0.5 lbm/bbl of caustic soda, 2 lbm/bbl of sodium sulfite, and 20.6 lbm/bbl of barite.
• the base composition had a density of 9.0 lbm/gal.
• Samples F3 75/25 SAS-latex
• G3 60/40 SAS-latex
• H3 70/30 SAS-latex
• CoF CoF that was generally lower than samples B1 (SAS) and Cl (latex), for example, at a torque of 250 in-lb.
• a base composition was prepared similar to that of EXAMPLE 3.
• Four samples were prepared: A4) base, B4) base with 6 lbm/bbl SAS, C4) base with 6 lbm/bbl powdered latex, and D4) base with 4.8 lbm/bbl SAS and 1.2 lbm/bbl powdered latex (80/20 or 4:1 SAS-latex blend).
• the samples were hot rolled for 16 hours at 250 °F.
• the rheological properties of samples A4 to D4 were determined and are presented in TABLE 8. Table 8
• FIG. 3 is a chart illustrating the lowered PPT fluid loss at 325 °F for water-based drilling mud compositions including both SAS and powdered latex and having a greater concentration of SAS than that of powdered latex relative to compositions that do not include one or both of SAS or latex.
• FIG. 4 is a chart illustrating the PPT fluid loss at 325 °F for the water-based drilling mud compositions including both SAS and powdered latex and having a greater concentration of SAS than that of powdered latex relative to compositions that do not include one or both of SAS or latex.
• Sample D4 with the 80/20 SAS-latex blend generally exhibited a decrease in PPT compared to samples A4 (base), B4 (SAS), and C4 (latex).
• FIG. 5 is a chart illustrating the lowered PPT fluid loss for water-based drilling mud compositions including both SAS and powdered latex and having a greater concentration of SAS than that of powdered latex relative to compositions that do not include SAS or latex at different temperatures (250 °F, 275 °F, and 300 °F).
• the mud with 80/20 SAS-latex blend was stable between 250 °F and 300 °F.
• a base composition was prepared similar to that of EXAMPLE 3.
• Four samples were prepared: A6) base, B6) base with 4.8 lbm/bbl SAS and 1.2 lbm/bbl powdered latex type A (a styrene butadiene copolymer, AxilatTM PSB 150, also known as XP-211, Synthomer, Roebuck, South Carolina) (80/20 or 4:1 SAS-latex blend), C6) base with 4.8 lbm/bbl SAS and 1.2 lbm/bbl powdered latex type B (VAE-RS 1220, Riteks, Houston, Texas) (80/20 or 4:1 SAS-latex blend), and D6) base with 4.8 lbm/bbl SAS and 1.2 lbm/bbl powdered latex type C (VAE-RS 1420,
• FIG. 6 is a chart illustrating PPT fluid loss at 275 °F for water-based drilling mud compositions including both SAS and different types of powdered latex and having a greater concentration of SAS than that of powdered latex relative to compositions that do not include SAS.
• EXAMPLE 7 The properties of oil-based drilling mud compositions including different concentrations of SAS and latex were evaluated.
• the base mud composition included 5.0 lbm/bbl of oleophilic clay, 6.0 lbm/bbl of a primary emulsifier, 6.0 lbm/bbl of an oil wetting agent, 0.5 lbm/bbl of Rev DustTM Inert Particulate (Milwhite, Inc., Brownsville, Texas), 25% of calcium chloride, 144.3 lbm/bbl of barite, 6.0 lbm/bbl of lime, and had an oil-water ratio of 85/15.
• the base composition had a density of 11.0 lbm/gal.
• FIG. 7 is a chart illustrating the lowered PPT fluid loss at 275 °F for oil-based drilling mud compositions including both SAS and powdered latex and having SAS in a concentration that is greater than or equal to that of powdered latex relative to compositions that do not include one or both of SAS or latex.
• EXAMPLE 8 The properties of oil-based drilling mud compositions including different concentrations of SAS and latex were evaluated.
• the base mud composition included 4.3 lbm/bbl of oleophilic clay, 4.25 lbm/bbl of a primary emulsifier, 0.8 lbm/bbl of an oil wetting agent, 1.0 lbm/bbl of a secondary emulsifier, 21.50 lbm/bbl of calcium chloride, 53 lbm/bbl of barite, 1.86 lbm/bbl of lime, and had an oil-water ratio of 85/15.
• the base composition had a density of 9.33 lbm/gal.
• FIG. 8 is a chart illustrating the lowered PPT fluid loss at 300 °F for oil-based drilling mud compositions including both SAS and powdered latex and having SAS in a concentration that is equal to that of powdered latex relative to compositions that do not include one or both of SAS or latex.
• Sample D8 (50/50 SAS-latex blend) exhibited a lowered PPT loss compared to samples A8 (base), B8 (latex), and C8 (SAS).
• the properties of oil-based drilling mud compositions including different concentrations of SAS and latex were evaluated.
• the base mud composition included 4.0 lbm/bbl of oleophilic clay, 5 lbm/bbl of a primary emulsifier, 4 lbm/bbl of an oil wetting agent, 25 % of calcium chloride, 302 lbm/bbl of barite, 4 lbm/bbl of lime, and had an oil- water ratio of 85/15.
• the base composition had a density of 13.6 lbm/gal.
• FIG. 9 is a chart illustrating the lowered PPT fluid loss at 300 °F for oil-based drilling mud compositions including both SAS and latex and having SAS in a concentration that is equal to that of powdered latex relative to compositions that do not include one or both of SAS or latex.
• Sample D9 (50/50 SAS-latex blend) exhibited a lowered PPT loss compared to samples A9 (base), B9 (latex), and C9 (SAS).
• a base mud composition included 7.0 pounds per barrel (lbm/bbl) of bentonite, 2 lbm/bbl of polyanionic cellulose, 0.75 lbm/bbl of a biopolymer, 10 lbm/bbl of Rev DustTM Inert Particulate (Milwhite, Inc., Brownsville, Texas), 0.5 lbm/bbl of caustic soda, and 2 lbm/bbl of sodium sulfite.
• the base composition had a density of 9.5 lbm/gal.
• FIG. 10 is a chart illustrating lowered PPT fluid loss and spurt loss at 275 °F for water-based drilling mud compositions including both SAS and powdered latex and having SAS in a concentration that is greater than that of powdered latex relative to compositions including other additives.
• Sample J10 including the SAS-latex blend exhibited a lower PPT loss and spurt loss than all other samples.
• the properties of oil-based drilling mud compositions including different additives were determined.
• the base mud composition included 9.0 lbm/bbl of oleophilic clay, 4.0 lbm/bbl of a primary emulsifier, 6.0 lbm/bbl of an oil wetting agent, 20 lbm/bbl of Rev DustTM Inert Particulate (Milwhite, Inc., Brownsville, Texas), 161.2 lbm/bbl of barite, 6.0 lbm/bbl of lime, 2.0 lbm/bbl of sodium sulfite, and had an oil-water ratio of 85/15.
• the base composition had a density of 11.0 lbm/gal.
• Sample Fll including the SAS-latex blend exhibited a higher electrical stability than all other samples, except for sample Hll including SAS.
• FIG. 11 is a chart illustrating lowered PPT fluid loss and spurt loss at 300 °F for oil- based drilling mud compositions including both SAS and powdered latex and having SAS in a concentration that is greater than that of powdered latex relative to compositions including other additives.
• Sample FI 1 including the SAS-latex blend exhibited a lower PPT loss and spurt loss than all other samples.
• EXAMPLE 12 The properties of water-based drilling mud compositions including different concentrations of SAS and powdered latex were evaluated.
• a base mud composition included 5.0 pounds per barrel (lbm/bbl) of bentonite, 17.5 lbm/bbl of potassium chloride, 0.5 lbm/bbl of HTHP polymer 1, HTHP polymer 2, 25% of a thinner, 50 lbm/bbl of calcium carbonate, and .75 lbm/bbl of caustic.
• the base composition had a density of 10.0 lbm/gal.
• FIG. 12 is a chart illustrating API and HTHP filtrate volumes at 375 °F for water- based drilling mud compositions including both SAS and powdered latex and having SAS in a concentration that is greater than that of powdered latex relative to compositions that do not include one or both of SAS or latex.
• Sample C12 with the SAS-latex blend exhibited a lower HTHP loss and a lower API loss than the other samples.
• EXAMPLE 13 The properties of water-based drilling compositions including different concentrations of SAS, powdered latex, and liquid latex were determined.
• a base mud composition included 7.0 pounds per barrel (lbm/bbl) of bentonite, 17.5 lbm/bbl of potassium chloride, 2 lbm/bbl of Drispac® SL Polymer (Drilling Specialties Company, The Woodlands, TX), 0.75 lbm/bbl of Flowzan® Biopolymer (Drilling Specialties Company, The Woodlands, TX), and .75 lbm/bbl of caustic.
• the base composition had a density of 9.2 lbm/gal.
• Sample C13 with the SAS-powdered latex blend had the highest shale recovery.
• the results of the CoF using EP Lubricity Meter were transformed calculating the Stribeck number to build the curve.
• the reduction of the CoF in the boundary lubrication region occurs when the asperities of the wellbore and the bit/BHA are in contact. This is explained by the adsorption of the novel solid-state lubricant onto the asperities providing a smooth surface.
• the novel solid-state lubricant has a wide particle distribution (PSD) to cover different size and height of asperities.
• PSD particle distribution
• the Stribeck curves of the novel solid-state lubricant show that the lubricant can reduce CoF in the boundary lubrication region where friction forces are highest as compared with a base fluid and other liquid lubricants.
• EP Lubricity Meter The more common lubricity test measures fluid resistance of various lubricating additives.
• the standard lubricity coefficient test is run at 60 rpm with 150 in-lb of force (the equivalent of approximately 600 psi (4,137 kPa) pressure of the intermediate fluid) and is applied to two hardened steel surfaces, a rotating ring, and a stationary block. Friction is measured as the CoF (m).
• the CoF between two solids is defined as the frictional force of the load or the force perpendicular to the surfaces.
• the CoF is independent of the apparent areas of contact as long as this area is not so small as to break through the film. The force to overcome friction will be the same for a small area as for a larger area.
• the force, F, required to slide the block and the ring surfaces across each other at a given rate is measured by the power required to turn the test ring shaft at a prescribed rate of revolutions per minute.
• the Coefficient of Friction (CoF), m Meter Reading /Load or force.
• the Lubricity Evaluation Monitor is a laboratory device designed to evaluate lubricants by direct comparison. It determines the CoF between an interchangeable wellbore sample (casing, formation, sandstone, etc.) pressed against a rotating steel bob while immersed in a circulating cup of test fluid.
• the LEM measures relative friction factors under ambient temperature and pressure. It is purpose- designed to provide lubricity comparisons between different fluid systems and/or fluid additives.
• the unit can utilize frictional materials such as sandstone or casing.
• a pneumatic ram applies side load, pushing the bob against the sample, periodically refreshing the test fluid by pulling the bob away from the sample at definable intervals.
• the clamp allows samples of casing, formation, sandstone, etc.
• the LEM has computerized data acquisition and control software. The user inputs rotational speed, side load, and refresh parameters. Testing archives provide access to historical data graphs which include: rotational speed (RPM), torque (in-lb), side load (lb), and CoF with respect to time. The test is run, and the machine collects 600 data points or until CoF values have been stabilized.
• Tribometer When lubrication is applied to reduce the wear/friction of moving surfaces, the lubrication contact at the interface can shift from several regimes such as Boundary, Mixed, and Hydrodynamic Lubrication.
• the thickness of the fluid film plays a major role in this process, mainly determined by the fluid viscosity, the load applied at the interface, and the relative speed between the two surfaces. How the lubrication regimes react to friction is shown in what is called a Stribeck curve.
• the trobometer shows a method with the ability to measure a continuous Stribeck Curve. Using advanced step-less speed control, from 2000 to 0.01 rpm, within 10 minutes the software directly provides a complete Stribeck Curve.
• the simple initial setup only requires users to select the Exponential Ramp Mode and enter initial and final speeds, rather than having to perform multiple tests or program a stepwise procedure at different speeds requiring data stitching for the conventional Stribeck curve measurements.
• the Stribeck Curve plots the CoF as a function of viscosity, speed, and load. The vertical axis is the CoF and the horizontal axis is a parameter that combines the other variables.
• Measuring objective The Stribeck curves were measured using two lubricant oils with different kinetic viscosities for comparison. A pin-on-disk tribometer equipped with the lubrication module was used. The rotational speed decreased at an exponential rate from 2000 to 0.01 rpm to showcase the continuous Stribeck Curve measurement and the precise sensitivity of the tribometer capabilities.
• the initial lubricity data was obtained using the standard EP lubricity meter.
• the CoF is defined based on the torque load of 150 in-lb while rotating at 60 rpm.
• the shape of the adjusted curve exhibited a characteristic profile.
• the solid-like lubricant (4: 1 or 80/20 SAS-latex blend) presented lower CoF at lower torque loads.
• FIG. 13 is a chart illustrating variation in coefficient of friction with torque for oil-based drilling mud compositions including a solid lubricant.
• the results of the EP Lubricity Meter were then plotted to build the Stribeck curve.
• the curve was used to present the EP Lubricity Meter data in a manner to show the importance of the solid-like lubricant in the boundary lubrication regime where the surfaces of the block and ring are in more close contact and obtain better correlation with lubricity data obtained with the Tribometer.
• the Stribeck number plays a similar role as the Reynolds number in fluids hydrodynamics. Usually two variables are maintained constant and another variable is changed.
• FIG. 14 is a chart illustrating variation in coefficient of friction with Stribeck number for oil-based drilling mud compositions excluding and including a solid lubricant.
• the base drilling mud composition included 8.2 lbm/bbl 90/10 OWR (oil-water ratio) with Gibson D822 oil (Gibson Energy, Houston, Texas).
• FIG. 15 is a chart illustrating variation in coefficient of friction with Stribeck number for oil-based drilling mud compositions excluding and including a solid lubricant and the particulate friction reducing material.
• the base drilling mud composition included 8.2 lbm/bbl 90/10 OWR with Gibson D822 oil (Gibson Energy, Houston, Texas).
• FIG. 16 is a chart illustrating variation in coefficient of friction with Stribeck number for oil-based drilling mud compositions excluding and including a solid lubricant and an organophibc clay.
• a lab sample of 85/15 OWR and 11.0 lbm/gallon Diesel OBM and a sample of base fluid with 2.0 lbm/bbl of solid-state lubricant were tested in the LEM. Although the measured CoF of both samples were 0.12, an assessment of the data showed that the fluid containing no solid-like lubricant presented a higher CoF static compared with the fluid containing the solid-state lubricant.
• the CoF static is the maximum peak observed in the initial part of each stage while the rotor starts moving in the boundary condition.
• the Stribeck curves of fluids containing the solid-state lubricant (4: 1 or 80/20 SAS- latex blend) as compared to liquid lubricants and their performance under boundary conditions were evaluated.
• the tribometer has the ability of producing a continuous Stribeck curve while varying the rpm between 0.01 and 1000 rpm. Instrument rotation speeds between 0.01 and 250 rpm were used for practical purposes. A fixed load of 150 in-lb was also selected while measuring the CoF values.
• the same fluid tested in the LEM was used to build the Stribeck curves using the tribometer.
• Four tests were run including the base fluid (BF) and samples of base fluid containing 2.0 lbm/bbl of solid-state lubricant and 2% by volume of two liquid lubricants.
• FIG. 17 is a chart illustrating coefficient of friction with time for a base oil-based drilling mud composition.
• FIG. 18 is a chart illustrating coefficient of friction with time for a base oil-based drilling mud composition including the solid lubricant.
• FIG. 19 is a chart illustrating variation of coefficient of friction with Stribeck number for oil-based drilling mud compositions excluding lubricant, including a solid lubricant, and including two different liquid lubricants.
• Lubricant 2 (Torque-Buster, Franklin Well Services, Vincennes, Indiana) showed a poor performance and caused adverse effect on the CoF of the base fluid.
• Lubricant 1 (Turbo- Lube, Farm-Oyl®, St. Paul, MN) presented better performance compared with Lubricant 2, providing a slight decrease of the CoF static and a similar CoF dynamic.
• the solid-state lubricant produced both a reduction of static and dynamic CoF in the entire range of rpm.
• the solid lubricant works in the boundary lubrication regime by producing atribofilm, which reduces the viscosity.
• a field trial using the novel solid lubricant was conducted in the Permian Basin using a direct emulsion water-based mud.
• the purpose of the field trial was to evaluate the potential replacement of the OBM by the direct emulsion mud and the solid-state lubricant (4:1 or 80/20 SAS-latex blend).
• the solid-state lubricant was added by pill application at a concentration of 3.0 lbm/bbl until reaching the final concentration of 3.0 lbm/bbl in the circulating system. The operator increased the concentration up to 6.0 lbm/bbl by interval total depth.
• FIG. 20 is a chart illustrating variation of upweight and downweight along a horizontal section with depth. While an increase of both upweight and downweight as depth increases is expected, both curves show a decrease of both measurements. The trend of the two curves are smooth when the concentration of the solid lubricant reached 3.0 lbm/bbl in the whole system.
• EXAMPLE 19 The effect of latex and/or xanthan on properties of different water-based drilling compositions was analyzed.
• Table 25 The compositions shown in TABLE 25.
• FIG. 21 is a chart illustrating coefficient of friction for the sample water- based drilling compositions in which latex is absent or present.
• the sample with latex had the lowest CoF (highest lubricity).
• a drilling mud composition comprising: a first concentration of powdered latex; and a second concentration of sodium asphalt sulfonate (SAS), wherein the second concentration of SAS (by mass) is greater than or equal to the first concentration of latex (by mass).
• SAS sodium asphalt sulfonate
• HTHP high temperature high pressure
• PPT average permeability plugging test
• API American Petroleum Institute
• API American Petroleum Institute
• a method comprising dispersing a first predetermined amount of powdered latex and a second predetermined amount of SAS in a water-based carrier to form a water-based mud comprising the composition of any of aspects 1 to 18.
• PPT average permeability plugging test
• API American Petroleum Institute
• a method comprising dispersing a first predetermined amount of powdered latex and a second predetermined amount of SAS in an oil-based carrier to form an oil-based mud comprising the composition of any of aspects 1 to 6 or 20 to 28.
• a water-based drilling mud composition comprising: an aqueous carrier; an asphalt sulfonate salt; and insoluble latex particles, wherein the insoluble latex particles promote stabilization of an emulsion formed in response to introduction of an oil phase in the composition.
• composition of aspect 34 wherein the insoluble latex particles have a population- averaged particle size in a range of less than 0.500 micrometers.
• composition of aspect 35, wherein the insoluble latex particles have a population- averaged particle size in a range of less than or about 0.150 micrometers.
• a water-based drilling mud composition comprising an oil-in-water emulsion, the emulsion comprising: an aqueous carrier; an oil phase dispersed as droplets in the aqueous carrier; an asphalt sulfonate salt; and insoluble latex particles, wherein the insoluble latex particles are present in an oil-water interface between the oil phase and an aqueous phase of the aqueous carrier.
• a water-based drilling mud composition comprising an oil-in- water emulsion, the emulsion comprising: an aqueous carrier; an oil phase dispersed as droplets in the aqueous carrier; an asphalt sulfonate salt; and insoluble latex particles, wherein the insoluble latex particles have a population-averaged particle size in a range of less than or about 0.150 micrometers.
• composition of any of aspects 30 to 41, wherein the insoluble latex particles comprise particles of at least one of a styrene butadiene copolymer or a vinyl acetate ethylene copolymer.
• a method comprising emulsifying a precursor composition to form the water-based drilling mud composition of any of aspects 30 to 72, wherein the precursor composition comprises an aqueous carrier, a powdered agglomerated dry latex, and an asphalt sulfonate salt.
• emulsifying comprises subjecting the precursor composition to a high shear in a wellbore formation or in a mixer.
• emulsifying comprises subjecting the precursor composition to mixing at at least 3000 rotations per minute (rpm) in the mixer.
• the precursor composition further comprises an oil-based composition.
• the emulsifying causes the powdered agglomerated dry latex to disperse to form insoluble latex particles, the insoluble latex particles having a population-averaged particle size in a range of less than or about 0.150 micrometers.

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