Process for mixing wellbore fluids

Abstract

A system for mixing drilling fluids that includes a fluid supply tank for supplying an unmixed drilling fluid, a mixing reactor fluidly connected to the fluid supply tank, the mixing reactor including an intake and an outlet; a mixing chamber disposed between the intake and the outlet, an inlet for injecting a compressible driving fluid into the mixing chamber and an inlet for injecting an aerating gas into the mixing chamber is disclosed.

Claims

1. A system for mixing drilling fluids, comprising: a fluid supply tank, having an agitator therein, for supplying an unmixed drilling fluid; a mixing reactor fluidly connected to the fluid supply tank, the mixing reactor comprising: an intake and an outlet; a mixing chamber connected to the intake and the outlet by a fluid line; an inlet for injecting a compressible driving fluid into the mixing chamber; and an inlet for injecting an aerating gas into the mixing chamber; wherein the unmixed drilling fluid is pumped into the mixing reactor by a pump connected to the fluid line and mixed drilling fluids exits the mixing reactor, and further wherein the mixing chamber is configured such that a velocity of the compressible driving fluid entering the mixing chamber increases to form a supersonic energy wave or shock zone in the mixing chamber for mixing the unmixed drilling fluid to form the mixed drilling fluid.

2. The system of claim 1, further comprising: a hopper operatively connected to the fluid supply tank for supplying drilling fluid components to the unmixed drilling fluid.

3. The system of claim 1, wherein the unmixed drilling fluid comprises a base fluid, and wherein the system further comprises a hopper fluidly connected to a fluid line between the fluid supply tank and the mixing reactor for supplying drilling fluid additives to the unmixed drilling fluid.

4. The system of claim 1, further comprising: a recycling line fluidly connecting the outlet of the mixing reactor to the intake of the mixing reactor.

5. The system of claim 1, further comprising: a receiving tank fluidly connected to the mixing reactor for collecting the mixed drilling fluid.

6. The system of claim 1, further comprising: a pump fluidly connected to the fluid supply tank and the mixing reactor for pumping unmixed drilling fluid to the mixing reactor.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 shows a system according to one embodiment of the present disclosure.

(2) FIG. 2 shows a cross-section of a mixing reactor of a system according to one embodiment of the present disclosure.

(3) FIG. 3 shows a method according to one embodiment of the present disclosure.

(4) FIG. 4 shows a system according to one embodiment of the present disclosure.

(5) FIG. 5 shows a system according to one embodiment of the present disclosure.

(6) FIG. 6 shows a system according to one embodiment of the present disclosure.

(7) FIG. 7 shows a system according to one embodiment of the present disclosure.

(8) FIG. 8 shows a system according to one embodiment of the present disclosure.

(9) FIG. 9A shows a system according to one embodiment of the present disclosure.

(10) FIG. 9B shows a partial view of the system shown in FIG. 9A.

(11) FIG. 10 shows a system according to one embodiment of the present disclosure.

DETAILED DESCRIPTION

(12) In one aspect, embodiments disclosed herein relate to methods and systems for mixing drilling fluid components to produce drilling fluids that are substantially homogenously mixed.

(13) Referring to FIG. 1, a system 100 for mixing drilling fluids in accordance with an embodiment of the present disclosure is shown. In this embodiment, fluid supply tank (i.e., mud pit in various embodiments) 102 is connected to mixing reactor 104 via fluid line 106 such that an unmixed drilling fluid flows from fluid supply tank 102 into mixing reactor 104. A mixed drilling fluid exits mixing reactor 104 and may be either collected in receiving tank 108 or if additional mixing is desired, the mixed fluid may be returned via recycling fluid line 110 through fluid supply tank 102 to fluid line 106 for a subsequent pass through mixing reactor 104. Alternatively, recycled fluid line 110 may be directly connected to fluid line 106, and the fluid need not be passed through fluid supply tank 102. A hopper 112 is shown connected to fluid line 106 between fluid supply tank 102 and mixing reactor 104. As the unmixed drilling fluid flows from fluid supply tank 102 to mixing reactor 104, drilling fluid additives, may flow from hopper 112 into the unmixed drilling fluid. However, one of skill in the art would recognize that in alternative embodiments, hopper 112 may be connected to fluid supply tank 102 so that additives may be poured directly into fluid supply tank 102, or in alternate embodiments, additives may be poured directly into fluid supply tank 102 without the use of hopper 112.

(14) As a base fluid and drilling fluid additives are introduced into system 100, a fluid regulation valve 114 (and additive regulation valve 116, if a hopper is used) may control the flow of base fluid and drilling fluid additives, respectively, into fluid line 106 and thus mixing reactor 104.

(15) Referring to FIG. 2, a mixing reactor 200 in accordance with one embodiment of the present disclosure is shown. Mixing reactor 200 includes a mixing chamber 202, defining a flow passage for the drilling fluid, and an intake 204 and an outlet 206 through which the drilling fluid, respectively, enters unmixed and exits mixed. After drilling fluid enters the mixing reactor 200 through intake 204, it flows into mixing chamber 202. Inlets 208 and 212 in the side wall of mixing chamber 202 provide a first and second aerating gas, respectively, to the flow path of unmixed drilling fluid. Inlet 210 in the side walls of mixing chamber 202 provides a compressible driving fluid to the unmixed drilling fluid. One of ordinary skill in the art would recognize that inlets 208, 210, and 212 may each individually include, for example, nozzle structures, ports, isolation valve and/or aperatures. In alternate embodiments, the mixing chamber 202 may have a single inlet for injecting an aerating gas and may be placed either upstream or downstream from the driving fluid inlet 210, or the aerating gas and the compressible driving fluid may be injected through the same inlet.

(16) As the driving fluid enters the mixing chamber, it may undergo a reduction in pressure and increase in velocity (typically to supersonic levels). As the high velocity driving fluid condenses via expansion and the cooling influence of the drilling fluid, a pressure reduction in the mixing chamber may result. The rapid pressure reduction is in effect an implosion within the mixing zone. A volumetric collapse of the driving fluid may draw further unmixed drilling fluid through the intake and mixing chamber. The high velocity of the driving fluid may also affect momentum transfer to the drilling fluid and accelerate the drilling fluid flow at an increased velocity. Consequently, unmixed drilling fluid may be entrained from the intake to the mixing chamber on a continuous basis. During operation of the mixing reactor, the driving fluid may be injected into the drilling fluid on a continual basis or on an intermittent basis such as in a pulsed fashion.

(17) As the velocity of the mixed driving fluid and drilling fluid becomes supersonic, it may form a shock wave. As the shockwave grows, a low density, low pressure, supersonic energy wave or shock zone may be formed in the mixing chamber across the bore diameter, thereby increasing energy transfer. High shear forces in the shock zone may homogeneously mix the gas and liquid to produce an aerated mix with fine bubble. The high shear forces in the shock zone may also form a substantially homogenously mixed drilling fluid.

(18) The compressible driving fluid may include a substantially gaseous fluid capable of rapid pressure reduction upon exposure to the cooling influence of the drilling fluid. In some embodiments, the compressible driving fluid may include a gas or a gaseous mixture. In other embodiments, compressible driving fluid may have particles such as liquid droplets entrained therein. In a particular embodiment, the driving fluid may, for example, comprise a condensable vapor such as steam. One of ordinary skill in the art would recognize that when the drilling fluid contains water, steam may be a particularly appropriate form of driving fluid so there is no undesirable contamination of the drilling fluid upon contact with the steam. The driving fluid may also be a multi-phase fluid, such as a mixture of steam, air, and water droplets, e.g., where the air and water droplets may be in the form of a mist. Such a multi-phase fluid may also serve to increase the mass flow rate of the driving fluid and the density of the driving fluid to a density more similar to the density of the drilling fluid.

(19) The compressible driving fluid injected into the unmixed drilling fluid may have a supply temperature proportional to its supply pressure. When the compressible driving fluid is injected into the unmixed drilling fluid it can have the effect as to increase the temperature of the drilling fluid. The degree of temperature increase may be dependent on the chosen flow rate of the compressible driving fluid. In one embodiment, the temperature of the driving fluid is a temperature of at least 50° C., providing a 30° C. temperature rise above the ambient condition of 20° C. In an alternate embodiment, a drilling fluid temperature rise of more than 50° C. above ambient temperature may be observed. The compressible driving fluid may also be pressurized prior to injection into the drilling fluid. In one embodiment, the compressible driving fluid may be subjected to a pressure ranging from about 3 to about 10 bar. The process of injecting the compressible driving fluid into a lower pressure environment may result in the compressible driving fluid pressure reaching equilibrium pressure to the local environment pressure.

(20) During operation of the mixing reactor, the driving fluid may be injected into the drilling fluid on a continual basis or on an intermittent basis (e.g., in a pulsed fashion). The flow rates of the driving fluid and the drilling fluid may be selected according to the desired flow rate of working fluid discharging at the outlet. The required total drilling fluid flow rate will dictate the physical size of the mixing reactor and hence the flow. Each size of mixing reactor may have a proportional relationship between the flow rate of driving fluid to that of the induced drilling fluid inlet flow rate.

(21) Referring to FIG. 3, a method 300 for mixing drilling fluids according to one embodiment disclosed herein is shown. Method 300 includes establishing a flow path for a base fluid at step 302. Drilling fluid additives may be added to the base fluid (step 304) either prior to or after the establishment of the flow path for the base fluid. The non-homogenous mixture of base fluid and drilling fluid additives may be injected with an aerating gas (step 306) and a compressible driving fluid (step 308) to form a substantially homogenously mixed drilling fluid. According to various embodiments, aeration (step 306) may occur prior to, post, or both prior to and post injection of the compressible driving fluid (step 308). The mixed drilling fluid may then be collected (step 310) and/or sieved (step 312) or may be recirculated (step 314) through the mixing reactor to receive a second pass (or third, etc) pass at aeration and injection of the compressible driving fluid.

(22) While FIG. 3 refers to one embodiment of a system for mixing drilling fluids, one of ordinary skill in the art will appreciate that variations in the system may be made without departing from the scope of the present disclosure. Referring to FIG. 4, a system 400 for mixing drilling fluids in accordance with an embodiment of the present disclosure is shown. In this embodiment, fluid supply tanks (i.e., mud pit in various embodiments) 402a and 402b are connected to mixing reactor 404 via fluid line 406 such that an unmixed drilling fluid flows from fluid supply tank 402a and/or 402b into mixing reactor 404. A mixed drilling fluid exits mixing reactor 404 and may be either returned via recycling fluid line 410 through either fluid supply tank 402a to fluid line 406 for a subsequent pass through mixing reactor 404 or through parallel fluid supply tank 402b. A hopper 412 is shown connected to fluid line 406 between fluid supply tank 402a/b and mixing reactor 404. As the unmixed drilling fluid flows from fluid supply tank 402 to mixing reactor 404, drilling fluid additives, may flow from hopper 412 into the unmixed drilling fluid. However, one of skill in the art would recognize that in alternative embodiments, hopper 412 may be connected to fluid supply tank 402 so that additives may be poured directly into fluid supply tank 402a or 402b, or in alternate embodiments, additives may be poured directly into fluid supply tank 402a or 404b without the use of hopper 412.

(23) As a base fluid and drilling fluid additives are introduced into system 400, fluid regulation valves 414a and/or 414b (and additive regulation valve 116, if a hopper is used) may control the flow of base fluid and drilling fluid additives, respectively, into fluid line 406 and thus mixing reactor 404.

(24) Referring to FIG. 5, a system 500 for mixing drilling fluids in accordance with another embodiment of the present disclosure is shown. In this embodiment, fluid supply tank (i.e., mud pit in various embodiments) 502, which may optionally include a tank agitator 520, is connected to mixing reactor 504 via fluid line 506 such that an unmixed drilling fluid flows from fluid supply tank 502 into mixing reactor 504. A mixed drilling fluid exits mixing reactor 504 may be returned via recycling fluid line 510 to fluid supply tank 502 (or to any other tank) or may flow through fluid supply tank 502 to fluid line 506 for a subsequent pass through mixing reactor 504. A hopper 512 is shown connected to fluid line 506 between fluid supply tank 502 and mixing reactor 504. As the unmixed drilling fluid flows from fluid supply tank 502 to mixing reactor 504, drilling fluid additives, may flow from hopper 512 into the unmixed drilling fluid. However, one of skill in the art would recognize that in alternative embodiments, hopper 512 may be connected to fluid supply tank 502 so that additives may be poured directly into fluid supply tank 502, or in yet other alternate embodiments, additives may be poured directly into fluid supply tank 502 without the use of hopper 512.

(25) As a base fluid and drilling fluid additives are introduced into system 500, a fluid regulation valve 514 (and additive regulation valve 516, if a hopper is used) may control the flow of base fluid and drilling fluid additives, respectively, into fluid line 506 and thus mixing reactor 504.

(26) Referring to FIG. 6, a system 600 for mixing drilling fluids in accordance with yet another embodiment of the present disclosure is shown. In this embodiment, fluid supply tank (i.e., mud pit in various embodiments) 602, which may optionally include a tank agitator 620, is connected to mixing reactor 604 via fluid line 606 such that an unmixed drilling fluid flows from fluid supply tank 602 into mixing reactor 604. The unmixed drilling fluid may be pushed into the mixing reactor 604 by pump 622 on flow line 606. A mixed drilling fluid exits mixing reactor 604 and may be returned via recycling fluid line 610 to fluid supply tank 602 (or to any other tank) or may flow through fluid supply tank 602 to fluid line 606 for a subsequent pass through mixing reactor 604. A hopper 612 is shown connected to fluid line 606 between pump 622 and mixing reactor 604. As the unmixed drilling fluid is pumped from fluid supply tank 602 to mixing reactor 604, drilling fluid additives may flow from hopper 612 into the unmixed drilling fluid. However, one of skill in the art would recognize that in alternative embodiments, hopper 612 may be connected to fluid supply tank 602 so that additives may be poured directly into fluid supply tank 602, or in yet other alternate embodiments, additives may be poured directly into fluid supply tank 602 without the use of hopper 612.

(27) As a base fluid and drilling fluid additives are introduced into system 600, a fluid regulation valve 614 (and additive regulation valve 616, if a hopper is used) may control the flow of base fluid and drilling fluid additives, respectively, into fluid line 606 and thus mixing reactor 604.

(28) Referring to FIG. 7, a system 700 for mixing drilling fluids in accordance with yet another embodiment of the present disclosure is shown. In this embodiment, fluid supply tank (i.e., mud pit in various embodiments) 702, which may optionally include a tank agitator 720, is connected to mixing reactor 704 via fluid line 706 such that an unmixed drilling fluid flows from fluid supply tank 702 into mixing reactor 704. In operation, an unmixed drilling fluid may be pumped from fluid supply tank 702 by pump 722 though fluid line 726. Unmixed drilling fluid may be pumped through eductor 724, which is connected to hopper 712a and to the outlet (not shown) of mixing reactor 704, and returned to fluid supply tank 702. As drilling fluid is pumped through eductor 724, a negative pressure draws unmixed drilling fluid from fluid supply tank 702 through mixing reactor 704 via fluid supply line 706. Once mixed, drilling fluid may be returned to fluid supply tank 702 (or any other tank) via recycling line 710. Drilling fluid additives may be added to the system at hopper 712a and/or 712b.

(29) As a base fluid and drilling fluid additives are introduced into system 700, a fluid regulation valve 714 may control the flow of base fluid into fluid line 726 and through eductor 724, and fluid regulation valve 717 may control the flow of base fluid into fluid line 706 and thus through mixing reactor 704. The entry of drilling fluid additives through hopper 712a may be controlled by additive regulation 718, and similarly, additive regulation valve 716 may control the entry of drilling fluid additives through hopper 112b.

(30) One of ordinary skill in the art would recognize that the system 700 shown in FIG. 7 may be a modification of a conventional mud mixing hopper system in which additives are added via hopper 712a to a base fluid that flows through eductor 724 and is returned to fluid supply tank 702. By connecting the outlet of mixing reactor 704 to outlet of eductor 724, the negative pressure generated in pumping fluid through the eductor may be used to draw drilling fluid through mixing reactor 704 and allow for the substantially homogenous mixture of a base fluid with additives supplied by hopper 712b. Further, one of ordinary skill in the art would also appreciate that other modifications to conventional mud mixing hopper systems may be performed without departing from the scope of the present disclosure.

(31) Referring to FIG. 8, a system 800 for mixing drilling fluids in accordance with yet another embodiment of the present disclosure is shown. In this embodiment, fluid supply tank (i.e., mud pit in various embodiments) 802, which may optionally include a tank agitator (not shown), is connected to mixing reactor 804 via fluid line 806 such that an unmixed drilling fluid flows from fluid supply tank 802 into mixing reactor 804. In operation, an unmixed drilling fluid may be pumped from fluid supply tank 802 by pump 822 though fluid supply line 806. As fluid from fluid supply line 806 is pumped through eductor 824, a negative pressure draws additives from hopper 812a into the fluid. The unmixed drilling fluid then flows through mixing reactor 804 and is mixed. Once mixed, drilling fluid may be returned to fluid supply tank 802 (or any other tank) via recycling line 810. One of ordinary skill in the art would appreciate that multiple hoppers may be used to add drilling fluid additives may be added to the system, such as at hopper 812a and/or 812b. The entry of drilling fluid additives through hopper 812a may be controlled by additive regulation 818, and similarly, additive regulation valve 816 may control the entry of drilling fluid additives through hopper 812b.

(32) One of ordinary skill in the art would recognize that the system 800 shown in FIG. 8 may be a modification of a conventional mud mixing hopper system in which additives are added via hopper 812a to a base fluid that flows through eductor 824 and is returned to fluid supply tank 802. Further, one of ordinary skill in the art would also appreciate that other modifications to conventional mud mixing hopper systems may be performed without departing from the scope of the present disclosure.

(33) Referring to FIGS. 9A-B, a system 900 for mixing drilling fluids in accordance with yet another embodiment of the present disclosure is shown. In this embodiment, fluid supply tank (i.e., mud pit in various embodiments) 902, which may optionally include a tank agitator (not shown), is connected to mixing reactor 904 via fluid line 906 such that an unmixed drilling fluid flows from fluid supply tank 902 into mixing reactor 904, which is located such that it forms the inlet or nozzle of eductor 924. In operation, an unmixed drilling fluid may be pumped from fluid supply tank 902 by pump 922 though fluid supply line 906. As fluid from fluid supply line 906 is pumped through eductor 924 and thus mixing reactor 904, a negative pressure draws additives from hopper 912 into the fluid. Additive regulation valve 916 may be used to control the entry of additives through hopper 912 into eductor 924. Unmixed drilling fluid flows through intake 904a and outlet 904b of mixing reactor 904 as gas(es), such as steam are injected 904c into mixing reactor 904. As gas(es) and/or fluid(s) are injected into the mixing reactor 904, they may undergo a reduction in pressure and increase in velocity (typically to supersonic levels), which as described above, may draw further unmixed drilling fluid into and through the mixing reactor, as drilling fluid additives are drawn into and mixed with the fluid in eductor 924. Once mixed, drilling fluid exits eductor 924 and may be returned to fluid supply tank 802 (or any other tank) via recycling line 910.

(34) Referring to FIG. 10, a system 1000 for mixing drilling fluids in accordance with yet another embodiment of the present disclosure is shown. In this embodiment, unmixed drilling fluid in fluid supply tank (i.e., mud pit in various embodiments) 1002, which may optionally include a tank agitator (not shown), is connected to mixing reactor 1004 through fluid supply line 1006. In operation, unmixed drilling fluid may be pumped from fluid supply tank 1002 by pump 1022 though fluid line 1026. As fluid from fluid supply line 1006 is pumped through eductor 1024, a negative pressure draws additives (such as additives entrained in fluid) from hopper 1012 into the fluid, which may be recycled back into fluid supply tank 1002 via recycling line 1010. Fluid from fluid supply tank 1002 (which may contain additives therein) may alternatively be pumped through fluid supply line 1006 to mixing reactor 1004 where steam (or other fluids) may be injected 1004c therein to form a homogenously mixed drilling fluid. A mixed drilling fluid exits mixing reactor 1004 and may be either collected in receiving tank 1008 or if additional mixing is desired, the mixed fluid may be returned (not shown) through fluid supply tank 1002.

(35) As a base fluid and drilling fluid additives are introduced into system 1000, a fluid regulation valve 1014 may control the flow of base fluid into fluid line 1026 and through eductor 1024, and fluid regulation valve 1017 may control the flow of base fluid into fluid line 1006 and thus through mixing reactor 1004. Further, the entry of drilling fluid additives through hopper 1012 may be controlled by additive regulation 1018. One of ordinary skill in the art would recognize that the system 1000 shown in FIG. 10 may be a modification of a conventional mud mixing hopper system in which additives are added via hopper 1012 to a base fluid that flows through eductor 1024 and is returned to fluid supply tank 1002.

(36) Further, one of ordinary skill in the art would appreciate that additional components such as sensors, gauges, etc that may be used to measure, inter alia, pressures, temperatures, densities, flow rates, and flow levels may be included in any of the systems of the present disclosure.

(37) The drilling fluids that may be mixed according to the embodiments disclosed herein may include water-based fluids as well as oil-based fluids. If the embodiments disclosed herein are used to mix oil-based fluids, it is also within the scope of the embodiments of the present disclosure that the disclosed method and system may also be used to form emulsions.

(38) Water-based wellbore fluids may include an aqueous base fluid. The aqueous fluid may include at least one of fresh water, sea water, brine, mixtures of water and water-soluble organic compounds and mixtures thereof. For example, the aqueous fluid may be formulated with mixtures of desired salts in fresh water. Such salts may include, but are not limited to alkali metal chlorides, hydroxides, or carboxylates, for example. In various embodiments of the drilling fluid disclosed herein, the brine may include seawater, aqueous solutions wherein the salt concentration is less than that of sea water, or aqueous solutions wherein the salt concentration is greater than that of sea water. Salts that may be found in seawater include, but are not limited to, sodium, calcium, sulfur, aluminum, magnesium, potassium, strontium, silicon, lithium, and phosphorus salts of chlorides, bromides, carbonates, iodides, chlorates, bromates, formates, nitrates, oxides, and fluorides. Salts that may be incorporated in a given brine include any one or more of those present in natural seawater or any other organic or inorganic dissolved salts. Additionally, brines that may be used in the drilling fluids disclosed herein may be natural or synthetic, with synthetic brines tending to be much simpler in constitution. In one embodiment, the density of the drilling fluid may be controlled by increasing the salt concentration in the brine (up to saturation). In a particular embodiment, a brine may include halide or carboxylate salts of mono- or divalent cations of metals, such as cesium, potassium, calcium, zinc, and/or sodium. One of ordinary skill would appreciate that the above salts may be present in the base fluid, or alternatively, may be added according to the method disclosed herein.

(39) Oil-based fluids may include an invert emulsion having an oleaginous continuous phase and a non-oleaginous discontinuous phase. The oleaginous fluid may be a liquid and more preferably may be a natural or synthetic oil and more preferably the oleaginous fluid is selected from the group including diesel oil, mineral oil, a synthetic oil, (e.g., hydrogenated and unhydrogenated olefins including polyalpha olefins, linear and branch olefins and the like, polydiorganosiloxanes, siloxanes, or organosiloxanes, esters of fatty acids, specifically straight chain, branched and cyclical alkyl ethers of fatty acids, mixtures thereof and similar compounds known to one of skill in the art), and mixtures thereof. The concentration of the oleaginous fluid should be sufficient so that an invert emulsion forms and may be less than about 99% by volume of the invert emulsion. In one embodiment the amount of oleaginous fluid is from about 30% to about 95% by volume, and more preferably about 40% to about 90% by volume of the invert emulsion fluid. The oleaginous fluid, in one embodiment, may include at least 5% by volume of a material selected from the group including esters, ethers, acetals, dialkylcarbonates, hydrocarbons, and combinations thereof.

(40) The non-oleaginous fluid used in the formulation of the invert emulsion fluid disclosed herein is a liquid and may be an aqueous liquid. In one embodiment, the non-oleaginous liquid may be selected from the group including sea water, a brine containing organic and/or inorganic dissolved salts, liquids containing water-miscible organic compounds and combinations thereof. The amount of the non-oleaginous fluid is typically less than the theoretical limit needed for forming an invert emulsion. Thus in one embodiment, the amount of non-oleaginous fluid may be less that about 70% by volume and preferably from about 1% to about 70% by volume. In another embodiment, the non-oleaginous fluid may preferably be from about 5% to about 60% by volume of the invert emulsion fluid. The fluid phase may include either an aqueous fluid, an oleaginous fluid, or mixtures thereof.

(41) Drilling fluid additives that may be added to the base fluids described above include a variety of compounds such as, for example, viscosifiers, corrosion inhibitors, lubricants, pH control additives, surfactants, solvents, thinners, thinning agents, and/or weighting agents, wetting agents, fluid loss control agents, dispersants, interfacial tension reducers, pH buffers, mutual solvents, and cleaning agents, among other additives. Some typical viscosifying additives include clays, organophilic clays, synthetic polymers, natural polymers and derivatives thereof such as xanthan gum and hydroxyethyl cellulose.

EXAMPLES

(42) The following examples were used to test the effectiveness of the methods and systems disclosed herein in mixing drilling fluids.

Sample 1: Gel Slurry

(43) A gel slurry was formed by adding bentonite (5.7 kg) to a fresh water flow (92.8 kg) and aerating/injecting steam into the flow using a mixing reactor system as described above. Steam was injected at a rate of 3.2-0.3 kg/min with a pressure of 5 bar for 30 seconds, thus injecting 1.5 kg of steam and forming a 100 kg gel slurry sample. The mixed slurry was visually examined for fisheyes, none of which were found in the sample.

Sample 2: 1 lb/bbl POLYPAC® UL, 0.333 lb/bbl DUO-VIS® in Gel Slurry

(44) A flow of 100 kg of Sample 1 gel slurry was established in the mixing reactor system described above. POLYPAC® UL (polyanionic cellulose) (0.286 kg) and DUO-VIS® (xanthan gum) (0.095 kg), both of which are available from M-I LLC, Houston, Tex., were added to the gel flow and the sample was formed by aerating/injecting steam into the flow. Steam was injected at a rate of 3.2-0.3 kg/min with a pressure of 5 bar for 30 seconds, thus injecting 1.5 kg of steam. After the first pass, the product was transferred back to the feeding tank for a second, and third, pass. After each pass, a sample of the product was visually examined for fisheyes, none of which were found in the samples.

Sample 3: 2 lb/bbl POLYPAC® UL, 0.667 lb/bbl DUO-VIS® in Gel Slurry

(45) A flow of 100 kg of Sample 1 gel slurry was established in the mixing reactor system described above. POLYPAC® UL (polyanionic cellulose) (0.572 kg) and DUO-VIS® (xanthan gum) (0.191 kg) were added to the gel flow and the sample was formed by aerating/injecting steam into the flow. Steam was injected at a rate of 3.2-0.3 kg/min with a pressure of 5 bar for 30 seconds, thus injecting 1.5 kg of steam. After the first pass, the product was transferred back to the feeding tank for a second, and third, pass. After each pass, a sample of the product was visually examined for fisheyes, none of which were found in the samples.

Sample 4: 3 lb/bbl POLYPAC® UL, 1 lb/bbl DUO-VIS® in Gel Slurry

(46) A flow of 100 kg of Sample 1 gel slurry was established in the mixing reactor system described above. POLYPAC® UL (polyanionic cellulose) (0.572 kg) and DUO-VIS® (xanthan gum) (0.191 kg) were added to the gel flow and the sample was fainted by aerating/injecting steam into the flow. Steam was injected at a rate of 3.2-0.3 kg/min with a pressure of 5 bar for 30 seconds, thus injecting 1.5 kg of steam. After the first pass, the product was sent directly to the feeding tank instead of the receiving tank, so no samples would be taken on the fly. Subsequent passes were attempted but not possible due to back pressure, causing the material to blow out from the hopper.

Sample 5: 1 lb/bbl Scleroglucan

(47) A gel slurry was formed by adding scleroglucan (0.286 kg) to a fresh water flow (98.2 kg) and aerating/injecting steam into the flow using a mixing reactor system as described above. Steam was injected at a rate of 3.2-0.3 kg/min with a pressure of 5 bar for 30 seconds, thus injecting 1.5 kg of steam and forming a 100 kg gel slurry sample. The sample was subjected to three passes in the mixing reactor.

Sample 6: 2 lb/bbl Scleroglucan

(48) A gel slurry was formed by adding scleroglucan (0.572 kg) to a fresh water flow (97.9 kg) and aerating/injecting steam into the flow using a mixing reactor system as described above. Steam was injected at a rate of 3.2-0.3 kg/min with a pressure of 5 bar for 30 seconds, thus injecting 1.5 kg of steam and forming a 100 kg gel slurry sample. The sample was subjected to three passes in the mixing reactor.

Sample 7: 1 lb/bbl Scleroglucan, pH 5

(49) A gel slurry was formed by adding scleroglucan (0.286 kg) to a fresh water flow (98.2 kg) having its pH adjusted to 5.0 using 32 g of citric acid and aerating/injecting steam into the flow using a mixing reactor system as described above. Steam was injected at a rate of 3.2-0.3 kg/min with a pressure of 5 bar for 30 seconds, thus injecting 1.5 kg of steam and forming a 100 kg gel slurry sample. The sample was subjected to three passes in the mixing reactor.

(50) The rheological properties of the mixed fluids in each of Samples 1-7 were determined using a Fann Model 35 Viscometer, available from Fann Instrument Company at 120° F. and a Brookfield Viscometer for Low Shear rate viscosity at room temperature. The samples were also subjected to a low pressure, low temperature filtration test to measure the static filtration behavior of the fluid at room temperature and 100 psi, according to specifications set by the API Fluid Loss test procedures. The gel strengths (i.e., measure of the suspending characteristics or thixotropic properties of a fluid) of the samples were evaluated by the 10 second and 10 minute gel strengths in pounds per 100 square feet in accordance with the procedures in API Bulletin RP 13B-2, 1990. The results of the tests are shown below in Table 1a-b.

(51) TABLE-US-00001 TABLE 1a Sample 1 2.1 2.2 2.3 3.1 3.2 3.3 4.1 4.2 Funnel Viscosity (sec) 63 130 100 70 130 215 160 488 410 Mud Weight (ppg) 8.45 8.55 8.60 8.60 8.50 8.50 8.50− 8.50− 8.60+ 600 rpm 23 38 33 30 40 50 46 67 64 300 rpm 17 26 22 20 27 34 31 47 44 200 rpm 15 20 17 16 20 28 25 39 36 100 rpm 12 15 12 12 13 21 18 29 26  6 rpm 10 6 4 4 5 9 7 12 10  3 rpm 10 6 3 4 4 8 6 10 9 Gels 10″ (lbs/100 ft.sup.2) 16 7 6 6 5 9 7 12 11 Gels 10′ (lbs/100 ft.sup.2) 32 18 17 15 17 22 16 27 25 PV (cP) 6 12 11 10 13 16 15 20 20 YP (cP) 11 14 11 10 14 18 16 27 24 Brookfield 0.3 rpm - 1 min 24000 22400 24700 23200 27000 38900 44900 55400 59100 (cP) Brookfield 0.3 rpm - 2 min 23000 26800 28100 24900 31300 43800 50900 62700 66600 (cP) Brookfield 0.3 rpm - 3 min 23700 28700 29500 26500 33300 46000 53800 66800 70500 (cP) pH 9.70 8.65 8.65 8.53 8.73 8.16 8.12 7.86 7.83 API FL (mL) 21.5 9.5 9.6 9.5 10.4 8.2 8.4 9.3 8.5

(52) TABLE-US-00002 TABLE 1b Sample 5.1 5.2 5.3 6.1 6.2 6.3 7.1 7.2 7.3 Funnel Viscosity (sec) 31 37 37 36 39 40 35 39 39 Mud Weight (ppg) 8.30 8.30 8.30 8.30 8.30 8.30 8.30 8.30 8.30 600 rpm 2 11 9 13 19 17 6 11 9 300 rpm 1 8 6 10 15 13 4 9 7 200 rpm 0 7 5 8 13 12 3 7 5 100 rpm 0 6 4 6 12 10 3 6 4  6 rpm 0 3 2 1 7 5 1 3 2  3 rpm 0 3 2 1 6 4 1 3 2 Gels 10″ (lbs/100 ft.sup.2) 0 3 4 2 6 4 1 3 2 Gels 10′ (lbs/100 ft.sup.2) 1 3 5 2 9 4 2 3 2 PV (cP) 1 3 3 3 4 4 2 2 2 YP (cP) 0 5 3 7 11 9 2 7 5 Brookfield 0.3 rpm - 1 min (cP) 60 720 700 180 6660 1300 1460 4640 3560 Brookfield 0.3 rpm - 2 min (cP) 60 740 1260 120 7260 1440 1560 4820 3580 Brookfield 0.3 rpm - 3 min (cP) 60 800 1260 120 7460 1460 1600 4900 3500 pH — — — — — — — — — API FL (mL) — — — — — — — — —

Sample 8A: 3 lb/bbl DUO-VIS®

(53) Water was first treated with M-I CIDE™ (0.05 vol %), a biocide available from M-I LLC, Houston, Tex. DUO-VIS® (xanthan gum) was added to the water flow to reach a concentration of 3 lb/bbl, and the sample was formed by aerating/injecting steam into the flow. Steam was injected at a rate of 3.2-0.3 kg/min with a pressure of 5 bar for 30 seconds, thus injecting 1.5 kg of steam. The sample was subjected to three passes in the mixing reactor.

Sample 9A: 5 lb/bbl HEC

(54) Water was first treated with M-I CIDE™ (0.05 vol %), a biocide. Hydroxyethylcellulouse (HEC) was added to the water flow to reach a concentration of 5 lb/bbl, and the sample was formed by aerating/injecting steam into the flow. Steam was injected at a rate of 3.2-0.3 kg/min with a pressure of 5 bar for 30 seconds, thus injecting 1.5 kg of steam. The sample was subjected to three passes in the mixing reactor.

(55) The rheological properties of the mixed fluids in each of Samples 8A and 9A were determined using a Fann Model 35 Viscometer, available from Fann Instrument Company at 120° F. a Brookfield Viscometer for Low Shear rate viscosity at room temperature. The samples were also subjected to a low pressure, low temperature filtration test to measure the filtration behavior of the fluid at room temperature and 100 psi, according to specifications set by the API Fluid Loss test procedures. The results are shown in Table 2a below.

(56) TABLE-US-00003 TABLE 2a Sample 8A.1 8A.2 8A.3 9A.1 9A.2 9A.3 Funnel Viscosity (sec) — — — — — — Mud Weight (ppg) 8.30 8.30 8.30 8.30 8.30 8.30 600 rpm 64 55 44 — 280 291 300 rpm 54 48 38 263 234 242 200 rpm 49 44 35 236 209 216 100 rpm 42 38 31 193 169 176  6 rpm 26 22 22 64 52 54  3 rpm 23 20 20 44 36 36 Gels 10″ (lbs/100 ft.sup.2) 24 21 21 44 35 36 Gels 10′ (lbs/100 ft.sup.2) 24 23 21 46 36 36 PV (cP) 10 7 6 — 46 49 YP (cP) 4 41 32 — 188 193 Brookfield 0.3 rpm - 1 min (cP) 37500 23400 21600 93800 79700 76500 Brookfield 0.3 rpm - 2 min (cP) 41100 24200 21700 — 100000 90400 Brookfield 0.3 rpm - 3 min (cP) 41800 24200 21800 — — 91300 pH 9.16 9.18 9.18 8.883 9.01 9.03

(57) The tests were repeated after Samples 8A and 9A were subjected to heat-rolling for 16 hours at 150° F. The results are shown below in Table 2b.

(58) TABLE-US-00004 TABLE 2b Sample 8A.1 8A.2 8A.3 9A.1 9A.2 9A.3 Funnel Viscosity (sec) — — — — — — Mud Weight (ppg) 8.30 8.30 8.30 8.30 8.30 8.30 600 rpm 47 46 38 258 261 256 300 rpm 41 40 34 212 214 207 200 rpm 39 38 32 190 190 184 100 rpm 35 34 29 154 152 147  6 rpm 24 22 21 49 45 43  3 rpm 21 20 18 34 31 29 Gels 10″ (lbs/100 ft.sup.2) 21 20 18 34 31 29 Gels 10′ (lbs/100 ft.sup.2) 26 25 25 36 31 30 PV (cP) 6 6 4 46 47 49 YP (cP) 35 34 30 166 167 158 Brookfield 0.3 rpm - 1 min (cP) 32500 22300 20900 80400 76000 71500 Brookfield 0.3 rpm - 2 min (cP) 34500 2300 21000 — 91000 86800 Brookfield 0.3 rpm - 3 min (cP) 34200 22800 21100 — 93800 86600 pH 9.31 9.21 9.20 7.56 7.52 7.77

Samples 8B (3 lb/bbl DUO-VIS®) and 9B (5 lb/bbl HEC)

(59) In order to determine the ability of the disclosed system to optimize the rheological properties of the mixed fluids, the mud formulations of Samples 8A and 9A were also formed using a conventional Silverson mixer at 4000 rpm for 1 hour to produce Samples 8B and 9B. The rheological properties of the mixed fluids in each of Samples 8B and 9B were determined using a Fann Model 35 Viscometer, available from Fann Instrument Company at 120° F. and a Brookfield Viscometer for Low Shear rate viscosity at room temperature. The samples were also subjected to a low pressure, low temperature filtration test to measure the filtration behavior of the fluid at room temperature and 100 psi, according to specifications set by the API Fluid Loss test procedures. The tests were each performed twice before heat rolling (BHR) and after heat rolling (AHR) for 16 hours at 150° F. Each repetition showed identical results to the first test. The results are shown in Table 3 below.

(60) TABLE-US-00005 TABLE 3 Sample 8B: BHR 8B: AHR 9B: BHR 9B: AHR Funnel Viscosity (sec) 76 81 9960 7200 Mud Weight (ppg) 8.3 8.3 8.3 8.3 600 rpm 39 33 — — 300 rpm 32 27 — 295 200 rpm 29 24 280 266 100 rpm 25 20 234 222  6 rpm 15 13 90 78  3 rpm 14 11 64 55 Gels 10″ (lbs/100 ft.sup.2) 17 14 65 55 Gels 10′ (lbs/100 ft.sup.2) 23 16 65 53 PV (cP) 7 6 — — YP (cP) 25 21 — — Brookfield 0.3 rpm - 49800 30100 82800 37300 1 min (cP) Brookfield 0.3 rpm - 51700 30000 77700 39700 2 min (cP) Brookfield 0.3 rpm - 57000 30000 82000 40100 3 min (cP) pH 6.91 6.16 7.37 6.38 API FL (mL) 33.0 — 55.0 100

Samples 8C-D (3 lb/bbl DUO-VIS®) and 9C-D (5 lb/bbl HEC)

(61) For samples 8C and 9C, the mud formulations described in Samples 8A and 9A were formed in a 4 bbl batch using a Silverson mixer fitted with a round holed shear head at 6000 rpm for 15 min, to simulate the API method for water-based mud mixing with reduced mixing time but increased shear/unit volume. For samples 8D and 9D, the mud formulations described in Samples 8A and 9A were mixed using a Heidoiph paddle mixer for 15 min to show the effect of reduced shear mixing.

(62) The rheological properties of the mixed fluids in each of Samples 8C-D and 9C-D were determined using a Fann Model 35 Viscometer, available from Fann Instrument Company at 120° F. and a Brookfield Viscometer for Low Shear rate viscosity at room temperature. The results are shown in Table 4a below.

(63) TABLE-US-00006 TABLE 4a Sample 8C 8D 9C 9D Funnel Viscosity (sec) 81 86 — — Mud Weight (ppg) 8.3 8.3 8.3 8.3 600 rpm 34 42 — — 300 rpm 31 35 — 280 200 rpm 29 33 271 256 100 rpm 26 29 227 215  6 rpm 17 18 84 83  3 rpm 15 16 60 60 Gels 10″ (lbs/100 ft.sup.2) 19 19 60 60 Gels 10′ (lbs/100 ft.sup.2) 26 26 60 60 PV (cP) 3 7 — — YP (cP) 28 26 — — Brookfield 0.3 rpm - 56000 72900 60000 64900 1 min (cP) Brookfield 0.3 rpm - 49100 64100 72800 81900 2 min (cP) Brookfield 0.3 rpm - 46700 62700 76800 88200 3 min (cP) pH 8.71 8.63 9.21 9.08

(64) The tests were repeated after Samples 8C-D and 9C-D were subjected to heat-rolling for 16 hours at 150° F. The results are shown below in Table 4b.

(65) TABLE-US-00007 TABLE 4b Sample 8C 8D 9C 9D Funnel Viscosity (sec) 83 86 — — Mud Weight (ppg) 8.3 8.3 8.3 8.3 600 rpm 36 40 — 288 300 rpm 31 35 254 239 200 rpm 29 32 227 214 100 rpm 25 28 185 173  6 rpm 16 17 62 56  3 rpm 14 15 44 39 Gels 10″ (lbs/100 ft.sup.2) 16 16 44 39 Gels 10′ (lbs/100 ft.sup.2) 24 20 44 39 PV (cP) 5 5 — 49 YP (cP) 26 30 4 39 Brookfield 0.3 rpm - 60000 66000 36400 36100 1 min (cP) Brookfield 0.3 rpm - 60400 71300 35000 36600 2 min (cP) Brookfield 0.3 rpm - 59300 71000 36200 36300 3 min (cP) pH 9.28 9.01 9.85 9.51

(66) It can be shown from the absence of fisheyes in the visual examination of the samples and the above results, that the drilling fluids may be more homogenously mixed using the methods and systems disclosed herein as compared to conventional mixing methods that produce drilling fluids encumbered by fisheyes. Additionally, in comparing the rheological properties of fluids mixed by a system of the present disclosure to fluid prepared by conventional mixing techniques, the fluids of the present disclosure showed improvements in the fluids' rheological properties without downhole circulation.

(67) Embodiments disclosed herein may provide for at least one of the following advantages. The methods disclosed herein may provide for a drilling fluid that may be substantially homogeneously mixed and substantially free of fisheyes. In enabling the formation of drilling fluids without agglomerates, the cost efficiency of the additives may be optimized by reducing the amount of additives that is filtered out by shale shakers prior to recirculation of a drilling fluid downhole. Additionally, performance of the drilling fluids downhole may be increased due to the decreased amount of agglomerated material. Increases in performance may result from the better achievement of the fluid's maximum rheological capabilities. Further cost efficiency may also be achieved by allowing for the modification of existing hopper systems to provide a substantially homogenous mixed drilling fluid.

(68) While the present disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as described herein. Accordingly, the scope of the invention should be limited only by the attached claims.