Foam Properties Evaluation under Harsh Conditions: Implications for Enhanced Eco-Friendly Underbalanced Drilling Practices

Summary Foam drilling offers advantages such as reduced formation damage and faster drilling in underbalanced drilling (UBD) operations. The efficacy of foam drilling is influenced by factors including pressure, temperature, salt content, foam quality, and pH levels. However, a gap exists in the evaluation of foam properties under rigorous conditions, particularly those involving high pH and mixed salt environments common in drilling scenarios, highlighting the need for further research. In this study, a high-pressure, high-temperature (HPHT) foam analyzer and rheometer were employed to examine the stability and rheological behavior of ammonium alchohol ether sulfate (AAES) foam under simulated alkaline drilling conditions. The foaming solution, designed to replicate such conditions, consisted of synthetic seawater (SW) with a salt mixture totaling approximately 67.70 g/L and a 0.5 wt.% foaming agent adjusted to a pH of 9.5. This approach differs from the individual salt studies prevalent in existing literature and provides a unique perspective on foam stability and behavior. Driven by environmental sustainability considerations, the effects of eco-friendly surfactant AAES and various drilling fluid additives: polyanionic cellulose (PAC), carboxymethyl cellulose sodium (CMC), and xanthan gum (XG), were investigated for foam formulation. The apparent viscosity of the AAES foam was evaluated at different pressures and temperatures across varying shear rates. A consistent decrease in foam viscosity with increasing shear rates was observed, irrespective of pressure and temperature. An increase in foam viscosity was also noted with higher pressures (from 14.7 psi to 3,000 psi) at low shear rates, with values rising from 8.04 cp to 14.74 cp, and from 3.71 cp to 5.79 cp at high shear rates of 1,000 s⁻¹. Increasing foam quality from 65% to 85% resulted in significant improvements in viscosity, approximately 37% at low shear rates and about 79% at high shear rates. The introduction of additives to AAES foam at 1,000 psi and 90°C led to a substantial increase in viscosity, with PAC showing the most significant enhancement: 33.28 cp at low shear rates and 18.15 cp at high shear rates. Conversely, the viscosity of both base AAES foam and additive-enhanced foams decreased with rising temperatures, although PAC exhibited the greatest resistance to viscosity variations due to temperature changes. The addition of PAC also resulted in a notable increase in foam yield stress, potentially leading to more efficient cuttings transport and hole cleaning. Furthermore, foam stability was significantly improved by the additives, with XG and CMC doubling stability to 48 minutes, and PAC resulting in a threefold increase in half-life to 65 minutes. This study presents AAES and the tested additives as viable components for eco-friendly foam formulations, promoting enhanced properties suitable for UBD applications.