Synergistic application of polypropylene and silica nanoparticle modified by (3-Aminopropyl) triethoxysilane for cuttings transport

Achieving the desired efficiency in cuttings transport has always been a challenge during drilling situations due to complex wellbore trajectories and drilling hydraulics. These issues require suitable additives to formulate the drilling muds. Hence, nanocomposite (NC) particles formed from silica and polypropylene was modified by (3-Aminopropyl) triethoxysilane (termed PP-SiO₂ NC-NH₂) and the impact of the concentrations of the PP-SiO₂ NC-NH₂ between 0.4 and 1.2 ppb on the cuttings transport efficiency (CTE) of complex water-based mud (WBM) system was assessed. Mud system containing 0.5 ppb PP-SiO₂ NC-NH₂ on CTE was measured and compared with that of partially hydrolyzed polyacrylamide (PHPA) using sandstone grains of diameters between 0.50 and 3.20 mm at hole angles 0, 30, 45, 60, and 90° with a 42 L/min pump rate. The zeta potential (ζ-potential), particle size distribution, morphology, and temperature resistance of the NC were examined. The ζ-potential data revealed the stability and the long-term stabilization of the modified NC in drilling muds. By adding the concentration of the modified NC into the WBM system, the thinning characteristics and consistency factors were enhanced as the NC concentration increases. Furthermore, the rheological test program reveals that the NC concentrations and 0.5 ppb PHPA increased the shear stress of the WBM with an increase in the shear rate. However, the mud system of PHPA exhibited a larger viscosity, while the NC samples showed a flat viscosity-profile. Also, the NC demonstrated better cuttings recovery than the PHPA product at 0.5 ppb concentration, especially at the worst hole angle of 45°. The cuttings recovery from a minimum to a maximum was found to occur in this order; 45°, 60°, 30°, 90°, and 0°. In contrast with the smallest and intermediate sand grains, the largest grains have complex and less fluid transport. With a pipe orbital motion of 150 rpm and a pump rate of 42 L/min, the CTE of the muds showed higher improvement. Overall, the mud properties of the modified NC exhibited a strong enhancing impact on the cuttings carrying capacity of the base mud than the PHPA.