Solids-Free Brine-in-Oil Emulsions for Well Completion

Summary An invert emulsion fluid composed of brine (e.g., NaCl, NaBr, CaCl2, CaBr2, and ZnBr2) emulsified into hydrocarbon oil (e.g., diesel, crude, or mineral) was formulated with a mixture of nonionic surfactant emulsifiers. Laboratory investigations were conducted to define the emulsion characteristics and to develop methods for controlling the fluid's rheological properties and emulsion stability at elevated temperatures. This system has oil as the external phase, and the stability of the emulsion in most cases is linked to the homogeneity and fineness of the brine-dispersed droplets. The emulsion stability is also related to its viscosity and to the strength of the interfacial film formed by the emulsifiers that coat the brine droplets. For packer-fluid applications, the solids-free invert emulsions offer several advantages over conventional oil- and water-based muds. For example, the fluid is virtually nonconductive, providing greater corrosion protection than conventional water-based muds and clear brines. It can also provide formation protection characteristics and can solve such problems as clay swelling and solids invasion. This new completion fluid is ideal for perforating, drilling in, under-reaming, and gravel packing. The emulsion can be filtered through a less-than-10-μm cartridge filter and can be reclaimed and used again. This new completion fluid was used successfully in the field as a packer fluid and as a perforating fluid for testing a reservoir that was drilled with conventional oil-based mud.