Nanoparticles in Drilling Fluids: A Review of Types, Mechanisms, Applications, and Future Prospects
Abstract
:1. Introduction
Background
2. Nano Fluids
- Selection of nanoparticles: Identify the exact properties, such as improved viscosity, increased thermal conductivity, and enhanced stability, to be addressed in a drilling fluid. Choose the appropriate nanoparticle, for example silica for viscosity, copper for thermal management, zinc oxide for antimicrobial characteristics, and titanium dioxide for stability.
- Synthesis of nanoparticles: Based on the chosen nanoparticles, employ respective synthesis methods such as the sol–gel process (suitable for generating metal oxides at controlled sizes), hydrothermal synthesis (includes elevated operational conditions of temperature and pressure for nanoparticle generation), and chemical vapor deposition (appropriate for generating pure/high-quality nanoparticles. Characterize the generated nanoparticles through their size, morphology, and surface properties using transmission electron microscopy (TEM) or scanning electron microscopy (SEM) [12].
- Preparation of base fluid: Select water or oil for the base of the drilling fluid, depending on the drilling environment. Choose the necessary additives, such as weighing agents or polymers, based on the drilling environment and based on which could complement the functions of selected nanoparticles.
- Dispersion of nanoparticles: Add dispersing agents such as surfactants or stabilizers to prevent the agglomeration of nanoparticles in the base fluid. Use high-shear mixers or ultrasonic dispersers to confirm the even distribution of nanoparticles throughout the drilling fluid.
- Mixing process: Add the nanoparticles slowly while maintaining continuous stirring to ensure good dispersion. Mechanical mixing or ultrasonication can guarantee a homogeneous mixture [19].
- Testing and optimization: Assess the rheological properties such as viscosity, yield point, and flow performance of the drilling fluid with the help of rheometers. Perform thermal stability tests on the fluid at different temperatures to warrant good performance in high-temperature environments. Analyze the test results and fine-tune the nanoparticle concentrations in the drilling fluid for the desired performance [20]. Figure 3 represents one of the basic processes of preparing a nanofluid.
2.1. Types of Nanofluids
2.1.1. Metal-Based Nanofluids
2.1.2. Oxide-Based Nanofluids
2.1.3. Carbide-Based Nanofluids
2.1.4. Nitride-Based Nanofluids
2.1.5. Carbon-Based Nanofluids
2.1.6. Composite Nanofluids
Type of Nanofluid | Cost | Base Fluid to be Used with | Reusability | Applicable under Conditions | References |
---|---|---|---|---|---|
Metal | High | Water, Oil | Moderate | High temperatures and pressures | [22,35] |
Metal Oxide | Moderate | Water, Oil, Glycol | High | Moderate to high temperatures | [36,37,38] |
Carbon-Based | High | Water, Organic Solvents | Moderate | High temperatures and pressures | [39] |
Composite/Hybrid | Variable | Water, Oil | Moderate | Depends on components and usually high performance | [40,41,42] |
Polymeric | Low | Water, Oil | High | Low to moderate temperatures, variable usage | [43,44] |
2.2. Nanofluids in the Drilling Industry
2.2.1. Silica Nanofluids
2.2.2. Alumina Nanofluids
2.2.3. Copper Oxide Nanofluids
2.2.4. Carbon Nanotube (CNT) Nanofluids
2.2.5. Graphene Nanofluids
2.2.6. Titanium Dioxide Nanofluids
2.2.7. Iron Oxide Nanofluids
3. Property-Based Applications
3.1. Lubrication
3.2. Fluid Stability
3.3. Heat Transfer
3.4. Sealing Microfractures
4. Drilling Applications
4.1. Fluid Loss Control
Nanoparticle Solutions for Fluid Loss in Drilling
4.2. Wellbore Stability
4.2.1. Reinforcement of the Filter Cake
4.2.2. Closing Microfractures and Pores
4.2.3. Improving Fluid Rheology
- Drilling fluid Density/Mud Weight: Density is the mass per unit volume of drilling fluid and is mostly measured in PPG (parts per gallon) or g/cm3 (gram per cubic centimeter). Mud weight is mainly responsible for maintaining hydrostatic pressure inside the wellbore to counteract formation pressures and prevent blowouts. Lower densities of the drilling fluid would lead to borehole breakout (shear failure of rocks) and wellbore collapse, while higher densities would result in problems such as decreased rate of penetration, probable loss of circulation, and formation damage. Nanoparticles can help in maintaining the fluid density through weight addition by using heavier nanoparticles like barite, which would improve its overall density [123,131].
- Plastic Viscosity (PV): The resistance of the fluid to flow due to the friction between the solid particles and the fluid layers of the drilling fluid. As PV depends on the viscosity of the base fluid (water, oil, and solids concentrations), higher mud weights and solids concentrations in drilling fluid would lead to higher PV values, resulting in reduced drilling speeds that are unfavorable [72]. Nanoparticles can improve plastic viscosity by increasing the contact area among the particles in the fluid, enhancing interparticle interactions, and leading to a thicker fluid structure. Silica nanoparticles are well known for improving viscosity by developing a network that stabilizes the fluid [99].
- Yield Point (YP): The point (stress level) at which the fluid yields its ability to resist the initial flow (shear thinning behavior) in non-Newtonian drilling fluids. The YP facilitates the capability of carrying drill cuttings through suspension during mud circulation (dynamic condition) in the wellbore, thereby avoiding differential sticking. Smaller particle sizes (of solids/additives) could lead to higher YP values due to the enhancement of the attractive forces between the solid particles and result in the better carrying of drill cuttings and in better hole cleaning [1]. Nanoparticles can yield thixotropic properties, resulting in fluid thickening when at rest and thinning under shear stresses, resulting in a better yield point when the fluid is still. Bentonite nanoparticles are one of the examples that exhibit thixotropic behavior. They increase the yield point by preserving a gel structure that refuses to flow until enough stress is employed [132].
- Gel Strength (GS): This is the force required to break the gel structure (attraction force between particles) of a fluid after resting for some time. GS is the measurement of drill cuttings suspension capability while the fluid is at rest (static condition), in contrast to YP. GS is time-dependent; if the fluid is static for longer, then the GS increases and more pressure is required to break the gel to restart circulation [72]. Nanoparticles such as palygorskite (Pal), a natural hydrous clay mineral with a fibrous rod-like needle microstructure, provide exclusive colloidal properties that help to improve gelation and the better suspension of drill cuttings in drilling fluids [90].
- v. Filtrate Loss and Mud Cake Thickness: Filtrate loss is the volume of liquid that escapes through a solid mud cake formation and infiltrates the surrounding formations due to the hydrostatic pressure being higher than the pore pressure. Suspended solids in the drilling fluid will fill the pores and form a mud cake. Higher solids concentrations in fluids tend to decrease the filtrate loss. Higher filtrate loss and mud cake thickness lead to differential pipe sticking. A good mud cake should be thin, strong, compressible, and have very low permeability [1,72]. The careful monitoring of factors such as drilling fluids composition, the amount of fluid loss control additives, the characteristics of suspended solids, and the thermal stability of the system helps us to achieve control over filtrate loss and mud cake thickness. Nanoparticles such as multi-walled carbon nanotubes (MWCNT) help us to achieve low filtrate volumes and thin impermeable filter cakes through high surface areas and nanotube structures [123,133].
4.2.4. Improving Thermal Stability by Reducing Friction and Drag
4.2.5. Improving Borehole Cleaning
References | Nanoparticle | Outcomes |
[99] | Silica (SiO2) | Due to high surface area and chemical stability, it enhanced mud rheology and reduced fluid loss. |
[138] | Amino nano-silica | Improved plugging performance compared to nano-silica. |
[139] | Alumina (Al2O3) | High hardness and thermal stability of the nanoparticles aided in improving lubrication and increasing cutting transportation. |
[140] | Titanium dioxide (TiO2)-bentonite nanocomposite | Improved lubricity and mud cake development, layering on shale and bentonite plugs, easing of clay and shale swelling, and a decrease in friction coefficient. |
[141] | Iron oxide (Fe2O3) | Improved coefficient of friction and fluid loss (filtrate loss). |
[105] | Graphene oxide (GO) | The linear swelling, filtration, uniaxial compressive strength, and imbibition of shale help prevent wellbore instability. |
[142] | Carbon nanotubes (CNTs) | Carbon nanotubes improve the performance of water-based drilling fluids in high-salinity and high-temperature conditions. |
[143] | Zinc oxide (ZnO) | Zinc oxide nanoparticles enhance the rheological properties of water-based drilling fluids even at high temperatures. |
[112] | Copper oxide (CuO) | Copper oxide nanoparticles are efficient in decreasing fluid loss and increasing wellbore stability in drilling fluids. |
[41] | Magnesium oxide (MgO) | Magnesium oxide nanoparticles in water-based drilling fluids can improve rheological, filtration, and viscoelastic properties and enhance wellbore stability. |
[144] | Bentonite nanoparticles | Decreases filtration loss by a mean of 34%, leading to better filtration; the nano-bentonite particles are layered onto the wellbore wall and close off the pores in the mud cake, thus helping with the “tight spot problem” in wellbores. |
4.2.6. Practical Precautions
4.3. Thermal Stability
4.3.1. Nanoscale Heat Management Mechanisms
4.3.2. Temperature Resistance:
4.3.3. Viscosity Control
4.3.4. Chemical Stability
4.3.5. Lubrication Control
References | Nanoparticle | Outcomes |
---|---|---|
[104] | CuO and ZnO | Proved to have better thermal and filtration properties. |
[101] | Fe3O4 | Increase in rheological and filtration properties along with improved thermal properties. |
[96] | TiO2 | Improved thermal properties. |
[160] | Y2O3 | Improved rheology and thermal properties. |
[52] | CuO and ZnO | Enhanced thermal characteristics. |
[166] | Carbon nanoparticles | Enhanced thermal conductivity. |
[167] | Al2O3 | Intensified thermal properties. |
[168] | Al2O3 | Improved thermal and rheological properties. |
[22] | Silver nanoparticles | Enhanced thermal properties. |
[51] | CuO | Enhanced the thermal and rheological properties. |
[77] | Multi-walled carbon nanotubes | Non-linear enhancement of thermal conductivity. |
[108,169] | Graphene nanosheets | Enhanced thermal conductivity of the nanofluid. |
[123,170] | Multi-walled carbon nanotubes | Modified MCNT enables the drilling fluid to have increased thermal conductivity and viscosity. |
[110] | Graphite–alumina | Improved zeta potential, electrical conductivity, thermal conductivity, and degree of structural recovery. |
[171] | Nano-silica | Improved thermal conductivity at high temperatures. |
[172] | Molybdenum disulphide | Improved lubricity and thermal stability. |
[90] | Palygorskite (Pal) | Good rheology modifier and improved thermal stability. |
5. Challenges and Future Scope
5.1. Challenges
5.1.1. Challenges in Nanoparticle Stability
5.1.2. Interactions with Drilling Fluid Components
5.1.3. Environmental Concerns
5.1.4. Heat Transfer Efficiency
5.1.5. Economic Viability
5.1.6. Safety Considerations
5.1.7. Other Technical Challenges
5.2. Future Scope and Technical Innovations
5.2.1. Strategies for Nanoparticle Stability and Compatibility Improvement
5.2.2. Environmental Stewardship and Sustainability
5.2.3. Nanomaterial Tuning for Heat Transfer Optimization
5.2.4. Economic Feasibility and Scalability
5.2.5. Safety First: Rigorous Risk Assessment and Regulation
6. Summary
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Type of Drilling Fluid | Composition | Preparation Process | Advantages | Disadvantages | References |
---|---|---|---|---|---|
Water-based Drilling Fluid | Seawater (as needed); Freshwater (as needed); Bentonite (0–50) (lbs/bbl); Barite (0–500) (lbs/bbl); NaOH (0–5) (lbs/bbl); Soda Ash (0–3) (lbs/bbl); NaHCO3 (0–3) (lbs/bbl); Drill solids (0–100) (lbs/bbl). | 1. Mix water with bentonite and hydrate by stirring. 2. Add barite gradually whilst mixing. 3. Add in polymer and other additives consistently. 4. Add dispersants. 5. Modify pH as required. | Ecofriendly; Low cost; Easy handling and disposal. | Unstable at high temperatures compared to oil-based muds. Possible shale instability in particular formations. | [1,5] |
Oil-based Drilling fluid | Base oil (diesel oil/mineral oil) (70–90% vol); Weighting agents (barite/CaCO3/hematite); Emulsifiers (lignosulfonates/fatty acids/tall oil); Filtrate control/wetting agent; Alkalinity control agents (NaOH/Ca (OH)2); Viscosifiers (Xantham gum/starches/organophilic clays). | 1. Mix base oil with emulsifier and keep stirring. 2. Add barite progressively. 3. Add surfactants and other additives. 4. Fluid loss control additives can be added as needed. | Exceptional lubrication; High thermal stability; Enhanced cuttings transportation. | High price; Environmental concerns; Hard to clean up. | [1,6] |
Synthetic-based drilling fluid | Synthetic organic compounds/esters/lubricants (30–90% vol); Salt (NaCl/KCl) brine; Emulsifiers; Wetting agents; Weighting material (barite, BaSO4, or ilmenite, FeTiO3) Clays; Lignite; Lime. | 1. Blend the synthetic base fluid with emulsifiers. 2. Stir and keep hydrated. 3. Gradually add in weighting materials. 4. Add in fluid loss control agents. 5. Include the surfactants. | Eco-friendly options are available; Elevated performance in extreme conditions; Improved fluid loss control characteristics. | Costs more than water-based drilling fluids; Possible toxicity of certain synthetic elements. | [4,7] |
References | Nanoparticle | Outcomes |
---|---|---|
[95] | Carbon nanotubes and nano-silica | Adding multi-walled carbon nanotubes and nano-silica enhanced mud rheological properties, such as plastic viscosity and yield point, compared to the base fluid. |
[98,99] | Nano-silica | Reduced fluid losses by 56% compared to the normal drilling fluid. |
[100] | Mesoporous nano-silica | Remarkable fluid loss reduction up to 41.81%, even under HTHP conditions. |
[15] | Fe3O4 | Reduced fluid losses by 40%, even under HTHP conditions of 250°F and 300 psi. |
[101] | Poly(sodium p-styrene sulfonate)-modified Fe3O4 | Enhanced thermal, rheological, and filtration properties. |
[93] | Fe2O3 | Better rheology and controlled fluid losses. |
[94] | Fe2O3—clay hybrid nanoparticles | Improved rheological properties of the drilling fluid. |
[102] | Iron-based nanoparticles | Better fluid loss control. |
[96] | TiO2 nanocomposites | Less thickness of mud cake and a 64% decrease in fluid losses compared to conventional drilling fluids. |
[15] | Calcium nanoparticles | Considerable fluid loss reduction and production of thinner filter cake which reduces permeability. |
[103,104] | CuO and ZnO | Reduced thickness of mud cake while upholding filtration properties. |
[105,106,107,108] | Graphene nanoparticles | Improved rheology and fluid loss control. |
[109] | Polymer graphene oxide | Stable filtration properties using polymer graphene oxide composites. |
[110] | Graphite–alumina | Reduction in fluid losses. |
[111] | Sepiolite nanoparticles | Enhanced rheological and filtration properties of the drilling mud. |
[112] | MgO | Decrease in fluid loss by 52% under HTHP conditions. |
[27] | Al2O3 | Enhanced filtration and rheological properties of water-based mud even under HTHP conditions. |
[113] | CaCO3 | Effective plugging of pores and reducing filter losses. |
[114] | BiFeO3 | Enhanced the force of attraction among clay particles due to NPs being highly ferroelectric and carrying permanent polarization, resulting in improved rheological properties, such as apparent viscosity and yield point. |
[115] | Carbon black | Significant reduction in fluid loss. |
[116] | Cellulose nanoparticles | Reduction in fluid loss at lower NP concentrations and improved rheology of the fluid. |
Type of Nanofluid | Best Application for | Environmental Impact | Reference |
---|---|---|---|
Copper | Improved thermal conductivity and lubrication properties. | Moderate, yet toxic in higher concentrations. | [145] |
Alumina (Al2O3) | Enhanced stability and viscosity. | Low, deemed safe in general but needs supervision. | [15] |
Zinc oxide (ZnO) | Better lubrication and antimicrobial properties. | Moderate, toxic to aquatic life if released. | [146] |
Titanium dioxide (TiO2) | Enhancement of fluid stability at high temperatures. | Low, safe yet concerning for inhalation risks. | [147] |
Iron oxide (Fe2O3) | Effective removal of cuttings. | Low and non-toxic, yet accountable disposal is required. | [148] |
Silver | Fluid quality maintenance and antimicrobial nature. | High, toxic for aquatic life in higher concentrations | [149] |
Silica | Improved fluid stability and transportation of cuttings. | Low and relatively non-toxic but carries risk of dust exposure. | [15] |
Graphene oxide | Enhanced mechanical properties and sealing of micropores. | Moderate, caution required due to environmental persistence and potential toxicity. | [150] |
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Gokapai, V.; Pothana, P.; Ling, K. Nanoparticles in Drilling Fluids: A Review of Types, Mechanisms, Applications, and Future Prospects. Eng 2024, 5, 2462-2495. https://doi.org/10.3390/eng5040129
Gokapai V, Pothana P, Ling K. Nanoparticles in Drilling Fluids: A Review of Types, Mechanisms, Applications, and Future Prospects. Eng. 2024; 5(4):2462-2495. https://doi.org/10.3390/eng5040129
Chicago/Turabian StyleGokapai, Vasanth, Prasad Pothana, and Kegang Ling. 2024. "Nanoparticles in Drilling Fluids: A Review of Types, Mechanisms, Applications, and Future Prospects" Eng 5, no. 4: 2462-2495. https://doi.org/10.3390/eng5040129
APA StyleGokapai, V., Pothana, P., & Ling, K. (2024). Nanoparticles in Drilling Fluids: A Review of Types, Mechanisms, Applications, and Future Prospects. Eng, 5(4), 2462-2495. https://doi.org/10.3390/eng5040129