Microwaving Graphene-Based Thermoset Polymers for Rapid and In-situ Wellbore Strengthening and Zonal Isolation

Abstract

The objective of this work is to develop a first-of-its-kind platform technology for in-situ and rapid wellbore strengthening as well as zonal isolation for geothermal wells such as EGS developments. Building on our recently elucidated scientific principles, the core of our technology uses functionalized graphene nanoribbons (GNRs) embedded in suitable solutions (e.g. drilling fluids or high performance polymers), which will be irradiated with a microwave (MV) downhole tool for rapid curing. In drilling applications, the nanoscale functionalize GNRs dispersed in the drilling fluid will diffuse deep inside the rocks and dramatically enhance the mechanics of the entire rock via effective curing and reinforcement. In completion applications, the polymer solutions with GNRs break into crumpled (flexible) bags attached to a downhole tool, significantly expanding them to conformably cover the rough wellbore walls, followed by MV curing. In both applications, the functionalized GNRs act as electromagnetic antenna for efficient absorption of MV, and rapid and in-situ polymer curing. This platform technology allows effective prevention of wellbore instability on-the-fly as the drill bit advances, and also enables rapid and in-situ isolation of the multiple fracture zones, demonstrating a significant first-step in wellbore strengthening, sealing and zonal isolation for EGS and broader complex wells. This R&D combine the fundamentals of cutting-edge materials science, polymer chemistry, and advanced engineering followed by thorough testing in lab-simulated environments that are tailored to improve drilling efficiency and zonal isolations in openholes of EGS conditions.