Abstract
Problems such as well loss and collapses in deep shale gas drilling are most often due to the development of cracks in the shale formation, resulting in significant leaks of drilling fluid, the sticking and burrowing of drilling tools, and other engineering accidents. In addition, the horizontal sections of wells are very long and issues of friction, rock transport, and formation contamination loom large. As a result, the performance of drilling fluids directly affects drilling efficiency, engineering accident rates, and reservoir protection effects. We first analyze the mechanisms of each emulsifier in an oil-based drilling fluid formulation and the filtration reduction mechanisms, taking into account the collapse-prone and abnormally high-pressure characteristics of shale formations. We undertake an experimental evaluation and optimization of polymeric surfactants, such as primary and secondary emulsions for high-performance oil-based drilling fluids. The design of rigid and deformable nano-micron plugging materials with a reasonable particle size range was achieved, and we obtained a low Oil—Water ratio and high-density oil-based drilling fluid system, with temperature resistance of 200 °C, an Oil—Water ratio as low as 70:30, compressive fracturing fluid pollution of 10%, and a maximum density of 2.6 g/cm3. The reuse rate reached 100%. The developed oil-based drilling fluid system with strong plugging, a high density, and a low Oil—Water ratio suitable for deep shale gas can effectively seal the well wall, reduce liquid invasion, prevent the wall from collapsing, reduce mud leakage, reduce the consumption of oil-based drilling fluid, improve the utilization rate of old mud, and reduce drilling costs.