RESEARCH PAPER

Research progress and development of deep and ultra-deep drilling fluid technology

  • SUN Jinsheng , 1, 2, * ,
  • YANG Jingbin 1 ,
  • BAI Yingrui 1 ,
  • LYU Kaihe 1 ,
  • LIU Fengbao 1
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  • 1. School of Petroleum Engineering, China University of Petroleum (East China), Qingdao 266580, China
  • 2. CNPC Engineering Technology R&D Company Limited, Beijing 102206, China

Received date: 2024-03-11

  Revised date: 2024-07-02

  Online published: 2024-08-15

Supported by

Projects of National Natural Science Foundation of China(52288101)

Projects of National Natural Science Foundation of China(52174014)

Projects of National Natural Science Foundation of China(52374023)

Abstract

The research progress of deep and ultra-deep drilling fluid technology systematically reviewed, the key problems existing are analyzed, and the future development direction is proposed. In view of the high temperature, high pressure and high stress, fracture development, wellbore instability, drilling fluid lost circulation and other problems faced in the process of deep and ultra-deep complex oil and gas drilling, scholars have developed deep and ultra-deep high-temperature and high-salt resistant water-based drilling fluid technology, high-temperature resistant oil-based/synthetic drilling fluid technology, drilling fluid technology for reservoir protection and drilling fluid lost circulation control technology. However, there are still some key problems such as insufficient resistance to high temperature, high pressure and high stress, wellbore instability and serious lost circulation. Therefore, the development direction of deep and ultra-deep drilling fluid technology in the future is proposed: (1) The technology of high-temperature and high-salt resistant water-based drilling fluid should focus on improving high temperature stability, improving rheological properties, strengthening filtration control and improving compatibility with formation. (2) The technology of oil-based/synthetic drilling fluid resistant to high temperature should further study in the aspects of easily degradable environmental protection additives with low toxicity such as high temperature stabilizer, rheological regulator and related supporting technologies. (3) The drilling fluid technology for reservoir protection should be devoted to the development of new high-performance additives and materials, and further improve the real-time monitoring technology by introducing advanced sensor networks and artificial intelligence algorithms. (4) The lost circulation control of drilling fluid should pay more attention to the integration and application of intelligent technology, the research and application of high-performance plugging materials, the exploration of diversified plugging techniques and methods, and the improvement of environmental protection and production safety awareness.

Cite this article

SUN Jinsheng , YANG Jingbin , BAI Yingrui , LYU Kaihe , LIU Fengbao . Research progress and development of deep and ultra-deep drilling fluid technology[J]. Petroleum Exploration and Development, 2024 , 51(4) : 1022 -1034 . DOI: 10.1016/S1876-3804(24)60522-7

Introduction

In recent years, the oil and gas demand of China has increased year by year, and the dependence on imported oil and gas remained high. In 2022, China's dependence on imported oil reached 71.2%, much higher than the international safety limit for oil, and dependence on imported gas was 40.2%, severely threatening the energy security of the country. Thus, it is urgent to enhance China’s oil and gas self-sufficiency [1]. China has abundant deep oil and gas resources, which have been less proved and will be realistic targets for future petroleum exploration and development [2]. Currently, the well drilling and completion technologies in deep (˃4 500 m) and ultra-deep (˃6 000 m) strata face severe challenges, such as bottomhole ultra-high temperature and high pressure, high stress, and fractures, which are likely to cause reservoir damage, borehole instability, serious lost circulation, and other complex incidents.
In the process of deep and ultra-deep drilling, the drilling fluid technologies may suffer the following complexities [3-6]. (1) The borehole is liable to be instable, or collapse and sloughing due to long open hole and well developed fractures, resulting in pipe sticking and other problems. Borehole stability is dependent on drilling fluid cooling, subcritical water, and other factors. The mechanism of borehole instability is complicated, and there are limited borehole stability technologies. (2) The drilling fluids are exposed to high-temperature, high- pressure and high-stress environments, where the additives may be degraded and changed structurally, making the drilling fluid performance uncontrollable. (3) Lost circulation is likely to occur due to presence of natural fractures and faults, and it is difficult to control. In fractured high-pressure gas reservoirs, natural gas may flow into the wellbore while drilling to possibly cause blowout. Also, the narrow safety density window keeps it difficult to define a safety drilling fluid density window.
Considering the complexities above, this paper overviews the research progresses in the high temperature and high salt resistant water base drilling fluid technology, the oil base/synthetic base drilling fluid technology, the reservoir protection drilling fluid technology, and the lost circulation control technology, makes clear the key problems in deep and ultra-deep drilling fluid technology in China and other countries, and proposes the development direction of the deep and ultra-deep drilling fluid technologies.

1. Researches on deep and ultra-deep drilling fluid technologies

To solve the problems of high temperature, high pressure, high stress, fracture development, borehole instability, and lost circulation in the process of deep and ultra-deep oil and gas well drilling, the petroleum professionals have developed the technologies of high-temperature and high-salt resistant water-based drilling fluid, high-temperature resistant oil-based/synthetic-based drilling fluid, reservoir protection drilling fluid, and lost circulation control.

1.1. High-temperature and high-salt resistant water-based drilling fluid technology

With the expansion of oil and gas exploration to deep and ultra-deep strata, traditional drilling fluids are no longer applicable in the extreme conditions such as high temperature and high salt. Thus, the high-temperature and high-salt resistant water-based drilling fluid technology is designed to improve the resistance of drilling fluid to high temperature and high salt and ensure its performance stability in deep drilling.

1.1.1. High-temperature resistant sulfonated/polysulfonated water-based drilling fluids

High-temperature resistant water-based drilling fluid in China has evolved in three stages: calcium-treated drilling fluid, sulfonated drilling fluid, and polysulfonated drilling fluid. The calcium-treated drilling fluid inhibits clay dispersion by calcium ions and has improved filtration and rheological properties at high temperature. The sulfonated drilling fluid, prepared with sulfonated lignite and sulfonated phenolic resin as additives, can resist high temperature up to 180 °C, but has a poor salt and calcium resistance, and it is mainly applied in deep freshwater drilling [7]. The polysulfonated drilling fluid incorporates temperature- and salt-resistant polymers on the basis of sulfonated drilling fluid, with improved rheological and filtration properties, and enhanced temperature resistance to 200 °C or above [8]. Polysulfonated drilling fluid has been studied mostly to optimize its performance and improve its applicability. For example, the proportions of polymers with different molecular weights (MWs) and the bentonite content are adjusted to improve the rheological properties of the drilling fluid. The volume of high-MW polymer encapsulating agent is increased or appropriate amount of inorganic salt is added to enhance the inhibitive properties of the drilling fluid. In addition, depending on the characteristics of deep well sections and intervals, the types of additives in the polysulfonated drilling fluid can be adjusted to achieve the optimal drilling results.
Polysulfonated drilling fluid is the popular high-temperature resistant water-based drilling fluid system in China now. It can resist a temperature up to 220 °C in case of salt water and up to 240 °C in case of fresh water [9]. Well Songke 2 in the Songliao Basin, NE China, with a well depth (WD) of 7 018 m and a bottomhole temperature of 241 °C, was successfully drilled using the high-temperature resistant potassium polysulfonated and high-temperature resistant polysulfonated drilling fluid systems, setting a new record of drilling at the highest temperature (241 °C) in China then. Well Luntan 1 in the Tarim Oilfield, NE China, with a WD of 8 882 m and a bottomhole temperature of 175 °C, was successfully drilled using the potassium polysulfonated drilling fluid system, creating the deepest well onshore in Asia [9]. Table 1 lists the typical applications of deep and ultra-deep high-temperature resistant polysulfonated water-based drilling fluids in China.
Table 1. Typical applications of deep and ultra-deep high- temperature resistant polysulfonated water-based drilling fluids in China [9]
Typical
well
WD/m Tempera-
ture/°C
Type of drilling fluid
Luntan 1,
Tarim
Oilfield
8 882 175 Potassium polysulfonated
drilling fluid
Songke 2,
Songliao Basin
7 018 241 High-temperature resistant potassium polysulfonated drilling fluid + high-temperature resistant polysulfonated drilling fluid
Bishen 1,
Henan
Oilfield
6 005 236 Polysulfonated drilling fluid and ultra-high-temperature resistant water-based drilling fluid
Shengke 1,
Shengli Oilfield
7 026 235 Polysulfonated drilling fluid
Moshen 1 7 500 204 Polysulfonated drilling fluid
Lignosulfonate water-based drilling fluid is the commonly-used high-temperature resistant sulfonated water-based drilling fluid in other countries. It demonstrated a temperature resistance up to 260 °C when it was applied in drilling high-temperature deep wells in the Pontchartrain Lake, Louisiana, the United States [9]. Baker Hughes synthesized a series of high-temperature resistant sulfonated high-MW polymers and high-temperature stabilizers by using 2-acrylamide-2-methylpropanesulfonic acid and monomers such as acrylamides and alkyl acrylamides with different long chains, and produced a polysulfonated drilling fluid system by adding inorganic salt or other agents, which has been satisfactorily applied in Well Yacheng 21-1-3 in the South China Sea [10].

1.1.2. High-temperature resistant polymer water-based drilling fluids

The research on high-temperature resistant polymer drilling fluid technology started early and has progressed rapidly oversea. Research, development and application of polymer drilling fluids can be traced back to the 1960s [1]. Currently, a significant progress has been made in research on high-temperature resistant polymer water-based drilling fluids, and innovative additives are consistently developed to improve the stability of drilling fluid performance in extreme conditions such as high temperature and high salt, providing an important technical support for drilling deep and ultra-deep wells. M-I SWACO developed a polymer drilling fluid system with a temperature resistance of 232 °C and a density of 2.20 g/cm3, which is resistant to high temperature, high salt and pollution, and has little damage to reservoirs [11]. Halliburton and Shell jointly developed a high-temperature resistant polymer water-based drilling fluid technology, which is well performed in hole cleaning and can increase the average rate of penetration (ROP) by more than 8 times in drilling horizontal wells in hard sandstone, and this technology has been successfully applied in drilling at a bottomhole temperature of 193.3 °C in Hail Oilfield, the United Arab Emirates [12]. M-I SWACO developed a polymer water-based drilling fluid system with a temperature resistance up to 204 °C and a density up to 2.30 g/cm3, which improves greatly in anti-pollution and reservoir protection and maintains a good settling stability under long-term high temperature aging conditions [9]. Wandji et al. [13] designed a new type of high- density polymer nano-composite material - bentonite hybrid system, which is thermally stable and prepared by incorporating the thermo-thickening/amphoteric vinyl- functionalized modified nano-silica (VMS) as a viscosifier. This system remains a viscosity retention rate over 60% at 220 °C and 20% mass fraction of NaCl, with a low viscosity attenuation. It has been satisfactorily used in drilling under high-salt and high-temperature conditions.
In China, the research on high-temperature resistant polymer water-based drilling fluids has been progressing. The stability of drilling fluids in extreme environments such as high temperature is improved by developing new additives, upgrading fillers, and incorporating modified techniques. Typical high-temperature resistant polymer drilling fluid systems that have been successfully applied in China include non-dispersible low-solid-phase polymer system, biomimetic polymer system, amphiphobic high- efficiency polymer system, and high-temperature resistant high-density polymer saturated brine system [6,14 -15]. Xuan et al. [14-15] developed a series of biomimetic drilling fluid materials, and established the theory and technology of biomimetic polymer drilling fluids, which were applied in horizontal drilling in the Su53 block of Sulige Gasfield, showing remarkable results with an average ROP enhanced by 27% and the drilling fluid cost reduced by 26.4%. In addition, Huang et al. [6] designed and developed three types of high-temperature resistant additives for polymer water-based drilling fluids, and established an ultra-high-temperature resistant high-density polymeric saturated brine-based drilling fluid system, which exhibits an excellent plugging and lubricating performance.

1.2. High-temperature resistant oil-based/synthetic-based drilling fluid technology

Compared with water-based drilling fluids, high-temperature resistant oil-based/synthetic-based drilling fluids are superior in borehole stability, lubrication, sticking release/prevention, inhibition of shale hydration and dispersion, prevention of formation clay from slurry, and optimal and fast drilling. They are primary choices for drilling complex high-temperature deep wells.

1.2.1. High-temperature resistant oil-based drilling fluids

The high-temperature resistant oil-based drilling fluids are mainly prepared with various grades of diesel oil and mineral oil as the base oils, together with high-temperature resistant emulsifier, flow pattern regulator, filtrate reducer and weighting materials. Other agents can be added depending on specific geological conditions, in order to ensure the wellbore integrity and deal with lost circulation in reservoirs.
The high-temperature resistant oil-based drilling fluid technology is relatively sophisticated overseas. Owning to variety of base fluids and upgrading of high-temperature resistant additives, this technology has been used widely. M-I SWACO developed an ultra-high- temperature resistant white oil-based drilling fluid by designing the polyfunctional group structure of polyether materials. This drilling fluid was stably performed before and after hot rolling at 300 °C during laboratory experiment, and it has been successfully applied in the Kuqa piedmont block of the Tarim Basin, NW China, Well F7H in western South China Sea, and Well Gulong 1 in Daqing Oilfield [16]. Halliburton developed a diesel-based drilling fluid system with fatty acid derivative emulsifier and tall oil filtrate reducer, which has a temperature resistance up to 260 °C and a strong resistance to salt water invasion, and has been applied in drilling in the Kuqa piedmont in the Tarim Basin [17].
In China, research on high-temperature resistant oil-based drilling fluids started later, but has evolved quickly in recent years. These efforts have helped breaking the monopoly of foreign oilfield service companies in the high-temperature resistant oil-based drilling fluid technology, and addressing the challenges from the extremely thick salt-gypsum layers, high-pressure saline layers and mud shales in the Kuqa pediment block of Tarim Basin, shale gas blocks in southwestern China, southern margin of Junggar Basin, and Shunbei area of Tarim Basin. Table 2 shows the typical applications of oil-based drilling fluids in ultra-deep wells in China [9,18]. Among the applications of high-temperature resistant oil-based drilling fluids in China, Well Guole 3C in the Tarim Oilfield is the deepest horizontal well (WD of 9 396 m), and Well Pengshen 6 in the Sichuan Basin, SW China, is the deepest vertical well (WD of 9 026 m); Well Tatan 1 in southwestern Sichuan Basin records the highest temperature, with a bottomhole temperature of 216 °C upon completion; and Well Letan 1 in the Junggar Basin establishes the highest drilling fluid density (2.68 g/cm3) [9]. Wang et al. [19] developed a high-density and high-salt resistant oil-based drilling fluid system with a temperature resistance up to 220 °C, a density of 2.60 g/cm3, and a resistance to salt water invasion capacity of 45%, which was applied in the fourth spud-in of Well Keshen 1101 in the Kuqa pediment to effectively avoid the occurrence of spill and loss in the same zone. Qin et al. [20] synthesized a primary emulsifier for high-temperature oil-based drilling fluid using tall oil fatty acids and maleic anhydride as main raw materials, and accordingly formulated a high-temperature resistant oil-based drilling fluid system, which was tested successfully in the drilling of shale gas wells on the Wei 204H5 platform in the Weiyuan block of the Sichuan Basin and has been widely promoted and applied. Zhao et al. [21] developed a high-temperature resistant and high-density oil-based drilling fluid system, which was successfully applied in the fourth spud-in of Well Dabei 12X in the Kelasu structural belt, Kuqa Depression, Tarim Basin, by providing a solution to drilling in high-temperature and (ultra-) high-pressure salt-gypsum strata.
Table 2. Typical applications of oil-based drilling fluids in ultra-deep wells in China [9,18]
Typical well WD/m Tempera-
ture/°C
Density/ (g·cm−3) Performance
Guole 3C 9 396 170 1.55 The deepest horizontal
well in Asia
Tatan 1 6 755 216 1.25 The highest temperature well in southwestern
Sichuan Basin
Pengshen 6 9 026 197 1.45 The deepest vertical
depth record in Asia
Letan 1 7 050 140 2.68 The highest density
on record
Shuangyu 001-H6 9 010 176 1.45 The largest well depth
record in the Sichuan-
Chongqing area
Hongxing 1 7 779 160 2.20 The first well with eight-section casing
program in China
Tianan 1 8 140 169 2.30 The first well with six-
section casing program
in Xinjiang Oilfield
Tianwan 1 8 166 172 2.24 The deepest well in
the Junggar Basin

1.2.2. High-temperature resistant synthetic-based drilling fluids

The synthetic-based drilling fluids adopt a biodegradable synthetic base oil as continuous phase, instead of traditional mineral oil or diesel oil, thus reducing the environmental pollution. The synthetic-based drilling fluids have demonstrated good lubrication, carrying capacity and anti-collapse [22], and they can meet the needs of drilling in complex formations through continuous optimization of rheology. These fluids have been successfully applied in several fields, especially offshore fields and complex fields.
Li et al. [23] applied the synthetic-based drilling fluid system in the inclined and horizontal sections of Well H6-6 during the third spud-in in the Changning block, enabling a standardized operation mode of environmental protection and safe and fast drilling in pressure-sensitive strata, and thus providing a solid technical foundation for shale gas development in the Changning block. Wang et al. [24] developed the SBM-II synthetic-based drilling fluid system by using special fluid-loss agent PF-FLB and gas-made oil PF-SGO. This system has the characteristics of low fluid loss, good rheology, strong inhibitive property, and high stability, and has been successfully applied in Well A4 of Bohai BZ25-1 oilfield.

1.3. Reservoir protection drilling fluid technology

In 1959, Monaghan et al. [25] first proposed the concept of reservoir damage and the method to prevent interaction between fresh water and clay. Since then, reservoir damage and protection has attracted great attention in the industry. Reservoir damage refers to a decrease of oil and gas reservoir permeability in the whole process of drilling, completion, downhole operation, and production [26]. Drilling fluids may result in serious damage to reservoirs by destroying their physical and chemical balances, since they are the first to contact reservoirs and have complex composition [27]. Therefore, how to mitigate or even avoid the damage of drilling fluids to reservoirs is a hot topic. The reservoir protection drilling fluid technology is designed to reduce such damage in drilling.

1.3.1. Temporary-plugging reservoir protection drilling fluids

The temporary-plugging reservoir protection drilling fluids prevent the reservoirs from damage by temporarily plugging the oil and gas layers during drilling to avoid invasion of the solid phase and liquid phase of drilling fluids into the reservoir [28]. As to the mechanism of reservoir protection, solid particles in drilling fluids are relied to form a near-wellbore temporary shielding zone with a near-zero permeability under a positive pressure difference. This shielding zone prevents further invasion of the solid phase and filtrate of drilling fluids and cement slurry into the reservoirs and thus avoids pollution to reservoirs.
With efforts in more than half a century, scholars around the world have launched three generations of temporary-plugging reservoir protection drilling fluid technology, i.e. shielding temporary plugging, fine temporary plugging, and physico-chemical membrane temporary plugging, indicating improved reservoir protection effects and significant economic benefits [5,14 -15,29]. Sun et al. [29] illustrated the basic principles and research progress of reservoir protection technologies such as physical particle temporary plugging and chemical film-forming temporary plugging, and proposed the future direction of tight/shale reservoir protection technologies. Jiang et al. [5,14 -15] introduced bionics into the theory of drilling fluids to protect reservoirs, and developed the bionic temporary-plugging reservoir protection technology of "super-amphiphobic, biofilm and synergistic effect" applicable to various reservoirs, which reduces the damage to reservoirs with different permeabilities and improves the single well production. It has been popularized and applied in China’s major oilfields such as Shengli, Tarim, and Dagang, with remarkable results.

1.3.2. Liquid casing reservoir protection drilling fluids

The liquid casing reservoir protection drilling fluid technology is applied by adding special additives into drilling fluids to reduce their density and viscosity, thereby reducing their pressure and friction in reservoirs, so that the reservoirs are protected [30]. "Liquid casing" is a special fluid used in drilling, and it forms a protective film on the borehole wall to function as traditional casing does, but work more flexibly and efficiently. Liquid casing generally consists of drilling fluid or completion fluid with specific properties, which can adhere tightly to the borehole wall and form an isolation layer to avoid reservoir damage during drilling and downhole operations.
Existing studies on liquid casing reservoir protection drilling fluid technology primarily focus on the solutions to improve the stability and durability of liquid casing and optimize its protection on reservoirs. Jiang et al. [31] developed a novel water-based drilling fluid using super-amphiphobic inhibitor, borehole strengthening agent and bonding lubricant synthesized by bionic technologies, together with other additives. This novel drilling fluid can form liquid casing while drilling to protect the reservoir, and it has been successfully applied in more than 1 000 complex wells in China (incl. shale gas wells in the Zhaotong block of the Sichuan Basin, shale oil wells in the Bohai Bay Basin, tight gas wells in the Sulige block of the Ordos Basin, tight gas wells in the Songliao Basin, tight oil wells in the Junggar Basin, and coalbed methane wells in Shanxi) and Chad. Compared with oil-based drilling fluids and other high-performance water-based drilling fluids used in the same block, this technology reduces the average rate of wellbore collapse by 82.6%, lost circulation by 80.6%, and blockage/sticking by 80.7%, and increases the ROP by 32.8% and the production by more than 1.5 times, suggesting remarkable application results.

1.3.3. Clay-free water-based/synthetic-based reservoir protection drilling fluids

The clay-free water-based drilling fluids are prepared with water as a continuous phase and no solid components, and by adding chemical additives to realize good rheological, inhibitive and environmental properties. They protect the reservoirs mainly by reducing solid content, inhibiting hydration, mitigating filtration and invasion, and providing effective lubrication and drag reduction. In foreign studies, clay-free water-based drilling fluid is mainly prepared by adding clay inhibitors and high-molecular polymers into fresh water, such as Halliburton's clay-free water-based drilling fluid system with a temperature resistance up to 180 °C, and M-I SWACO's VeraTherm system with a temperature resistance up to 204 °C [32]. In China, the scholars have developed clay-free water-based organic salt drilling fluid, and clay-free water-based weak gel drilling fluid, etc., which are all designed for mitigating reservoir damage and improving drilling efficiency. Specifically, the organic salt drilling fluid combines high-molecular polymer and soluble salt to effectively protect the reservoir; the weak gel drilling fluid can form a weak gel structure to enhance the carrying capacity and borehole stability. Ma et al. [33] developed a high-temperature resistant clay-free organic salt reservoir protection drilling fluid system with the temperature resistance up to 200 °C by using the additives such as high-temperature resistant flow pattern regulator, high-temperature resistant colloid protecting agent, polyamine inhibitor and potassium formate weighting material, and the system has been successfully applied in 3 horizontal wells in tight sandstone gas reservoirs in the Mi 38 block of Shenmu gas field, the Ordos Basin. Shi et al. [34] developed the cesium formate clay-free drilling fluid system with a temperature resistance up to 220 °C, and a density up to 2.37 g/cm3, which exhibits good rheology and lubrication, and can effectively avoid barite settling in high-density condition, except for its disadvantage of high cost.
The clay-free synthetic-based drilling fluid technology is an important object in the drilling sector. This technology realizes a significant improvement in the stability and environmental property of drilling fluids by optimizing the formula to remove the clay component. In recent years, a significant progress has been made in research on the clay-free synthetic-based drilling fluid technology [35-36]. A variety of new clay-free synthetic- based drilling fluid systems with excellent borehole stability, low drag, and performance stability at high temperature have been developed for drilling in complex strata. Wang et al. [35] developed a flow pattern regulator for synthetic-based drilling fluids, and prepared a high-temperature resistant and high-density clay-free synthetic-based drilling fluid system with a temperature resistance up to 180 °C and the maximum density of 2.0 g/cm3, which exhibits high demulsification voltage before and after aging, small filtration, and excellent rheological properties, and can meet the requirements of field operation. Zhang et al. [36] used the biomass synthetic base fluid LAE-12 to prepare a clay-free synthetic-based drilling fluid with a temperature resistance up to 150 °C and a density of 1.20-2.50 g/cm3, which demonstrated good results in its first field test in Well ZJ204H in the Sichuan Basin.

1.4. Lost circulation control technology

In deep and ultra-deep drilling, the lost circulation control (LCC) performance of drilling fluids should be maintained in the downhole extreme environment of high temperature and high pressure, so that the fluid loss can be plugged and the borehole stability be maintained effectively.

1.4.1. Bridging material LCC technology

The bridging material LCC technology provides a powerful solution to the lost circulation in fractured strata. The plugging slurry is formed by mixing bridging materials of different shapes and sizes with drilling fluids at different concentrations, and it bridges, accumulates and fills in fractures to form a plugging layer near the fracture entrance, blocking the transfer of drilling fluid pressure and fluid medium [37]. The common bridging materials include walnut shell, calcium carbonate, fiber, and mica flake. However, the particle sizes of these bridging materials poorly match with the sizes of the leaking channels in strata. Due to the influence of gravity settlement and erosion inside fractures, etc., bridging materials are difficult to retain in large fractures with large widths and high vertical extensions, especially in karst caves, so the plugging layers in these fractures are low in pressure-bearing capacity [38].
Bridge plugging is a common and effective LCC technique. Nevertheless, the common bridging lost circulation materials (LCMs) have weak high-temperature resistance, poor compatibility of particle sizes with fracture scales, and poor stability of plugging layers formed by particle stacking in fractures, leading to ineffective fracture plugging or high risk of repeated leakage. Thus, these LCMs cannot meet the increasing demand for LCC in ultra-deep drilling. Bao et al. [39] optimized the high-temperature resistant bridging formulas for fractures with different apertures by controlling the particle size distribution and concentration of various LCMs, showing a reliable plugging capacity at high temperature and high pressure up to 15 MPa. The fracture plugging layer formed by bridging LCMs becomes more instable in complex environments such as high temperature, high pressure and high in-situ stress, leading to the plugging success rate and performance far behind expectations [40-41]. Kang et al. [40] established the high-temperature aging performance evaluation method and index system for bridging LCMs used in deep and ultra-deep drilling after analyzing the morphology, particle size distribution and mechanical properties of bridging LCMs such as walnut shell and calcium carbonate. Based on the measured data of particle size distribution of a single bridging material, Zhu et al. [41] proposed a new method to predict the particle size distribution of bridging LCMs and formulas by using the segmental cubic Hermite interpolation method. The bridge plugging technology requires a good matching between material particle sizes and fracture scales, and is likely to witness the phenomenon of plugging at the fracture tip or loss within the plugged fracture during plugging operations, possibly accompanied by backflow and repeated fluid loss during subsequent drilling. Zhang [42] proposed a progressive bridge plugging technology, with fluid injecting while being prepared with bridging materials in ascending orders of particle size and concentration, and this technology has been applied in 6 wells, with a success rate of up to 100%.

1.4.2. Gel material LCC technology

Polymer gel LCMs are mainly used to form the high-strength gel with a 3D network structure by chemical crosslinking reaction or molecular interaction to plug the leaking channels in complex strata [43]. For large fractures and cavernous or vuggy lost-circulation formations, bridging materials and other LCMs cannot retain to form plugging layers, while polymer gels highly capable of deformation and retention have no defects of granular materials and can achieve an ideal plugging performance [44].
Gel LCMs include chemical gels, which are formed mainly by chemical reaction, and crosslinked polymer gels, which are formed by crosslinking reaction between polymers and crosslinkers. Currently, a variety of gel materials, such as polyacrylamide gel and polyvinyl alcohol gel, have been developed and applied in the industry. These materials have their own characteristics in crosslinking reaction, high-temperature resistance, and environmental protection. Bai et al. [45] presented a double network self-healing hyrogel based on hydrophobic association and ionic bond, which effectively improves the plugging under pressure in lost-circulation strata. Jia et al. [46] synthesized an environmental and strength-enhanced nanosilica-based composite gel for well temporary plugging in high-temperature reservoirs, which has good mechanical and elastic properties to enhance the plugging effect. Lecolier et al. [47] developed the solid particle enhanced gel slug plugging technology based on the crosslinked polymer as the lost circulation material, in combination with fiber and rigid particles, which has been successfully applied for lost circulation treatment in Louisiana and northern Iran. Baker Hughes launched MAX-LOCK, an MgO-base thixotropic inorganic gel LCM, and optimized the gel curing time by the factors such as fluid-loss rate, temperature and size of leaking channel in strata, thus forming a specific gel LCC technology for carbonate reservoirs, which has well performed in wells with serious lost circulation in carbonate reservoirs in the Middle East [37].

1.4.3. Curable material LCC technology

The curable material LCC technology realizes a high- strength plugging of fractures by using the prepared curable plugging slurry, which is injected into the wellbore and then enters the leaking channels under the pressure difference before it is cured under the geothermal action. The curable plugging slurry has a high pressure-bearing capacity after curing and is widely used in wells with serious lost circulation [48]. Curable LCMs are characterized by diverse sources, low cost, high strength, simple preparation process, and high cementation strength, but they are liable to high safety risks in operations, poor in resistance to pollution by high-salinity formation water, and susceptible to fluid dilution which will impede their curing effects. Compared with conventional bridging LCMs, curable LCMs have higher pressure-bearing capacity and better curing performance. Moreover, the plugging layer is not destroyed under the pressure of drilling fluid column in the process of circulation drilling, so that the plugging operations can be reduced greatly.
The curable material LCC technology is critical in the industry, and it realizes plugging of cavities or fractures by virtue of curable materials. There are a variety of curable LCMs under the categories of cement, epoxy resin and poly-urethane [49]. These materials are well capable of physical plugging and curing cementation, and they can effectively plug the leaking channels in strata and improve the pressure-bearing capacity of strata. Field applications have demonstrated a significant reduction of possible lost circulation accidents. Halliburton developed a one-bag plugging technology to plug the leaking channels and control the lost circulation, and the technology can effectively plug the fractures with widths of 3-25 mm under a pressure up to 20 MPa, and has a good temperature resistance [49]. In the X structure of the Yinggehai Basin, western South China Sea, natural fractures exist universally, the formation temperature reaches up to 204 °C, and the formation pressure coefficient peaks at 2.19, suggesting low formation pressure-bearing capacity and narrow safety density window. These conditions may probably lead to complexities such as lost circulation. To address these challenges, the “cleaning fluid + cement slurry" intermittent squeeze cementing process was adopted in over 10 wells for plugging under pressure, showing a 100% success. This practice ensured safe and smooth drilling of the ultra-high temperature and high-pressure formations in the X structure.

1.4.4. Composite material LCC technology

The composite LCMs are usually prepared by mixing various components (e.g. fibers, particulates and flakes) in a certain proportion. These components play their respective roles in composite LCMs, and jointly constitute a LCC system with an excellent performance. Fibers function for enhancement and toughness. Particulates can fill and block micro pores and fractures. Flakes are good bridges and seals in plugging process.
The composite material LCC technology has emerged gradually along with the advancement of drilling technology and to deal with challenges from complex geological conditions. It integrates the advantages of various LCMs for purpose of ideal plugging. Currently, the popular composite slug processes include bridge plug + curing, bridge plug + high water loss, and gel + cement. For the formations with high temperature, high pressure and narrow safety density window (<0.10 g/cm3) in the Yingqiong Basin, Han et al. [50] proposed a high-density (2.30 g/cm3) bridge plug + high water loss composite plugging technology, which increases the safety density window to 0.16 g/cm3, thereby contributing a significant improvement of drilling efficiency. Liu et al. [51] synthesized a nano-micro deformable spherical gel, and combined it with mica flake and fiber to obtain a composite LCM with a good compatibility with oil-based drilling fluids, which was successfully applied in shale gas wells in Fuling area. Wang et al. [52] introduced some rigid LCMs of different particle sizes (e.g. walnut shell, cottonseed shell, and mica flake) and deformable particles (e.g. sawdust) to obtain close packing and consolidation of the plugging layers, thereby enhancing the pressure-bearing capacity of the formations. The resulting LCC system has been tested in 5 wells in the hinterland of Huoyan Mountain, with the average loss volume, lost time and drilling period reduced by 74.3%, 93.5% and 57.8%, respectively, compared with other wells in the same block.

2. Problems in deep and ultra-deep drilling fluid technologies

2.1. High-temperature and high-salt resistant water-based drilling fluid technology

The high-temperature resistant water-based drilling fluid technology provides a critical solution to drilling in high temperature environment, but it has some problems in application.
(1) The high-temperature resistant water-based drilling fluids exhibit low stability at high temperature (≥200 °C, the same hereinafter). The polymers and other additives in the drilling fluids are likely to thermally degrade, impeding the performance of drilling fluids, and possibly inducing phase separation of components in drilling fluids which will affect the uniformity and stability of drilling fluids.
(2) At high temperature, the viscosity of drilling fluids is difficult to control - possibly too high or too low, impeding the drilling efficiency and borehole stability. Moreover, the high-temperature resistant water-based drilling fluids may have poor shear dilution at high temperature and high shear rate, which prejudices the ROP enhancement and the cutting carrying capacity.
(3) With the rising temperature, the control over drilling fluid loss becomes increasingly difficult, resulting in borehole instability and reservoir damage. Moreover, the formed filter cake may deteriorate in quality to destroy its functions for borehole protection and lost circulation prevention.
(4) Some high-temperature resistant water-based drilling fluids may react with minerals or fluids in the formations, resulting in a reduction of reservoir permeability or a blockage. In terms of reservoir protection, some high-temperature resistant water-based drilling fluids are not qualified in some specific conditions, leading to reservoir damage and reduced productivity.

2.2. High-temperature resistant oil-based/synthetic-based drilling fluid technology

The high-temperature resistant oil-based/synthetic-based drilling fluid technology is of great significance in drilling of deep wells, ultra-deep wells and complex strata, but it is insufficient in some aspects.
(1) At high temperature, the components of oil-based/ synthetic-based drilling fluids may change chemically or physically, resulting in unstable properties, such as increased viscosity and gelation. Moreover, as the temperature rises, it is difficult to predict and control the rheology of drilling fluids, which will affect the drilling efficiency and hole cleaning.
(2) It is challenging to select an applicable emulsifier to maintain the emulsion stability of drilling fluids at high temperature. The performance of emulsifier has a direct impact on the stability and service life of drilling fluids. After drilling, the demulsification at high temperature is more difficult, which may lead to environmental pollution and increased costs of waste disposal.
(3) Reaction of oil-based/synthetic-based drilling fluids with some minerals or fluids in the formations decreases the formation permeability or induces solid deposits. The compatibility of oil-based/synthetic-based drilling fluids with cement slurry is a key issue in cementing operation. Incompatibility possibly results in a poor cementing quality or a decreased borehole stability.
(4) Oil-based/synthetic-based drilling fluids possibly cause environmental pollution in drilling operation. Especially in offshore drilling, attention should be paid to the potential impact on marine ecosystems. Moreover, some components may decompose and produce toxic or flammable gases at high temperature, thereby imposing higher safety risks.

2.3. Reservoir protection drilling fluid technology

The above-mentioned reservoir protection drilling fluid technologies have been adequately studied and satisfactorily applied, but still face several problems and challenges.
(1) The existing technologies work well in some types of reservoirs, but not in others. The technologies should be selected and applied according to the specific reservoir properties and drilling conditions, which increases the complexity and difficulty in technology application.
(2) Additives and materials in the reservoir protection drilling fluids may possibly be invalid or have their properties changed in high-temperature, high-pressure and corrosive environments, thereby resulting in reservoir damage or degraded drilling fluid performance. The stability of materials during long-term storage and transportation should be also considered.
(3) Real-time monitoring of performances of the reservoir protection drilling fluids and reservoir damage during drilling is critical in optimizing drilling operation. In addition, due to the complexity and uncertainty of the reservoir, any real-time monitoring may not necessarily identify drilling problems in a timely and accurate manner. This possibly results in reservoir damage or reduced drilling efficiency.

2.4. LCC technology

The LCC technology is vital in oil and gas exploration and development. Nonetheless, the several existing LCC technologies have a series of problems and challenges in the following aspects.
(1) Technology selection and compatibility. Formations are very different in physical and chemical properties, including porosity, permeability, rock type, and fracture development. Due to the complexity and diversity of formations, LCC technologies may be only applicable in specific strata.
(2) Performance of LCMs. The commonly used bridging materials, gel materials, and curable materials may exhibit decreased performance in conditions of high temperature and high pressure or in contact with corrosive fluids. The LCMs should have physical properties (e.g. particle size distribution, density and viscosity) compatible with reservoir properties to achieve effective plugging.
(3) Complexity and efficiency of plugging operation. When lost circulation occurs, rapid diagnostics and applicable measures are needed to prevent worse conditions. Nevertheless, due to the complexity and uncertainty of the drilling environment, quick and accurate identification of lost circulation positions, type and size is a challenging task.
(4) Environmental and safety impacts. Some LCMs, such as heavy metals and toxic chemicals, may cause environmental pollution. Thus, strict environmental protection measures are needed when applying these materials. Moreover, both lost circulation and improper treatments may lead to safety risks, such as wellbore collapse, and blowout.

3. Prospects of deep and ultra-deep drilling fluid technologies

3.1. High-temperature and high-salt resistant water-based drilling fluid technology

(1) Improve the stability at high temperature. To solve the problems of thermal degradation and phase separation of drilling fluids at high temperature, future study on the high-temperature resistant water-based drilling fluid technology will focus on improving the stability at high temperature. New high-temperature stabilizers and antioxidants should be developed to enhance the thermal stability of polymers and other additives in drilling fluids and reduce the risk of thermal degradation.
(2) Improve the rheology control. More efforts will be devoted to control the rheological properties of drilling fluids at high temperature. New flow pattern regulators and viscosity control agents will be introduced to precisely control the drilling fluid viscosity, so as to avoid the impacts of a too low or high viscosity on drilling efficiency and borehole stability.
(3) Enhance the filtration control. Future study on the high-temperature resistant water-based drilling fluid technology should focus on enhanced control over fluid filtration at high temperature. New filtrate reducers and filter cake enhancers will be developed to reduce the fluid loss and improve the cake quality, thereby ensuring the borehole stability and reducing the risk of reservoir damage.
(4) Improve the compatibility with strata. More efforts will be put in selection of drilling fluid systems and additives compatible with the formation characteristics, so as to keep high-temperature resistant water-based drilling fluids compatible with strata. By studying the mineral and fluid properties in strata, the chemical composition and properties of drilling fluids will be adjusted to reduce the risk of reaction with strata.
(5) Promote the development of intelligent and green technologies. With the advancing technology and improving environmental awareness, high-temperature resistant water-based drilling fluids with intelligent and green features will be pursued. Advanced sensors and monitoring technology will be introduced to realize real-time monitoring of drilling fluid properties and formation variation, providing data support for optimizing drilling fluid formulas and adjusting process parameters.

3.2. High-temperature resistant oil-based/synthetic-based drilling fluid technology

(1) Improve the stability and rheology at high temperature. Future study on the high-temperature resistant oil-based/synthetic-based drilling fluid technology will focus on development of efficient high-temperature stabilizers and flow pattern regulators. These additives maintain the chemical and physical stability of drilling fluids at high temperature and regulate the rheology of drilling fluids to ensure drilling efficiency and wellbore cleanliness.
(2) Improve emulsification stability and demulsification effect. More efforts will be put in developing high- performance emulsifiers and demulsifiers. The new emulsifiers should have stronger emulsification capacity and thermal stability to maintain the emulsion stability of drilling fluids at high temperature. Moreover, demulsifiers should have higher demulsification efficiency and lower environmental impact.
(3) Enhance the compatibility with cement slurry and strata. More attention should be paid to selecting and optimizing additives. Through in-depth study on the reaction mechanism of drilling fluids with formation minerals and fluids, applicable additives will be selected to reduce the risk of reaction with strata. Moreover, the compatibility of drilling fluids with cement slurry will be optimized to ensure the cementing quality and borehole stability.
(4) Improve environmental protection and safety. In terms of environmental protection, future study on the high-temperature resistant oil-based/synthetic-based drilling fluid technology will focus on developing the environmentally friendly additives with low toxicity and easy degradation to reduce the risk of environmental pollution. Moreover, the drilling fluid formulas and process parameters will be optimized to reduce waste and discharge. In terms of safety, research will be enhanced on the safety performance of drilling fluids at high temperature to prevent generation of toxic or flammable gases.

3.3. Reservoir protection drilling fluid technology

(1) Improve the technical applicability. The applicability of reservoir protection drilling fluid technology will be improved to adapt to various reservoirs. By in-depth study on the reservoir physical and chemical properties, such as porosity, permeability, rock type and sensitivity, the targeted drilling fluid formulas and processes will be developed. Moreover, advanced simulation technologies will be used to predict and optimize the performances of drilling fluids in various reservoir conditions, thereby improving the technology applicability and effectiveness.
(2) Improve the properties and stability of materials. In future development of the reservoir protection drilling fluid technology, more efforts will be put in new high-performance additives and materials, which have stronger resistance to high temperature, high pressure and corrosion, allowing them to be stable in extreme environments. Moreover, the molecular structure and surface properties of materials will be optimized to reduce the risks of adverse reactions with fluids or rocks in the reservoirs.
(3) Enhance real-time monitoring and adjustment. In future development of the reservoir protection drilling fluid technology, more efforts will be put in enhancing the real-time monitoring technology and improving the sensor accuracy and data transmission speed. Advanced sensor networks and artificial intelligence algorithms will be introduced to realize real-time monitoring, analysis and prediction of drilling fluid properties and reservoir damage.

3.4. LCC technology

(1) Integrate and enhance the intelligent technology. Advanced technologies such as artificial intelligence, big data analysis and machine learning will be introduced to realize real-time acquisition, processing and analysis of formation data, thereby facilitating the accurate identification of formation characteristics and prediction of the risk of lost circulation, and providing a scientific basis for selection of applicable LCC technologies. The intelligent technology will be also applied in real-time monitoring and diagnosis during drilling, thus enabling a rapid determination of lost circulation position, type and size for purpose of plugging in a more efficient and accurate manner.
(2) Develop and apply high-performance LCMs. In future development of LCC technology, more efforts will be put in high-performance LCMs, which have stronger resistance to high temperature, high pressure, corrosion and shear in extreme conditions underground. Moreover, the physical properties (e.g. particle size distribution, density and viscosity) of materials will be optimized, and special chemical functional groups will be introduced, in order to improve the compatibility of LCMs with strata for effective plugging.
(3) Explore diversified LCC technologies and processes. In future development of the LCC technology, diversified technologies and processes will be considered, and new plugging principles and technologies, such as nano-material plugging, microbial plugging, and chemical reaction plugging, will be investigated. These technologies and processes are expected to provide additional solutions to lost circulation in complex strata and extreme conditions.
(4) Enhance environmental protection and safety awareness. In future development of the LCC technology, more efforts should be put in environmental protection and safe operation. New technologies will be developed and applied with consideration to their environmental impacts and by preferring environmentally friendly materials and processes. Moreover, lost circulation risk assessment and early warning mechanism will be established and enhanced to realize timely discovery and treatment of potential safety hazards and ensure the safety of drilling operation.

4. Conclusions

Deep and ultra-deep drilling fluid technologies are critical in oil and gas exploration and development. Nonetheless, they face several challenges and problems involving the stability in extreme environments of high temperature, high pressure and high stress, the applicability in complex strata, and uncertainties arising from the interactions between drilling fluids and strata.
In terms of the high-temperature resistant water-based drilling fluid technology, a variety of drilling fluid systems have been developed, but there are still several problems in application, such as insufficient stability at high temperature, difficulty in controlling rheological properties and filtration, and inadequate compatibility with strata. Future efforts will be focused on stability at high temperature, rheological properties, filtration, and compatibility with strata.
In terms of the high-temperature resistant oil-based/ synthetic-based drilling fluid technology, there are problems involving the stability and rheology at high temperature, emulsion stability and demulsification treatment, compatibility with strata and cement slurry, and environmental protection and safety. Further efforts will be made on research and development of high-temperature stabilizers and flow pattern regulators, emulsifiers and demulsifiers, environmentally friendly additives with low toxicity and easy degradation, and supporting technologies.
In terms of the reservoir protection drilling fluid technology, future research will be focused on technical applicability, material properties and stability, real-time monitoring and adjustment, and new high-performance additives and materials will be developed to improve the technology applicability and effect. Moreover, advanced sensor networks and artificial intelligence algorithms will be introduced to improve the real-time monitoring technology.
In terms of LCC technology, several technologies are available, but there are still many problems in technology selection and compatibility with strata, material properties, operation complexity and efficiency, and environmental and safety impact. Future efforts will be devoted to integration and application of intelligent technology, development and application of high-performance LCMs, exploration of diversified LCC technologies and processes, and improvement of environmental protection and safe operation awareness.
In general, worldwide researches on deep and ultra-deep drilling fluid technologies have made certain progress, but still face some key problems. The deep and ultra-deep drilling fluid technologies will be developed towards high performance, intelligence and environmental protection. Advanced technologies such as artificial intelligence and big data will be introduced to realize intelligent control of drilling process and thus improve drilling efficiency and oil and gas production. These efforts are expected to contribute additional great breakthroughs in the deep and ultra-deep drilling fluid technologies.
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