Xianfa Zhang

With the continuous increase in horizontal displacement during unconventional oil and gas drilling, drilling operations are commonly plagued by high frictional resistance, severe pipe sticking issues and difficulties in directional drilling. Conventional single-component water-based drilling fluid lubricants fail to satisfy multifunctional demands, including high-temperature resistance, salt tolerance and long-term lubrication. In this work, a novel microsphere lubricant, RB-Si, with high-temperature and high-salinity resistance was developed by combining the merits of solid and liquid lubricants. The product was synthesized using myristic acid and triethanolamine as raw materials via co-reaction with boric acid and nano-silica. Laboratory tests reveal that after aging at 180 °C, the lubrication coefficient reduction rates of based mud, saturated salinity-based mud and a high-density (2.0 g/cm³) drilling fluid gel system containing 1.0 wt% RB-Si reached 90.1%, 83.3% and 62.8%, respectively. Meanwhile, RB-Si can effectively plug the micropores in the filter cake, reduce fluid loss, inhibit shale hydration and swelling, and exhibit excellent compatibility with drilling fluids. RB-Si rapidly adsorbs onto the surfaces of metallic drill strings and formation rocks to construct a durable and high-strength lubricating film, accompanied by the rolling friction of the incorporated microspheres, thereby reducing frictional drag between the drill string/casing and the drill string/borehole wall. This lubricant effectively mitigates high frictional resistance under prolonged friction conditions, and is expected to provide technical support for long-horizontal-well drilling.

Drilling fluids play an essential role in shale gas development. It is not possible to scale up the use of water-based drilling fluid in shale gas drilling in Yunnan, China, because conventional inhibitors cannot effectively inhibit the hydration of the illite-rich shale formed. In this study, the inhibition performance of modified asphalt was evaluated using the plugging test, expansion test, shale recovery experiment, and rock compressive strength test. The experimental results show that in a 3% modified asphalt solution, the expansion of shale is reduced by 56.3%, the recovery is as high as 97.8%, water absorption is reduced by 24.3%, and the compression resistance is doubled compared with those in water. Moreover, the modified asphalt can effectively reduce the fluid loss of the drilling fluid. Modified asphalt can form a hydrophobic membrane through a large amount of adsorption on the shale surface, consequently inhibiting shale hydration. Simultaneously, modified asphalt can reduce the entrance of water into the shale through blocking pores, micro-cracks, and cracks and further inhibit the hydration expansion of shale. This demonstrates that modified asphalt will be an ideal choice for drilling shale gas formations in Yunnan through water-based drilling fluids.

Ensuring wellbore stability is of utmost importance for safety when drilling in deep formations. However, high temperatures severely disrupt the drilling fluid gel system, leading to severe stability issues within ultra-deep formations containing micropores. This study focused on the development of a polymer-based plugging material capable of withstanding high temperatures up to 200 °C. A kind of microsphere, referred to as SST (styrene–sodium styrene sulfonate copolymer), was synthesized with a particle size of 322 nm. Compared to polystyrene, the thermal stability of SST is greatly improved, with a thermal decomposition temperature of 362 °C. Even after subjecting SST to hot rolling at 200 °C for 16 h, the particle size, elemental composition, and zeta potential remained stable within an aqueous dispersion system. The results of core displacement and NMR tests demonstrate that SST considerably reduces the pore diameter with a remarkable plugging efficiency of 78.9%. Additionally, when drilling fluids reach 200 °C, SST still enhances drilling fluid suspension and dispersion, and reduces fluid loss by over 36% by facilitating the dispersion of clay particles, improving the gel structure of the drilling fluid, resisting clay dehydration, and promoting plugging. The development of SST provides valuable insights into the preparation of high-temperature-resistant microspheres and the formulation of effective plugging agents for deep-well drilling fluids.

With the gradual depletion of shallow oil and gas, deep oil and gas has become the focus of development. However, deep formations generally face the challenge of high-temperature and high-salinity, and drilling fluid agents are prone to failure, leading to drilling fluid intrusion into the formation that can cause serious drilling accidents such as well bore collapse. For this, a styrene-based nano-microsphere (SSD) modified with amphoteric ions was developed, with a particle size of 228 nm which could resist temperatures up to 200 °C and sodium chloride (NaCl) up to saturation. SSD has significant salt-responsive properties and its aqueous dispersion becomes transparent with increasing salinity. The SSD provided superior plugging performance in solutions containing NaCl, with a core plugging efficiency of 95.2%, and it was significantly better than the anion-modified microspheres. In addition, in drilling fluids under high temperature and high-salinity conditions, the SSD promotes particle gradation of drilling fluids and improves the zeta potential through its own plugging and synergistic effect with clay, which significantly improves the comprehensive performance of drilling fluids, such as stability, rheological performance, and filtration reduction performance. The development of SSD provides a new idea for research of high-temperature and high-salinity-resistant drilling fluid agents.

During drilling in deep formations, it is challenging to form an effective plug to avoid borehole collapse under high temperatures and pressures. In order to simultaneously improve the high‐temperature resistance and interparticle interaction capability of traditional plugging agents, a new gel plugging agent (PCAA) with self‐healing capability was developed using chitosan, acrylamide, and acrylic acid. The rheological properties of the PCAA indicate that all monomers of PCAA are essential components to improve the performance of the plugging agent. Each monomer has a unique capability, such as acrylamide playing a dominant role in the construction of the gel network, acrylic acid enhancing the gel structure, and chitosan improving the gel adhesion. PCAA can be stretched to 8.8 times prolonged, and its tensile stresses and self‐healing rate in 16 h are 17.2 kPa and 78.5%, respectively. Under the extreme conditions of 180°C and 8% NaCl, PCAA still performs well in preventing drilling fluid from invading the sand layer due to its self‐healing and plugging effects. In addition, the interaction of PCAA and clay improves the stability, rheological properties, and filtration reduction of drilling fluids at high temperatures. The developed PCAA has been successfully applied to the field with extreme conditions, providing insights into plugging agent design.