Encapsulated lost circulation materials based on shape-memory polymer foam

Patent metadata

Field	Value
Publication number	US-12258821-B2
Application number	US-202318449378-A
Country	US
Kind code	B2
Filing date	Aug 14, 2023
Priority date	Aug 14, 2023
Publication date	Mar 25, 2025
Grant date	Mar 25, 2025

Abstract

An encapsulated lost circulation material includes: a particulate having a core including a compressed shape-memory polymer foam, and a disintegrating agent, the disintegrating agent including at least one of a phase change material or a gas-producing material; and a shell encapsulating the core. A method of reducing lost circulation includes: introducing into a subsurface a wellbore fluid including the encapsulated lost circulation material; heating the disintegrating agent to cause the phase change material to expand, or to cause the gas-producing material to produce a gas, or a combination thereof to break the shell; and releasing the compressed shape-memory polymer foam from the encapsulated lost circulation material; expanding the released shape-memory polymer foam; and filling a void or fracture of the subsurface with the expanded compressed shape-memory polymer foam to reduce fluid loss.

First claim

What is claimed is:

1. An encapsulated lost circulation material comprising a particulate having
a core comprising a compressed shape-memory polymer foam and a disintegrating agent, the disintegrating agent comprising a phase change material; and
a shell encapsulating the core,
wherein the phase change material has (i) a phase transition temperature between 125° F. and 1,000° F. and (ii) a volumetric expansion of at least 3% during a phase transition relative to a volume of the phase change material before the phase transition wherein the volumetric expansion exerts sufficient pressure on the shell to break the shell and release the compressed shape-memory polymer foam.

2. The encapsulated lost circulation material of claim 1 , wherein the phase change material comprises at least one of an inorganic salt, an eutectic mixture of inorganic salts, a metal hydroxide, an eutectic mixture of an inorganic salt with an organic material, a hydrate of an inorganic salt, a hydrate of metal hydroxide, or an organic material, wherein the organic material is selected from the group consisting of a paraffin, d-mannitol, hydroquinone, adipic acid, urea, acetamide, erythritol, phthalic anhydride, maleic acid, 2-chlorobenzoic acid, a sugar, a sugar alcohol, and a fatty acid.

3. The encapsulated lost circulation material of claim 1 , wherein the shell comprises at least one of alginate, cellulose, starch, chitosan, dextran sulfate, pectin, xanthan gum, a polymethacrylate, a polydimethylsiloxane, a polystyrene, a polyvinyl acetate, a polyvinylpyrrolidone, silica, alumina, titania, sodium silicate, calcium carbonate, nickel, nickel phosphorus, a nickel alloy, an iron oxide, an oxyhydroxide, or an iron salt.

4. The encapsulated lost circulation material of claim 1 , wherein the compressed shape-memory polymer foam comprises closed cells.

5. The encapsulated lost circulation material of claim 1 , wherein the compressed shape-memory polymer foam comprises open cells.

6. The encapsulated lost circulation material of claim 1 , further comprising a magnetic material.

7. The encapsulated lost circulation material of claim 6 , wherein the magnetic material is disposed in the shell of the encapsulated lost circulation material.

8. The encapsulated lost circulation material of claim 6 , wherein the magnetic material is disposed in the core of the encapsulated lost circulation material.

9. The encapsulated lost circulation material of claim 6 , wherein the magnetic material is coated on the disintegrating agent.

10. A wellbore fluid comprising a carrier and the encapsulated lost circulation material of claim 1 .

11. The wellbore fluid of claim 10 , wherein the wellbore fluid is a drilling fluid.

12. The wellbore fluid of claim 10 , further comprising an activator.

13. A method of reducing lost circulation, the method comprising:
introducing into a subsurface a wellbore fluid comprising an encapsulated lost circulation material having (1) a core comprising a compressed shape-memory polymer foam and a disintegrating agent, the disintegrating agent comprising a phase change material, and (2) a shell encapsulating the core, wherein the phase change material has (i) a phase transition temperature between 125° F. and 1000° F. and (ii) a volumetric expansion of at least 3% during a phase transition relative to a volume of the phase change material before the phase transition;
heating the disintegrating agent to cause the volumetric expansion of the phase change material to break the shell; and
releasing the compressed shape-memory polymer foam from the encapsulated lost circulation material;
expanding the released shape-memory polymer foam; and
filling a void or fracture of the subsurface with the expanded compressed shape-memory polymer foam to reduce fluid loss.

14. The method of claim 13 , wherein the wellbore fluid is a drilling fluid.

15. The method of claim 13 , wherein the encapsulated lost circulation material further comprises a magnetic material.

16. The method of claim 15 , wherein the method further comprises applying an electromagnetic radiation to the magnetic material to generate heat, and heating the disintegrating agent with the heat generated from the magnetic material.

17. The method of claim 13 , wherein expanding the released shape-memory polymer foam comprises contacting the released shape-memory polymer with the wellbore fluid, wherein the wellbore comprises an activator.

Assignees

• Baker Hughes Oilfield Operations Llc

Inventors

• Dolog Rostyslav
• Darugar Qusai A
• Suresh Radhika
• Mazyar Oleg

Classifications

• C09K8/518

  Foams · CPC title

• C09K8/035

  Organic additives · CPC title

• C09K8/536

  characterised by their form or by the form of their components, e.g. encapsulated material · CPC title

• C09K8/516

  characterised by their form or by the form of their components, e.g. encapsulated material · CPC title

• E21B21/003 Primary

  Means for stopping loss of drilling fluid (plastering the borehole wall E21B33/138) · CPC title