US-12624274-B2 - Lost circulation compositions comprising red mud

Abstract

The invention is directed to lost circulation material (LCM) compositions capable of forming geopolymers, said LCM compositions comprising red mud, a silica source, a developed alkaline activator (DAA), and an aqueous source, and methods and systems related thereto for treating a lost circulation zone within a subterranean formation using the LCM compositions which form said geopolymers therein so as to at least partially prevent lost circulation.

Inventors

• Khawlah ALANQARI
• Abdullah Al-Yami
• Mohammad Alharthi

Assignees

• SAUDI ARABIAN OIL COMPANY

Dates

Publication Date

20260512

Application Date

20240809

Claims (17)

1. 1 . A method comprising: providing a lost circulation material (LCM) composition comprising: a red mud; a silica source comprising silicon dioxide (SiO 2 ); a developed alkaline activator (DAA), wherein the DAA comprises a sodium silicate ((SiO 2 ) n :Na 2 O) and sodium hydroxide (NaOH); and an aqueous source; wherein the red mud comprises a sodium content in an amount in the range of about 20 wt. % to about 40 wt. % based on total weight of the red mud; placing the LCM composition in a lost circulation zone in a subterranean formation; and allowing the LCM composition to set to form a geopolymer in the lost circulation zone so as to at least partially prevent lost circulation.
2. 2 . The method of claim 1 , wherein the red mud is present in the LCM composition in an amount in the range of about 50 wt. % to about 70 wt. % based on total solids in the LCM composition.
3. 3 . The method of claim 1 , wherein the silica source further comprises silica fume, Portland cement, or any combination thereof.
4. 4 . The method of claim 1 , wherein the silica source is present in the LCM composition in an amount in the range of about 0.1 wt. % to about 50 wt. % based on total weight of the red mud.
5. 5 . The method of claim 1 , wherein the DAA comprises sodium silicate and sodium hydroxide at a molar ratio of about 1.5:1 to about 2.5:1.
6. 6 . The method of claim 1 , wherein the LCM composition comprises silicon dioxide and aluminum oxide in a molar ratio of about 2 to about 4.
7. 7 . The method of claim 1 , wherein the LCM composition comprises the DAA and aluminum oxide in a molar ratio of about 0.4 to about 1.
8. 8 . The method of claim 1 , wherein the aqueous source comprises an aqueous source selected from the group consisting of deionized water, tap water, fresh water, salt water, natural brine, synthetic brine, municipal water, formation water, produced water, well water, filtered water, distilled water, sea water, purified contaminated water, and any combination thereof.
9. 9 . The method of claim 1 , wherein the aqueous source is present in the LCM composition in an amount in the range of about 10 wt. % to about 70 wt. % based on total weight of the red mud.
10. 10 . The method of claim 1 , wherein the LCM composition further comprises a calcium source; wherein the calcium source is present in the LCM composition in an amount in the range of about 2 wt. % to about 8 wt. % based on total weight of the red mud; and wherein the calcium source is lime.
11. 11 . The method of claim 1 , wherein the LCM composition has a density in the range of about 70 lb/ft 3 to about 170 lb/ft 3 .
12. 12 . The method of claim 1 , wherein the LCM composition has a viscosity in the range of about 10 cP to about 150 cP.
13. 13 . The method of claim 1 , wherein the LCM composition has a plastic viscosity in the range of about 10 cP to about 50 cP and a yield point in the range of about 2 lbf/100 ft 2 to about 40 lbf/100 ft 2 .
14. 14 . The method of claim 1 , wherein the LCM composition has a thickening time at a temperature of about 100° F. of about 1 hour to about 6 hours and a setting time at a temperature of about 180° F. of equal to or greater than about 24 hours.
15. 15 . The method of claim 1 , wherein, after setting the LCM composition at a temperature of about 180° F. and a time of about 24 hours, the geopolymer has a compressive strength in the range of about 500 psi to about 700 psi.
16. 16 . The method of claim 1 , wherein the formation temperature conditions are in the range of 70° F. to 290° F.
17. 17 . A system comprising: a tubular extending into a wellbore in a subterranean formation; and a pump fluidly coupled to the tubular, wherein the pump is configured to convey a lost circulation material (LCM) composition into the wellbore via the tubular at a pressure sufficient for the LCM composition to penetrate a lost circulation zone of the subterranean formation, the LCM composition comprising: a red mud; a silica source comprising silicon dioxide (SiO 2 ); a developed alkaline activator (DAA), wherein the DAA comprises a sodium silicate ((SiO 2 ) n :Na 2 O) and sodium hydroxide (NaOH); and an aqueous source; and wherein the red mud comprises a sodium content in an amount in the range of about 20 wt. % to about 40 wt. % based on total weight of the red mud.

Description

FIELD OF THE DISCLOSURE The present disclosure relates generally to geopolymer lost circulation compositions comprising red mud and methods and systems related thereto. BACKGROUND OF THE DISCLOSURE Hydrocarbon producing wells are typically formed by drilling a wellbore into a subterranean formation. A drilling fluid is circulated through a drill bit within the wellbore as the wellbore is being drilled. The drilling fluid is produced back to the surface of the wellbore with drilling cuttings. The drilling fluid maintains a specific, balanced hydrostatic pressure within the wellbore, permitting all or most of the drilling fluid to be produced back to the surface. However, the hydrostatic pressure of the drilling fluid may be compromised if the drill bit encounters certain unfavorable subterranean zones, such as low-pressure zones caused by natural fissures, fractures, vugs, or caverns into which the drilling fluid may become lost into the formation, termed “lost circulation zones” or “fluid loss zones.” After a wellbore is drilled, a cement column may be placed around a casing (or liner string) in the wellbore. In some instances, the cement column is formed by pumping a cement slurry through the bottom of the casing and out through an annulus between the outer casing wall and the formation face of the wellbore. The cement slurry then cures in the annular space, thereby forming a sheath of hardened cement that, among other functions, supports and positions the casing in the wellbore and bonds the exterior surface of the casing to the subterranean formation. However, like drilling fluid, the cement slurry may be lost to lost circulation zones, thereby compromising the integrity of the cement column. Stimulation of subterranean formations may be performed using fracturing operations using a fracturing fluid to obtain hydrocarbons. During stimulation, the fracturing fluid may become lost to lost circulation zones, as well. In such circumstances, the fracturing operation may be compromised. The consequences of these types of lost circulation may be economically and environmentally devastating, ranging from minor volume loss of treatment fluids (e.g., drilling fluids, cement slurries, fracturing fluids, and the like), to delayed drilling and production operations, to an underground well blow-out, and the like. Therefore, the occurrence of fluid loss during hydrocarbon well operations typically require immediate remedial steps. Remediation often involves introducing a composition into the wellbore to seal unfavorable subterranean zones and prevent leakoff of the treatment fluids within the formation to lost circulation zones. Such compositions are generally referred to as “lost circulation material (LCM)” compositions. Some previously disclosed LCM compositions are toxic and thus may harm the environment. Due to environmental regulations, costly procedures often must be followed to dispose of the treatment fluids containing such LCM compositions, ensuring that they do not contact the marine environment and groundwater. Thus, it is desirable to use low environmental impact additives for fluid loss control. SUMMARY OF THE DISCLOSURE Various details of the present disclosure are hereinafter summarized to provide a basic understanding. This summary is not an extensive overview of the disclosure and is neither intended to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter. According to an embodiment consistent with the present disclosure, lost circulation material (LCM) methods comprise: providing a lost circulation material (LCM) composition comprising: a red mud; a silica source; a developed alkaline activator (DAA); and an aqueous source; placing the LCM composition in a lost circulation zone in a subterranean formation; and allowing the LCM composition to set to form a geopolymer in the lost circulation zone so as to at least partially prevent lost circulation. According to an embodiment consistent with the present disclosure, LCM compositions comprise: a red mud comprising aluminum oxide and silicon dioxide; a silica source; a developed alkaline activator (DAA) comprising sodium hydroxide and sodium silicate; and an aqueous source. According to an embodiment consistent with the present disclosure, LCM systems comprise: a tubular extending into a wellbore in a subterranean formation; and a pump fluidly coupled to the tubular, wherein the pump is capable of conveying a lost circulation material (LCM) composition into the wellbore via the tubular at a pressure sufficient for the LCM composition to penetrate a lost circulation zone of the subterranean formation, the LCM composition comprising: a red mud comprising aluminum oxide and silicon dioxide; a silica source; a developed alkaline activator (DAA); and an aqu