BACKGROUND

Field of the Disclosure

[0001] The present disclosure generally relates to controlling lost circulation in a wellbore during drilling with a drilling fluid. More specifically, embodiments of the disclosure relate to a lost circulation materials (LCMs) for moderate and severe loss zones.

Description of the Related Art

[0002] Lost circulation is one of the frequent challenges encountered during drilling operations. Lost circulation can be encountered during any stage of operations and occurs when drilling fluid (such as drilling mud) pumped into a well returns partially or does not return to the surface. While some fluid loss is expected, excessive fluid loss is not desirable from a safety, an economical, or an environmental point of view. Lost circulation is associated with problems with well control, borehole instability, pipe sticking, unsuccessful production tests, poor hydrocarbon production after well completion, and formation damage due to plugging of pores and pore throats by mud particles. In extreme cases, lost circulation problems may force abandonment of a well.

[0003] Lost circulation can occur in various formations, such as naturally fractured formations, cavernous formations, and high permeable formations. Lost circulation can be categorized by the amount of fluid or mud lost as seepage type, moderate type, severe type, and total loss. The extent of the fluid loss and the ability to control the lost circulation with an LCM depends on the type of formation in which the lost circulation occurs.

SUMMARY

[0004] Moderate and severe loss zones may contain gaps, fractures, vugs, and channels having sizes greater than 5 millimeters (mm ). A moderate loss zone may refer to loss zones exhibiting fluid losses of in the range of 10 barrels/hour (bbl/hr) to 100 bbl/hr. A severe loss zone may refer to loss zones exhibiting fluid losses of 100 barrels//hour (bbl/hr) or greater. Existing particulate or chip LCMs may be unable to create effective bridges and flow barriers in the openings in these moderate and severe loss zones.

[0005] Typical materials used to address lost circulation in moderate and severe loss zones may include calcium carbonate chips or graphite chips having sizes in the range of 2 mm to 6 mm and densities greater than 2 grams per cubic centimeter (g/cm ³ ). However, calcium carbonate chips settle and sag in the stock tank or drilling fluid circulation system and are difficult to suspend in a carrier fluid during circulation and placement of a slurry into a loss zone. Graphite chips may also suffer from the settlement and sagging problems in the stock tank and drilling fluid circulation system. These settlement and sagging of calcium carbonate or graphite chips may be more problematic in deviated or horizontal wellbores.

[0006] Additionally, the suspension capability of a drilling mud or carrier fluid decreases in proportion to the density of the materials in tire mud or fluid. Consequently, the densities of the calcium carbonate or graphite chips may make such chips difficult to suspend in the drilling mud or carrier fluid and decrease the success rate of an LCM treatment. Additionally, tor a given mass concentration, the number of chips that can be incorporated into a drilling mud or carrier fluid increases with a decrease in density and may also affect the success rate of an LCM treatment.

[0007] In one embodiment, a method to reduce lost circulation of a drilling fluid in a wellbore in a formation is provided. The method includes introducing an altered drilling fluid into the wellbore while drilling such that a loss circulation material (LCM) contacts a lost circulation zone, such that tire altered drilling fluid includes the drilling fluid and the LCM. The LCM consists of a plurality of chips produced from date tree seeds, each of the plurality of chips having a size in the range of greater than 2.38 millimeters (mm) to less than 6.73 mm.

[0008] In some embodiments, the altered drilling fluid consists of the drilling fluid and the LCM. In some embodiments, the drilling fluid is a water-based drilling mud or an oil-based drilling mud. In some embodiments, the plurality of chips are produced from untreated date tree seeds. In some embodiments, the plurality of chips are produced by: washing date tree seeds, drying the date tree seeds after the washing, the drying including air-drying the date tree seeds for a first time period of at least two hours, hot rolling the date tree seeds at a temperature of at least 80°C for a second time period of at least two hours, and cooling the hot-rolled date tree seeds for a third time period of at least two hours. The plurality of chips are further produced by grinding the cooled date tree seeds, and sorting tire ground date tree seeds into the plurality of chips, in some embodiments, the LCM has a specific gravity of 1.1.

[0009] In some another embodiment, an altered drilling fluid is provided. The altered drilling fluid includes a drilling fluid and a lost circulation material (LCM). The LCM consists of a plurality of chips produced from date tree seeds, each of the plurality of chips having a size in the range of greater than 2.38 millimeters (mm) to less than 6.73 mm. the altered drilling fluid consists of the drilling fluid and the LCM. In some embodiments, the drilling fluid is a water-based drilling mud or an oil-based drilling mud. In some embodiments, the plurality of chips are produced from untreated date tree seeds. In some embodiments, the plurality of chips are produced by: washing date tree seeds, drying the date tree seeds after tire washing, the drying including air-drying the date tree seeds for a first time period of at least two hours, hot rolling the date tree seeds at a temperature of at least 80°C for a second time period of at least two hours, and cooling the hot-rolled date tree seeds for a third time period of at least two hours. The plurality of chips are further produced by grinding the cooled date tree seeds, and sorting the ground date tree seeds into the plurality of chips.

[0010] In another embodiment, a lost circulation material (LCM) composition is provided. The LCM composition consists of a plurality of chips produced from date tree seeds, each of the plurality of chips having a size in the range of greater than 2.38 millimeters (mm) to less than 6.73 mm. In some embodiments, the plurality of chips are produced from untreated date tree seeds.

[0011] In another embodiment, a method of manufacturing a lost circulation material (LCM) is provided. The method includes obtaining date tree seeds, washing the date tree seeds, and drying the date tree seeds after the washing. The drying includes air-drying the date tree seeds at ambient conditions for a first time period of at least two hours, hot rolling the date tree seeds at a temperature of at least 80°C for a second time period of at least two hours, and cooling the hot-rolled date tree seeds at for a third time period of at least two hours. The method further includes grinding the cooled date tree seeds sorting the ground date tree seeds into a plurality of chips, each chip having a size in the range of greater than 2.38 millimeters (mm) to less than 6.73 sum. In some embodiments, washing the date seeds includes washing the date seeds using pressurized water with mechanical agitation. In some embodiments, sorting the dried date seeds includes using a plurality of sieves. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is a process for the manufacture and use of a date palm seed-based chip LCM in accordance with an embodiment of the disclosure;

[0013] FIG. 2 is a bar graph depicting the measured log on grinding index (LOG I) for an example date palm seed-based chip LCM and the three commercially available calcium carbonate chips in accordance with an embodiment of the disclosure;

[0014] FIG. 3 is a bar graph of the specific gravities of an example date palm seed-based chip LCM and the two commercially available calcium carbonate chips in accordance with an embodiment of the disclosure;

[0015] FIGS. 4 A and 4B are photographs of an example date palm seed-based chip LCM and commercially available calcium carbonate chips in a viscous fluid after a time period in accordance with an embodiment of the disclosure; and

[0016] FIG. 5 is a graph of the number of chips per 350 cubic centimeters (cc) of drilling mud tor an example date tree seed-based LCM and commercially available calcium carbonate chips in accordance with an embodiment of the disclosure.

DETAILED DESCRIPTION

[0017] The present disclosure will be described more fully with reference to the accompanying drawings, which illustrate embodiments of the disclosure. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0018] Embodiments of the disclosure include a date tree seed-based chip lost circulation material (LCM) having chips formed from date tree seeds. As used in the disclosure, the term date palm seeds (also referred to as “date seeds”) refers to the seeds produced from date trees (also referred to as “date palms”), such as used in the production of date fruits (also referred to as “dates”). The date tree seed-based chip LCM includes chips having a particle size in the range of greater than 2.38 millimeters (mm) to less than 6,73 mm. The chips formed from date tree seeds may include chips passed through a sieve of 6.73 mm (0.265 inches) mesh size and retained on a sieve of 2.38 millimeters (No. 8) mesh size

[0019] in some embodiments, the date palm seed-based chip LCM may have a log on grinding index (LOG I) of about 5.5. In some embodiments, the specific gravity of the date palm seed-based chip LCM may be about 1.1. The density of the date palm seed-based chip LCM may be about 1.1 g/cm ³ . The density of the date palm seed-based chip LCM may ensure minimal to no settlement (that is, settling of the solids at the bottom of a liquid to form a sediment) of the LCM in a fluid tank and fluid circulation system (for example, a drilling fluid circulation system), minimal to no sagging (that is, settling of the solids in a well annulus) in a deviated hole sections, and minimal to no bedding (that is, setling of solids at the botom) in horizontal wellbores. When introduced into a loss zone, the date palm seed-based chip LCM may form plugs, seals, bridges, flow barriers, or other structures in gaps, fractures, vugs, channels, and other openings having sizes greater than 5 mm.

[0020] The date palm seeds may he obtained from pruning waste and date processing plants to provide a sustainable source of material for the date palm seed-based chip LCM. The date palm seeds are obtained from the species phoenix dactylifera. It should be appreciated that, in some embodiments, the date palm seeds may be obtained from genetically modified date trees (that is, genetically modified organisms (GMOs)).

[0021] in some embodiments, the date palm seeds may include untreated date palm seeds to preserve the environmentally-friendly and biodegradable properties of the manufacturing process, the date palm seeds, and the resulting LCM composition. As used in the disclosure, the term “untreated” or ‘"without treating” refers to not treated with alkali or acid, not bleached, not chemically altered, not oxidized, and without any extraction or reaction process other than possibly drying of water. The term “untreated” or “without treatments” does not encompass grinding or heating to remove moisture but does encompass chemical or other processes that may change the characteristics or properties of the particles, in such embodiments, the chips may be manufactured without treating before, during, or after crushing, grinding, drying, or any other processing.

[0022] The date palm seed-based chip LCM may be added to a carrier fluid or a drilling fluid that is circulated (for example, via a pump) to position the LCM into contact with a lost circulation zone in a wellbore. In some embodiments, the date palm seed-based chip LCM may be added directly to a drilling fluid, such as a drilling mud, to create an altered drilling fluid having the date palm seed-based chip LCM. For example, so imn e embodiments, the date palm seed-based chip LCM may be added to (for example, blended with) an oil-based drilling mud or a water-based drilling mud. in some embodiments, the date palm seed-based chip LCM may be added at the mud pit of a mud system. After addition of the date palm seed-based chip LCM to a drilling fluid, the altered drilling fluid may be circulated at a pump rate effective to position the altered drilling fluid into contact with a lost circulation zone in a wellbore, such that the date palm seed-based chip LCM alters the lost circulation zone (for example, by forming structures in gaps, fractures, vugs, channels, and other openings a in formation).

[0023] In some embodiments, the date palm seed-based chip LCM may have a concentration in the range of about 10 pounds-per-barrel (ppb) to about 50 ppb in a drilling fluid. In some embodiments having moderate, the date palm seed-based chip LCM may have a concentration in the range of about 15 ppb to about 30 ppb in a drilling fluid. In some embodiments, the drilling fluid or carrier fluid may be water-based mud, such as a bentonite mud, a potassium chloride (KCl)-polymer mud, a low solids non -dispersed (LSND) mud, a calcium chloride (CaCl ₂ -polymer mud, a sodium chloride (NaCl)-polymer mud, or other water-based muds. An example bentonite mud may include water, bentonite, caustic soda, and soda ash. An example KC1-polymer mud may include water, caustic soda, soda ash, bentonite, KC1, Xanthomonas campestris (XC or xanthan gum) polymer, and a filtrate control additive. In some embodiments, the drilling fluid or carrier fluid may an oil-based mud, such as diesel-, mineral-, or synthetic-oil based muds.

[0024] FIG. 1 depicts a process 100 for the production and use of a date palm seed-based chip LCM in accordance with an example embodiment of the disclosure. As shown in FIG. 1, whole date tree seeds may be collected (block 102). In some instances, the whole date seeds are collected from date tree waste produced by date tree fanning and date processing industries. The date palm seeds may he washed to remove fruit particles and other debris and foreign substances (block 104), such as by pressurized water or an air jet in a closed loop system with mechanical agitation. The washed whole date seeds may be then be dried using one or more techniques (block 106). in some embodiments, the whole date seeds may be dried using a hot rolling to improve the ductility of the date seeds. In such embodiments, the washed whole date seeds are first air-dried at ambient temperature for a time period of at least two hour, then hot rolled (for example, in a roller oven) at a temperature of at least 80°C for a time period of at least two hours, then cooled at ambient conditions (temperature and pressure) for a time period of at least two hours.

[0025] The dried whole date seeds may then be ground into chips (block 108) using a commercial grinder. The chips may be sorted into different sizes using sieves of the appropriate mesh sizes (block 110). For example, the chips may be sorted using a sieve of 6.73 mm (0.265 inches) mesh size and a sieve of 2.38 millimeters (No. 8) mesh size. The sorted date tree seed- based chips may be packed for transportation and use (block 112). In some embodiments, a suitable amount of packed mixed particles may then be transported to an oil and gas operations site for use as an LCM.

[0026] The date palm seed-based chip LCM may be added directly to a drilling fluid (block 114), such as a drilling mud, to create an altered drilling fluid having the date palm seed-based chip LCM. For example, in some embodiments, the date palm seed-based chip LCM may be added to (for example, blended with) an oil-based drilling mud or a water-based drilling mud. In some embodiments, the date palm seed-based chip LCM may be added at the mud pit of a mud system.

[0027] After addition of the date palm seed-based chip LCM to a drilling fluid, the altered drilling fluid may be circulated at a pump rate effective to position the drilling fluid into contact with a lost circulation zone in a wellbore, such that the date palm seed-based chip LCM alters the lost circulation zone (for example, by entering and blocking gaps, fractures, vugs, channels, and other openings in a formation in the lost circulation zone). In some embodiments, the lost circulation zone may be a moderate loss zone or a severe loss zone, including loss zones having gaps, fractures, vugs, channels, and other openings greater than 5 mm in size. The date palm seed-based chip LCM may form structures (for example, plugs or seals) at gaps, fractures, vugs, channels, and other openings in a loss zone. In some embodiments, the reduced rate of lost circulation may be negligible.

[0028] In other embodiments, the date palm seed-based chip LCM and one or more additional LCMs may be added to a drilling fluid, such as a drilling mud, to create an altered drilling fluid having the LCMs. For example, in some embodiments, the date palm seed-based chip LCM and one or more additional LCMs may be added to an oil-based drilling mud or a water-based drilling mud. [0029] EXAMPLES

[0030] The following examples are included to demonstrate embodiments of the disclosure. It should be appreciated by those of skill in the art that the techniques and compositions disclosed in the example which follows represents techniques and compositions disco vered to function well in the practice of the disclosure, and thus can be considered to constitute modes for its practice. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or a similar result without departing from the spirit and scope of the disclosure.

[0031] The following non-limiting example of a date palm seed-based chip LCM was prepared and evaluated against a commercially available LCM. The example date palm seed- based chip LCM included chips having a particle size in the range of greater than 2.38 millimeters (mm) to less than 6.73 mm.

[0032] The degradation potential of the example date palm seed-based chip LCM was evaluated by measuring the loss on grinding index (LOG I). The loss on grinding index was measured by determining the ratio of material lost after two hours of wet grinding to the original mass of the material. The wet grinding was performed to simulate the attrition effect of surface and subsurface tools and the hydrodynamic forces of circulating fluid that would impact an LCM. The wet grinding test used a test cell to simulate a piece of a wellbore, a free rotating metal cylinder to simulate the attrition effect of surface and subsurface tools and equipment, and water as the carrier fluid to simulate hydrodynamic forces. The wet grinding test used rotating equipment to the rotate the test cell at a rotational speed of about 35 revolutions per minute (rpm) to simulate aggressive hydrodynamic forces.

[0033] The example date tree seed-based chip LCM was compared against three commercially available calcium carbonate chips. The LOG I of the each of the three calcium carbonate chips was measured using the same testing conditions. About 20 to 25 grams (g) of the example date tree seed-based chip LCM or the calcium carbonate (CaCO ₃ ) chips were placed in the test cell and rotated at the rotational speed for a time period of about two hours at room temperature. The mass of the material lost was measured and used to determine the LOG 1 from the original 25 g. [0034] FIG. 2 is a bar graph 200 depicting the measured LOG I for the example date palm seed-based chip LCM and each of the three commercially available calcium carbonate chips. The y-axis 202 depicts the LOG I (in percentage (%)), and the x-axis 204 depicts each tested material. As shown in FIG. 2, the example date palm seed-based chip LCM (illustrated by bar 206) had a LOG I of 5.5. As also shown in FIG. 2, the first commercially available calcium carbonate chips (illustrated by bar 208) had a LOG I of 4.5, the second commercially available calcium carbonate chips (illustrated by bar 210) had a LOG I of 6, and the third commercially available calcium carbonate chips (illustrated by bar 212) had a LOG I of 7.5. Thus, the date tree seed-based chip LCM exhibited on average similar performance to the commercially available calcium carbonate chips. The results of the degradation testing show that the date tree seed-based chip LCM has similar degradation resistance to the calcium carbonate chips when subjected to simulated mechanical and hydrodynamic forces encountered in a wellbore during operations and fluid circulation.

[0035] The specific gravity of the example date palm seed-based chip LCM was also determined and compared against commercially available calcium carbonate chips and commercially available graphite chips. FIG. 3 is a bar graph 300 of the specific gravities of the example date palm seed-based chip LCM and the two commercially available calcium carbonate chips. The y-axis 302 corresponds to the specific gravity, and the x-axis 304 corresponds to each material. As shown in FIG. 3, the commercially available calcium carbonate chips (illustrated by bar 306) have a specific gravity of 2.7, and the commercially available graphite chips (illustrated by bar 308) have a specific gravity of 2.16. As also shown in FIG. 3, the example date tree seed-based chip LCM (illustrated by bar 310) has a specific gravity of 1.1. Thus, the example date tree seeds LCM has a specific gravity about 2.45 times less than the commercially available calcium carbonate chips and about 1.9 times less than the commercially available graphite chips. As compared to the calcium carbonate chips or graphite chips, the reduced specific gravity of the example date palm seed-based chip LCM may enable easier suspension of the LCM in a drilling fluid or carrier fluid with no or negligible settlement or sagging while circulating, thus providing for easier placement in a loss zone and increasing the likelihood of a successful LCM treatment.

[0036] The suspension capacity of the example date palm seed-based chip LCM and one of the commercially available calcium carbonate chips were evaluated using a vicious fluid having viscous characteristics similar to a earner fluid typically used in oil and gas well drilling. The viscous fluid was prepared by mixing 2.5 g of XC polymer (xanthan gum) in 350 cubic centimeters (cc) of water and mixing using a commercially available mixer. The resulting carrier fluid had low shear yield point (LSYP) equal to 19.5 lbs/100 ft ² . The date palm seed- based chip LCM and calcium carbonate chips were placed in separate containers with the viscous fluid, stirred, and observed over a time period of about 2 minutes to 5 minutes.

[0037] FIG. 4A is a photograph 400 of the example date palm seed-based chip LCM in the viscous fluid after the time period, and FIG. 4B is a photograph 402 of the calcium carbonate chips in the viscous fluid after the time period. The date seed-based chips were initially suspended inthe carrier fluid and, as shown in FIG. 4A, the date seed-based chips remained suspended in the carrier fluid after the time period. In contrast, as shown in FIG. 4B, the calcium carbonate chips showed poor suspension capability and quickly settled at the bottom of the container of viscous fluid. The reduced suspension capacity and greater settlement of the calcium carbonate chips indicate that it may be difficult to transport the calcium carbonate chips to a loss zone and enable sealing, plugging, and blocking of gaps, fractures, vugs, and channels in the loss zone. In contrast, the greater suspension capacity and zero or negligible settlement of the date tree seed-based chips may provide for the transportation of nearly all of the chips in a fluid to a loss zone for effective sealing, plugging, and blocking of gaps, fractures, vugs, and channels in the loss zone. Based on the results of the testing, the date palm seed- based chip LCM will likely have minimal to no settling or sagging during pumping or placement into a loss zone, thus improving the likelihood of success of an LCM treatment in such zones.

[0038] Moderate to severe loss zones typically have greater concentrations of gaps, fractures, vugs, and channels than other types of loss zones. LCMs that provide a greater number of particles per unit mass will transport a greater number of particles into such loss zones. Accordingly, the number of particles per unit mass for the example date tree seed-based chip LCM was determined and compared to one of the commercially available calcium carbonate chips. For the determinations, the chip size was assumed to be equivalent to a sphere having a diameter of 0.30 centimeters (cm). FIG. 5 is a graph 500 of the number of chips per 350 cubic centimeters (cc) of drilling mud for the date tree seed-based LCM and the one of the commercially available calcium carbonate chips. The y-axis 502 corresponds to the number of ehips/350 cc of drilling mud (chip number/350 cc mud) and the x-axis 504 corresponds to the chips concentration in grams per 350 cc of drilling mud (gm/350 cc mud). The chip concentration for the date tree seed-based chip LCM is shown by line 506, and the chip concentration for the calcium carbonate chips is shown by line 508. As shown in FIG. 5, the date tree seed-based chip LCM provides more than twice the number of particles as compared to the calcium carbonate chips at the same mass concentration . The greater number of particles per unit mass shows that the date tree seed-based chip LCM has a greater likelihood of plugging, sealing, and blocking tire channels, gaps, fractures, vugs, channels, and other openings in a loss zone as compared to the calcium carbonate chips.

[0039] Ranges may be expressed in the disclosure as from about one particular value, to about another particular value, or both. When such a range is expressed, it is to be understood that another embodiment is from the one particular value, to the other particular value, or both, along with all combinations within said range.

[0040] Further modifications and alternative embodiments of various aspects of the disclosure will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is tor the purpose of teaching those skilled in the art the general manner of carrying out the embodiments described in the disclosure. It is to be understood that the forms shown and described in the disclosure are to be taken as examples of embodiments. Elements and materials may be substituted for those illustrated and described in the disclosure, parts and processes may be reversed or omitted, and certain features may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description. Changes may be made in the elements described in the disclosure without departing from the spirit and scope of the disclosure as described in the following claims. Headings used in the disclosure are for organizational purposes only and are not meant to be used to limit the scope of the description.