U.S. patent application number 11/601399 was filed with the patent office on 2008-05-22 for foamed resin compositions and methods of using foamed resin compositions in subterranean applications.
This patent application is currently assigned to Halliburton Energy Services, Inc.. Invention is credited to Philip D. Nguyen, Thomas D. Welton.
Application Number | 20080115692 11/601399 |
Document ID | / |
Family ID | 39415649 |
Filed Date | 2008-05-22 |
United States Patent
Application |
20080115692 |
Kind Code |
A1 |
Welton; Thomas D. ; et
al. |
May 22, 2008 |
Foamed resin compositions and methods of using foamed resin
compositions in subterranean applications
Abstract
Methods are provided that include a method comprising: providing
a foamed resin composition comprising a resin, a foaming agent, a
compressible gas, and an aqueous fluid; and introducing the foamed
resin composition into at least a portion of a subterranean
formation. Additional methods are provided.
Inventors: |
Welton; Thomas D.; (Duncan,
OK) ; Nguyen; Philip D.; (Duncan, OK) |
Correspondence
Address: |
ROBERT A. KENT
P.O. BOX 1431
DUNCAN
OK
73536
US
|
Assignee: |
Halliburton Energy Services,
Inc.
|
Family ID: |
39415649 |
Appl. No.: |
11/601399 |
Filed: |
November 17, 2006 |
Current U.S.
Class: |
106/122 |
Current CPC
Class: |
E21B 43/025 20130101;
C09K 8/518 20130101; C09K 8/56 20130101; C09K 8/80 20130101 |
Class at
Publication: |
106/122 |
International
Class: |
E21B 33/13 20060101
E21B033/13 |
Claims
1. A method comprising: providing a resin composition comprising a
resin and an aqueous fluid; foaming the resin composition using a
method comprising a foaming agent and a compressible gas to form a
foamed resin composition; and introducing the foamed resin
composition into an unconsolidated portion of a subterranean
formation.
2. The method of claim 1 wherein the resin comprises at least one
resin selected from the group consisting of: bisphenol A diglycidyl
ether resin, butoxymethyl butyl glycidyl ether resin, bisphenol
A-epichlorohydrin resin, polyepoxide resin, novolak resin,
polyester resin, phenol-aldehyde resin, urea-aldehyde resin, furan
resin, urethane resin, a glycidyl ether resin, and any combination
thereof.
3. The method of claim 1 wherein the resin is present in the foamed
resin composition in an amount in the range of from about 0.1% to
about 10% by weight of the foamed resin composition.
4. The method of claim 1 wherein the foaming agent comprises at
least one foaming agent selected from the group consisting of: a
mixture of an ammonium salt of an alkyl ether sulfate, a
cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine
oxide surfactant, sodium chloride, and water; a mixture of an
ammonium salt of an alkyl ether sulfate surfactant, a
cocoamidopropyl hydroxysultaine surfactant, a cocoamidopropyl
dimethylamine oxide surfactant, sodium chloride, and water;
hydrolyzed keratin; a mixture of an ethoxylated alcohol ether
sulfate surfactant, an alkyl or alkene amidopropyl betaine
surfactant, and an alkyl or alkene dimethylamine oxide surfactant;
an aqueous solution of an alpha-olefinic sulfonate surfactant and a
betaine surfactant; and any combination thereof.
5. The method of claim 1 wherein the foaming agent is present in
the foamed resin composition in an amount in the range of from
about 0.01% to about 6% by weight of the foamed resin
composition.
6. The method of claim 1 wherein the compressible gas comprises at
least one compressible gas selected from the group consisting of:
air, nitrogen, carbon dioxide, and any combination thereof.
7. The method of claim 1 wherein the compressible gas is present in
an amount sufficient to produce a final foamed resin composition
density from about 6 to about 12 pounds per gallon based on weight
of water.
8. The method of claim 1 wherein the foamed resin composition
further comprises a viscosifier.
9. A method comprising: providing a resin composition comprising a
resin and an aqueous fluid; foaming the resin composition using a
method comprising a foaming agent and a compressible gas to form a
foamed resin composition; introducing the foamed resin composition
into at least a portion of a subterranean formation; and allowing
the foamed resin composition to at least partially consolidate at
least a portion of the subterranean formation.
10. The method of claim 9 wherein the resin comprises at least one
resin selected from the group consisting of: bisphenol A diglycidyl
ether resin, butoxymethyl butyl glycidyl ether resin, bisphenol
A-epichlorohydrin resin, polyepoxide resin, novolak resin,
polyester resin, phenol-aldehyde resin, urea-aldehyde resin, furan
resin, urethane resin, a glycidyl ether resin, and any combination
thereof.
11. The method of claim 9 wherein the foaming agent comprises at
least one foaming agent selected from the group consisting of: a
mixture of an ammonium salt of an alkyl ether sulfate, a
cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine
oxide surfactant, sodium chloride, and water; a mixture of an
ammonium salt of an alkyl ether sulfate surfactant, a
cocoamidopropyl hydroxysultaine surfactant, a cocoamidopropyl
dimethylamine oxide surfactant, sodium chloride, and water;
hydrolyzed keratin; a mixture of an ethoxylated alcohol ether
sulfate surfactant, an alkyl or alkene amidopropyl betaine
surfactant, and an alkyl or alkene dimethylamine oxide surfactant;
an aqueous solution of an alpha-olefinic sulfonate surfactant and a
betaine surfactant; and any combination thereof.
12. The method of claim 9 wherein the foaming agent is present in
the foamed resin composition in an amount in the range of from
about 0.01% to about 6% by weight of the foamed resin
composition.
13. The method of claim 9 wherein the compressible gas comprises at
least one compressible gas selected from the group consisting of:
air, nitrogen, carbon dioxide, and any combination thereof.
14. The method of claim 9 wherein the compressible gas is present
in an amount sufficient to produce a final resin composition
density from about 6 to about 12 pounds per gallon based on weight
of water.
15. A method comprising: providing a resin composition comprising a
resin and an aqueous fluid; foaming the resin composition using a
method comprising a foaming agent and a compressible gas to form a
foamed resin composition: introducing the foamed resin composition
into at least a portion of a subterranean formation; and allowing
the foamed resin composition to modify the stress-activated
reactivity of at least a portion of a mineral surface in the
subterranean formation.
16. The method of claim 15 wherein the resin comprises at least one
resin selected from the group consisting of: bisphenol A diglycidyl
ether resin, butoxymethyl butyl glycidyl ether resin, bisphenol
A-epichlorohydrin resin, polyepoxide resin, novolak resin,
polyester resin, phenol-aldehyde resin, urea-aldehyde resin, furan
resin, urethane resin, a glycidyl ether resin, and any combination
thereof.
17. The method of claim 15 wherein the foaming agent comprises at
least one foaming agent selected from the group consisting of: a
mixture of an ammonium salt of an alkyl ether sulfate, a
cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine
oxide surfactant, sodium chloride, and water; a mixture of an
ammonium salt of an alkyl ether sulfate surfactant, a
cocoamidopropyl hydroxysultaine surfactant, a cocoamidopropyl
dimethylamine oxide surfactant, sodium chloride, and water;
hydrolyzed keratin; a mixture of an ethoxylated alcohol ether
sulfate surfactant, an alkyl or alkene amidopropyl betaine
surfactant, and an alkyl or alkene dimethylamine oxide surfactant;
an aqueous solution of an alpha-olefinic sulfonate surfactant and a
betaine surfactant; and any combination thereof.
18. The method of claim 15 wherein the foaming agent is present in
the foamed resin composition in an amount in the range of from
about 0.01% to about 6% by weight of the foamed resin
composition.
19. The method of claim 15 wherein the compressible gas comprises
at least one compressible gas selected from the group consisting
of: air, nitrogen, carbon dioxide, and any combination thereof.
20. The method of claim 15 wherein the compressible gas is present
in an amount sufficient to produce a final resin composition
density from about 6 to about 12 pounds per gallon based on weight
of water.
Description
BACKGROUND
[0001] The present invention relates to resin compositions and
methods of using such compositions in subterranean formations. More
particularly, the present invention relates to foamed resin
compositions and methods of using such compositions, for example,
to consolidate relatively unconsolidated portions of subterranean
formations, to modify the stress-activated reactivity of
subterranean fracture faces and other surfaces in subterranean
formations, and/or for fluid diversion.
[0002] Hydrocarbon wells are often located in subterranean zones
that contain unconsolidated particulates that may migrate out of
the subterranean formation with the oil, gas, water, and/or other
fluids produced by the wells. The presence of unconsolidated
particulates (e.g., formation fines, proppant particulates, etc.),
in produced fluids is undesirable in that the particulates may
abrade pumping and other producing equipment and reduce the fluid
production capabilities of the producing zones. "Unconsolidated
subterranean zones" as that term is used herein include those that
contain loose particulates and those wherein the bonded
particulates have insufficient bond strength to withstand the
forces produced by the production of fluids through the zones.
"Zone" as used herein simply refers to a portion of the formation
and does not imply a particular geological strata or
composition.
[0003] One method of controlling particulates in unconsolidated
formations involves placing a filtration bed containing gravel near
the well bore in order to present a physical barrier to the
transport of unconsolidated formation fines with the production of
hydrocarbons. Typically, such so-called "gravel packing operations"
involve the pumping and placement of a quantity of a desired
particulate into the unconsolidated formation in an area adjacent
to a well bore. Such packs may be time consuming and expensive to
install. Weakly consolidated formations also have been treated by
creating fractures in the formations and depositing proppant in the
fractures wherein the proppant is consolidated within the fractures
into hard, permeable masses using a resin or tackifying composition
to reduce the migration of sand. In some situations the processes
of fracturing and gravel packing are combined into a single
treatment to provide a stimulated production and an annular gravel
pack to prevent formation sand production. Such treatments are
often referred to as "frac pack" operations.
[0004] Another method used to control particulates in
unconsolidated formations involves consolidating unconsolidated
subterranean producing zones by applying a resin followed by a
spacer fluid, and then a catalyst. Such techniques, however, may be
problematic when, for example, an insufficient amount of spacer
fluid is used between the application of the resin and the
application of the external catalyst. The resin may come into
contact with the external catalyst in the well bore itself rather
than in the unconsolidated subterranean producing zone, which may
result in rapid polymerization, potentially damaging the formation
by plugging the pore channels, halting pumping when the well bore
is plugged with solid material, or resulting in a down hole
explosion as a result of the exothermic heat generated by the
polymerization. Also, using conventional resin compositions may not
be practical due, at least in part, to the high cost and
flammability of most solvents used with conventional resin
compositions.
[0005] One additional problem that can negatively impact
conductivity and further complicate the effects of particulate
migration is the tendency of mineral surfaces in a subterranean
formation to undergo chemical reactions caused, at least in part,
by conditions created by mechanical stresses on those minerals
(e.g., fracturing of mineral surfaces, compaction of mineral
particulates, etc.). These reactions are herein referred to as
"stress-activated reactions" or "stress-activated reactivity." As
used herein, the term "mineral surface in a subterranean formation"
and derivatives thereof refer to any surface in a subterranean
formation comprised of minerals and/or the surface of a
particulate. These minerals may comprise any mineral found in
subterranean formations, including silicate minerals (e.g., quartz,
feldspars, clay minerals), carbonaceous minerals, metal oxide
minerals, and the like. The mineral surface in a subterranean
formation treated in the methods of the present invention may have
been formed at any time. The term "modifying the stress-activated
reactivity of a mineral surface" and its derivatives as used herein
refers to increasing or decreasing the tendency of a mineral
surface in a subterranean formation to undergo one or more
stress-activated reactions, or attaching a compound to the mineral
surface that is capable of participating in one or more subsequent
reactions with a second compound.
[0006] One type of reaction caused, at least in part, by conditions
created by mechanical stresses on minerals is a diageneous
reaction. As used herein, the terms "diageneous reaction,"
"diageneous reactivity," and "diagenesis," and any derivatives
thereof are used herein to refer to chemical and physical processes
that move a portion of a mineral sediment and/or convert the
mineral sediment into some other mineral form in the presence of
water. A mineral sediment that has been so moved or converted is
herein referred to as a "diageneous product." Any mineral sediment
may be susceptible to these diageneous reactions, including
silicate minerals (e.g., quartz, feldspars, clay minerals),
carbonaceous minerals, metal oxide minerals, and the like.
[0007] Two of the principle mechanisms that diageneous reactions
are thought to involve are pressure solution and precipitation
processes. Where two water-wetted mineral surfaces are in contact
with each other at a point under strain, the localized mineral
solubility near that point is thought to increase, causing the
minerals to dissolve. Minerals in solution may diffuse through the
water film outside of the region where the mineral surfaces are in
contact (e.g., in the pore spaces of a proppant pack), where they
may precipitate out of solution. The dissolution and precipitation
of minerals in the course of these reactions may reduce the
conductivity of the formations by, among other things, clogging the
conductive channels in the formation with mineral precipitate
and/or collapsing those conductive channels by dissolving solid
minerals in the surfaces of those channels.
[0008] Moreover, in the course of a fracturing treatment, new
mineral surfaces may be created in the "walls" surrounding the open
space of the fracture. These new walls created in the course of a
fracturing treatment are herein referred to as "fracture faces."
Such fracture faces may exhibit different types and levels of
reactivity, for example, stress-activated reactivity. In some
instances, fracture faces may exhibit an increased tendency to
undergo diageneous reactions. In other instances, fracture faces
also may exhibit an increased tendency to react with substances in
formation fluids and/or treatment fluids that are in contact with
those fracture faces, such as water, polymers (e.g.,
polysaccharides, biopolymers, etc.), and other substances commonly
found in these fluids, whose molecules may become anchored to the
fracture face. This reactivity may further decrease the
conductivity of the formation through, inter alia, increased
diageneous reactions and/or the obstruction of conductive fractures
in the formation by any molecules that have become anchored to the
fracture faces.
SUMMARY
[0009] The present invention relates to resin compositions and
methods of using such compositions in subterranean formations. More
particularly, the present invention relates to foamed resin
compositions and methods of using such compositions, for example,
to consolidate relatively unconsolidated portions of subterranean
formations, to modify the stress-activated reactivity of
subterranean fracture faces and other surfaces in subterranean
formations, and/or for fluid diversion.
[0010] In one embodiment, the present invention provides a method
comprising: providing a foamed resin composition comprising a
resin, a foaming agent, a compressible gas, and an aqueous fluid;
and introducing the foamed resin composition into at least a
portion of a subterranean formation.
[0011] In another embodiment, the present invention provides a
method comprising: providing a foamed resin composition comprising
a resin, a foaming agent, a compressible gas, and an aqueous fluid;
introducing the foamed resin composition into at least a portion of
a subterranean formation; and allowing the foamed resin to at least
partially consolidate at least a portion of the subterranean
formation.
[0012] In yet another embodiment, the present invention provides a
method comprising: providing a foamed resin composition comprising
a resin, a foaming agent, a compressible gas, and an aqueous fluid;
introducing the foamed resin composition into at least a portion of
a subterranean formation; and allowing the foamed resin composition
to modify the stress-activated reactivity of at least a portion of
a mineral surface in the subterranean formation.
[0013] The features and advantages of the present invention will be
readily apparent to those skilled in the art. While numerous
changes may be made by those skilled in the art, such changes are
within the spirit of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0014] The present invention relates to resin compositions and
methods of using such compositions in subterranean formations. More
particularly, the present invention relates to foamed resin
compositions and methods of using such compositions, for example,
to consolidate relatively unconsolidated portions of subterranean
formations, to modify the stress-activated reactivity of
subterranean fracture faces and other surfaces in subterranean
formations, and/or for fluid diversion. Other uses will be evident
to one skilled in the art.
[0015] The foamed resin compositions of the present invention
generally comprise a resin; a foaming agent; a compressible gas;
and an aqueous fluid. One of the many advantages of the present
invention is that the foamed resin compositions and methods
presented herein may allow for the consolidation of relatively
unconsolidated portions of subterranean formations, modification of
the stress-activated reactivity of subterranean fracture faces and
other surfaces in subterranean formations, and/or fluid diversion
without the use of additional flammable solvents. Other benefits,
objects, and advantages will be apparent to one of ordinary skill
in the art with the benefit of this disclosure.
[0016] The resins utilized in the present invention are generally
two-component epoxy based resins comprising a hardenable resin
component and a hardening agent component. The hardenable resin
component is comprised of a hardenable resin and an optional
solvent. The solvent may be added to the resin to reduce its
viscosity for ease of handling, mixing and transferring. It is
within the ability of one skilled in the art with the benefit of
this disclosure to determine if and how much solvent may be needed
to achieve a viscosity suitable to the subterranean conditions.
Factors that may affect this decision include geographic location
of the well and the surrounding weather conditions. An alternate
way to reduce the viscosity of the liquid hardenable resin is to
heat it. This method avoids the use of a solvent altogether, which
may be desirable in certain circumstances. The second component is
the hardening agent component, which is comprised of a hardening
agent. Optionally, the hardening agent may further comprise a
silane coupling agent, a surfactant, and a hydrolyzable ester for,
among other things, breaking gelled fracturing fluid films on the
proppant particles, and an optional liquid carrier fluid for, among
other things, reducing the viscosity of the hardening agent
component. It is within the ability of one skilled in the art with
the benefit of this disclosure to determine if and how much liquid
carrier fluid is needed to achieve a viscosity suitable to the
subterranean conditions. In some embodiments of the present
invention, the resin may be included in the foamed resin
composition in an amount in the range of from about 0.1% to about
10% by weight of the foamed resin composition.
[0017] Examples of hardenable resins that can be used in the
hardenable resin component include, but are not limited to, organic
resins such as bisphenol A diglycidyl ether resin, butoxymethyl
butyl glycidyl ether resin, bisphenol A-epichlorohydrin resin,
polyepoxide resin, novolak resin, polyester resin, phenol-aldehyde
resin, urea-aldehyde resin, furan resin, urethane resin, a glycidyl
ether resin, and combinations thereof. The hardenable resin used is
included in the hardenable resin component in an amount in the
range of from about 60% to about 100% by weight of the hardenable
resin component. In some embodiments the hardenable resin used is
included in the hardenable resin component in an amount of about
70% to about 90% by weight of the hardenable resin component.
[0018] Any solvent that is compatible with the hardenable resin and
achieves the desired viscosity effect may be suitable for use in
the hardenable resin component of the foamed resin compositions of
the present invention. Some preferred solvents are those having
high flash points (e.g., about 125.degree. F.) because of, among
other things, environmental and safety concerns; such solvents
include butyl lactate, butylglycidyl ether, dipropylene glycol
methyl ether, dipropylene glycol dimethyl ether, dimethyl
formamide, diethyleneglycol methyl ether, ethyleneglycol butyl
ether, diethyleneglycol butyl ether, propylene carbonate, methanol,
butyl alcohol, d'limonene, fatty acid methyl esters, and
combinations thereof. Other preferred solvents include aqueous
dissolvable solvents such as, methanol, isopropanol, butanol,
glycol ether solvents, and combinations thereof. Suitable glycol
ether solvents include, but are not limited to, diethylene glycol
methyl ether, dipropylene glycol methyl ether, 2-butoxy ethanol,
ethers of a C.sub.2 to C.sub.6 dihydric alkanol containing at least
one C.sub.1 to C.sub.6 alkyl group, mono ethers of dihydric
alkanols, methoxypropanol, butoxyethanol, hexoxyethanol, and
isomers thereof. Selection of an appropriate solvent is dependent
on the resin composition chosen and is within the ability of one
skilled in the art with the benefit of this disclosure.
[0019] As described above, use of a solvent in the hardenable resin
component is optional, but in some instances, may be desirable to
reduce the viscosity of the hardenable resin component for ease of
handling, mixing, and transferring. It is within the ability of one
skilled in the art, with the benefit of this disclosure, to
determine if and how much solvent is needed to achieve a suitable
viscosity. In some embodiments the amount of the solvent used in
the hardenable resin component is in the range of from about 0.1%
to about 30% by weight of the hardenable resin component.
Optionally, the hardenable resin component may be heated to reduce
its viscosity, in place of, or in addition to, using a solvent.
[0020] Examples of the hardening agents that can be used in the
hardening agent component include, but are not limited to,
piperazine, derivatives of piperazine (e.g., aminoethylpiperazine),
2H-pyrrole, pyrrole, imidazole, pyrazole, pyridine, pyrazine,
pyrimidine, pyridazine, indolizine, isoindole, 3H-indole, indole,
1H-indazole, purine, 4H-quinolizine, quinoline, isoquinoline,
phthalazine, naphthyridine, quinoxaline, quinazoline, 4H-carbazole,
carbazole, .beta.-carboline, phenanthridine, acridine,
phenathroline, phenazine, imidazolidine, phenoxazine, cinnoline,
pyrrolidine, pyrroline, imidazoline, piperidine, indoline,
isoindoline, quinuclindine, morpholine, azocine, azepine,
2H-azepine, 1,3,5-triazine, thiazole, pteridine, dihydroquinoline,
hexa methylene imine, indazole, amines, aromatic amines,
polyamines, aliphatic amines, cyclo-aliphatic amines, amides,
polyamides, 2-ethyl-4-methyl imidazole,
1,1,3-trichlorotrifluoroacetone, and combinations thereof. The
chosen hardening agent often effects the range of temperatures over
which a hardenable resin is able to cure. By way of example and not
of limitation, in subterranean formations having a temperature from
about 60.degree. F. to about 250.degree. F., amines and
cyclo-aliphatic amines such as piperidine, triethylamine,
N,N-dimethylaminopyridine, benzyldimethylamine,
tris(dimethylaminomethyl) phenol, and
2-(N.sub.2N-dimethylaminomethyl)phenol are preferred with
N,N-dimethylaminopyridine most preferred. In subterranean
formations having higher temperatures, 4,4'-diaminodiphenyl sulfone
may be a suitable hardening agent. Hardening agents that comprise
piperazine or a derivative of piperazine have been shown capable of
curing various hardenable resins from temperatures as low as about
70.degree. F. to as high as about 350.degree. F. In some
embodiments of the present invention, the hardening agent used is
included in the hardening agent component in the range of from
about 40% to about 60% by weight of the hardening agent component.
In some embodiments the hardening agent used is included in the
hardening agent component in an amount of about 45% to about 55% by
weight of the hardening agent component.
[0021] While not required, a silane coupling agent may be used,
among other things, to act as a mediator to help bond the resin to
formation particulates and/or proppant. Examples of suitable silane
coupling agents include, but are not limited to,
N-.beta.-(aminoethyl)-.gamma.-aminopropyl trimethoxysilane,
N-2-(aminoethyl)-3-aminopropyltrimethoxysilane,
3-glycidoxypropyltrimethoxysilane, and combinations thereof. The
silane coupling agent used is included in the hardening agent
component in an amount capable of sufficiently bonding the resin to
the particulate. In some embodiments of the present invention, the
silane coupling agent used is included in the hardening agent
component in the range of from about 0.1% to about 3% by weight of
the hardening agent component.
[0022] Any surfactant compatible with the hardening agent and
capable of facilitating the coating of the resin onto particles in
the subterranean formation may optionally be used in the hardening
agent component of the foamed resin compositions of the present
invention. Such surfactants include, but are not limited to, an
alkyl phosphonate surfactant (e.g., a C.sub.12-C.sub.22 alkyl
phosphonate surfactant), an ethoxylated nonyl phenol phosphate
ester, one or more cationic surfactants, and one or more nonionic
surfactants. Mixtures of one or more cationic and nonionic
surfactants also may be suitable. Examples of such surfactant
mixtures are described in U.S. Pat. No. 6,311,773 issued to Todd et
al. on Nov. 6, 2001, the relevant disclosure of which is
incorporated herein by reference. The surfactant or surfactants
used may be included in the hardening agent component in an amount
in the range of from about 1% to about 10% by weight of the
hardening agent component.
[0023] While not required, examples of hydrolyzable esters that can
be used in the hardening agent component include, but are not
limited to, a mixture of dimethylglutarate, dimethyladipate, and
dimethylsuccinate; sorbitol; catechol; dimethylthiolate; methyl
salicylate; dimethyl salicylate; dimethylsuccinate;
ter-butylhydroperoxide; and combinations thereof. When used, a
hydrolyzable ester is included in the hardening agent component in
an amount in the range of from about 0.1% to about 3% by weight of
the hardening agent component. In some embodiments a hydrolyzable
ester is included in the hardening agent component in an amount in
the range of from about 1% to about 2.5% by weight of the hardening
agent component.
[0024] Use of a diluent in the hardenable resin composition is
optional and may be used to reduce the viscosity of the hardenable
resin component for ease of handling, mixing and transferring. It
is within the ability of one skilled in the art, with the benefit
of this disclosure, to determine if and how much diluent is needed
to achieve a viscosity suitable to the subterranean conditions. Any
suitable diluent that is compatible with the hardenable resin and
achieves the desired viscosity effects is suitable for use in the
present invention. Some preferred diluents are those having high
flash points (e.g., about 125.degree. F.) because of, among other
things, environmental and safety concerns; such solvents include
butyl lactate, butylglycidyl ether, dipropylene glycol methyl
ether, dipropylene glycol dimethyl ether, dimethyl formamide,
diethyleneglycol methyl ether, ethyleneglycol butyl ether,
diethyleneglycol butyl ether, propylene carbonate, methanol, butyl
alcohol, d'limonene, fatty acid methyl esters, and combinations
thereof. Other preferred diluents include aqueous dissolvable
solvents such as, methanol, isopropanol, butanol, glycol ether
solvents, and combinations thereof. Suitable glycol ether liquid
carrier fluids include, but are not limited to, diethylene glycol
methyl ether, dipropylene glycol methyl ether, 2-butoxy ethanol,
ethers of a C.sub.2 to C.sub.6 dihydric alkanol containing at least
one C.sub.1 to C.sub.6 alkyl group, mono ethers of dihydric
alkanols, methoxypropanol, butoxyethanol, hexoxyethanol, and
isomers thereof. Selection of an appropriate diluent is dependent
on the resin composition chosen and is within the ability of one
skilled in the art with the benefit of this disclosure.
[0025] The resin compositions of the present invention further
comprise a foaming agent. Any suitable foaming agent may be used in
the foamed resin compositions of the present invention. Among other
things, the foaming agent may facilitate the foaming of a resin
composition. Suitable foaming agents may include, but are not
limited to: mixtures of an ammonium salt of an alkyl ether sulfate,
a cocoamidopropyl betaine surfactant, a cocoamidopropyl
dimethylamine oxide surfactant, sodium chloride, and water;
mixtures of an ammonium salt of an alkyl ether sulfate surfactant,
a cocoamidopropyl hydroxysultaine surfactant, a cocoamidopropyl
dimethylamine oxide surfactant, sodium chloride, and water;
hydrolyzed keratin; mixtures of an ethoxylated alcohol ether
sulfate surfactant, an alkyl or alkene amidopropyl betaine
surfactant, and an alkyl or alkene dimethylamine oxide surfactant;
aqueous solutions of an alpha-olefinic sulfonate surfactant and a
betaine surfactant; and combinations thereof. An example of a
suitable hydrolyzed keratin is described in U.S. Pat. No.
6,547,871, the relevant disclosure of which is incorporate herein
by reference. Examples of suitable mixtures of an ethoxylated
alcohol ether sulfate surfactant, an alkyl or alkene amidopropyl
betaine surfactant, and an alkyl or alkene dimethylamine oxide
surfactant are described in U.S. Pat. No. 6,063,738, the relevant
disclosure of which is incorporated herein by reference. Examples
of suitable aqueous solutions of an alpha-olefinic sulfonate
surfactant and a betaine surfactant is described in U.S. Pat. No.
5,879,699, the relevant disclosure of which is incorporated herein
by reference. In one certain embodiment, the foaming agent
comprises a mixture of an ammonium salt of an alkyl ether sulfate,
a cocoamidopropyl betaine surfactant, a cocoamidopropyl
dimethylamine oxide surfactant, sodium chloride, and water. In some
embodiments of the present invention, the foaming agent is included
in the resin composition in the range of from about 0.01% to about
6% by weight of the foamed resin composition.
[0026] The foamed resin compositions of the present invention
further comprise a compressible gas. Any compressible gas that does
not adversely react with or affect the other components of the
resin composition may be used in accordance with the present
invention. Suitable compressible gases include air, nitrogen,
carbon dioxide and combinations thereof. Carbon dioxide may be
contraindicated based on the resin type selected. For example,
where an epoxy resin is used, the acidity of a carbon dioxide
compressible gas may prevent adequate curing of the resin.
Similarly, where a furan resin is chosen, the acidity of the carbon
dioxide may cause premature curing and potential safety concerns.
One of ordinary skill in the art, with the benefit of this
disclosure, will recognize situations wherein carbon dioxide is
contraindicated. In some embodiments of the present invention, the
compressible gas is included in the resin composition in an amount
sufficient to produce a final resin composition density from about
6 to about 12 pounds per gallon based on weight of water.
[0027] The aqueous fluid utilized in the resin compositions of the
present invention may be any aqueous-based fluid, from any source,
provided that it does not contain an excess of compounds that may
adversely react with the other components used in accordance with
this invention or with the subterranean formation. Such
aqueous-based fluids may comprise fresh water, salt water (e.g.,
water containing one or more salts dissolved therein), brine (e.g.,
saturated salt water), or seawater. In some embodiments, the
aqueous fluid may be present in an amount in the range of from
about 20% to about 99.99% based on weight of water.
[0028] Optionally, the foamed resin compositions of the present
invention may further comprise a gelling agent. Any gelling agent
suitable for use in subterranean applications may be used in these
foamed resin compositions, including, but not limited to, natural
biopolymers, synthetic polymers, cross linked gelling agents,
viscoelastic surfactants, and the like. Guar and xanthan are
examples of suitable gelling agents. A variety of gelling agents
may be used, including hydratable polymers that contain one or more
functional groups such as hydroxyl, carboxyl, sulfate, sulfonate,
amino, or amide groups. Suitable gelling agents typically comprise
polysaccharides, biopolymers, synthetic polymers, or a combination
thereof. Examples of suitable polymers include, but are not limited
to, guar gum and derivatives thereof, such as hydroxypropyl guar
and carboxymethylhydroxypropyl guar, cellulose derivatives, such as
hydroxyethyl cellulose, locust bean gum, tara, konjak, tamarind,
starch, cellulose, karaya, diutan, scleroglucan, succinoglycan,
wellan, gellan, xanthan, tragacanth, and carrageenan, and
derivatives and combinations of all of the above. Additionally,
synthetic polymers and copolymers may be used. Examples of such
synthetic polymers include, but are not limited to, polyacrylate,
polymethacrylate, polyacrylamide, polyvinyl alcohol, and
polyvinylpyrrolidone. Commonly used synthetic polymer acid-gelling
agents are polymers and/or copolymers consisting of various ratios
of acrylic, acrylamide, acrylamidomethylpropane sulfonic acid,
quaternized dimethylaminoethylacrylate, quaternized
dimethylaminoethylmethacrylate, mixtures thereof, and the like. In
some embodiments, the viscosifier may be present in the foamed
resin compositions of the present invention in an amount sufficient
to provide a desired degree of solids suspension or viscosity.
[0029] In some embodiments, the present invention provides a method
comprising: providing a foamed resin composition comprising a
resin, a foaming agent, a compressible gas, and an aqueous fluid;
and introducing the foamed resin composition into at least a
portion of a subterranean formation.
[0030] In another embodiment, the present invention provides a
method comprising: providing a foamed resin composition comprising
a resin, a foaming agent, a compressible gas, and an aqueous fluid;
introducing the foamed resin composition into at least a portion of
a subterranean formation; and allowing the foamed resin to at least
partially consolidate at least a portion of the subterranean
formation.
[0031] In yet another embodiment, the present invention provides a
method comprising: providing a foamed resin composition comprising
a resin, a foaming agent, a compressible gas, and an aqueous fluid;
introducing the foamed resin composition into at least a portion of
a subterranean formation; and allowing the foamed resin composition
to modify the stress-activated reactivity of at least a portion of
a mineral surface in the subterranean formation.
[0032] To facilitate a better understanding of the present
invention, the following examples of certain aspects of some
embodiments are given. In no way should the following examples be
read to limit, or define, the entire scope of the invention.
EXAMPLE 1
[0033] A sample resin composition of the present invention was
prepared by first adding 0.5 grams of a gelling agent, "WG-24,"
which is commercially available from Halliburton Energy Services,
Duncan, Okla., to 100 milliliters ("mL") of water. After hydration
of the gelling agent, 1 mL of a foaming agent, "HC-2.TM. Agent,"
which is commercially available from Halliburton Energy Services,
Duncan, Okla., was added to the water and hydrated gelling agent.
Next, 2.5 mL of an epoxy resin and 2.5 mL of a hardening agent were
added to form a stable solution. The resulting solution was then
sheared to form a foam that had a half-life of over five minutes
and an initial foam quality of 71. Foam quality is the ratio of gas
to the total volume of a system, expressed as a percent.
[0034] Therefore, the present invention is well adapted to attain
the ends and advantages mentioned as well as those that are
inherent therein. The particular embodiments disclosed above are
illustrative only, as the present invention may be modified and
practiced in different but equivalent manners apparent to those
skilled in the art having the benefit of the teachings herein.
Furthermore, no limitations are intended to the details of
construction or design herein shown, other than as described in the
claims below. It is therefore evident that the particular
illustrative embodiments disclosed above may be altered or modified
and all such variations are considered within the scope and spirit
of the present invention. In particular, every range of values (of
the form, "from about a to about b," or, equivalently, "from
approximately a to b," or, equivalently, "from approximately a-b")
disclosed herein is to be understood as referring to the power set
(the set of all subsets) of the respective range of values, and set
forth every range encompassed within the broader range of values.
Also, the terms in the claims have their plain, ordinary meaning
unless otherwise explicitly and clearly defined by the
patentee.
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