Experimental Study on the Performance of Frictional Drag Reducer with Low Gravity Solids

Abstract

Reducing energy consumption during drilling operations is beneficial to both the environment and economy. Frictional drag reducers (FDR) are widely used to reduce the energy loss caused by turbulent flow. FDR plays an important role in flow lines as they can reduce the frictional pressure drop effectively, and benefit the selection of circulating fluid and pump. However, several factors can influence the performance of FDR, including fluid additives and incorporated solids, such as drill solids. Thus, the main objective of this paper is to study the influence of low gravity solids (LGS) on the performance of the FDR. This paper is mainly based on experimental study. The experimental work contains two parts: rheology characterization and flow loop tests. Rheology characterization tests were performed to calculate the flow consistency index (K) and flow behavior index (n). Flow loop experiments were conducted for two geometry (0.457 inch and 0.797 inch diameter). Xanthan gum was used as a fractional drag reducer. Bentonite and quartz sand were added as low gravity solids. Three designed water-based mud systems are tested for drag reduction efficiency of Xanthan gum. Flow rate of the mud varied from 3 gpm to 16 gpm. Concentration of Xanthan ranged from 0.1 lbm/bbl to 0.6 lbm/bbl. Low weight solids were added with weight percentage of 0.5%, 1%, 2% and 2.5%. The result shows that xanthan gum is an efficient drag reducer for adequate reasons. Firstly, even at al low concentration, xanthan gum shows high resistance to degradation. Secondly, the maximum drag reduction with xanthan gum is up to 70.54% with a concentration of 0.6 lbm/bbl. However, the existence of different low gravity solids influence the efficiency of xanthan gum in different styles. Experiment results indicate that the higher the weight percentage of bentonite, the lower the drag reduction effectiveness. While with the increasing concentration of quartz sand, the drag reduction does not show an intense change. This study intents to give an instructive guidance on usage of frictional drag reducers in drilling mud system design. Removal of low gravity solids from the mud is difficult, which pose a danger to the drilling fluid. By understanding the effectiveness of FDR, we can reduce energy consumption when irremovable low gravity solids exist. FDR can be used for modifying the mud contents to develop a lower pressure gradient under turbulent flow condition. In the same scenario, adding FDR can suppress turbulent at a constant pressure gradient but with a higher flow rate.