•

HYDRO-FOIL S8
SILICATE
SYSTEM
 HYDRO-FOIL S8 -SILICATE SYSTEM

A superior inhibitive water-based drilling fluid

system

Silicates provide superior clay and shale stabilizing

characteristics. They are regarded as an environmentally-
friendly and cost effective alternative to OBM or SBM.
 SILICATE SYSTEM

Silicate Muds

HYDRO-FOIL S8 is essentially a HYDRO-FOIL system that

utilises 5 – 15% v/v Sodium or Potassium Silicate solution to
enhance inhibition and mechanical wellbore stability,
particularly in highly fractured or unconsolidated formations.

The system pH is engineered to +/- 12 which has an adverse

affect on certain polymer additives.

The system is formulated using most conventional polymers,

with the exception of ENCAPSUL-8 (PHPA)

.
 SILICATE SYSTEM

Silicate Muds

The main application for silicate fluids is to replace oil and

synthetic fluids in difficult drilling applications such as wells
containing reactive claystones.

Silicate fluids exhibit a very high degree of shale inhibition

which exceeds that of glycol muds.

However they also have a number of limitations which must

be considered in fluid selection.
 SILICATE SYSTEM

Silicates – Features and Benefits

• Excellent shale & limestone/chalk inhibition and stability

• Potential to seal micro-fractured shales.
• Cheaper than glycol systems although maintenance
additions are expected to be higher so this cost advantage
can be eroded if the rig has poor solids control.
• Low corrosion rates
• Good environmental properties for offshore and onshore
applications.
• Ease of handling (liquid mud pre-blends, bulk inventories)
• Engineering (easy to use once up & running)
• Low cost advantage over synthetic fluids
 SILICATE SYSTEM

Silicates Disadvantages

• Debatable use for reservoir drilling (Unless perforate

Liner)
• Needs close monitoring (pH / Silicate)
• Sensitive to Hardness (divalent ions)
• Anhydrite formations / Acid Gases
• Temperature stability only to +/- 260 F
• “Green” Cement (Depletion of SiO2)
• Lower Lubricity (M-M Coefficient of Friction - 0.34)
 SILICATE SYSTEM

Silicate History

• The idea of adding silicate to water-based muds

dates back to the 1930’s, but controlling their
rheological properties proved too difficult to make
them viable at that time.

• In the mid 1990’s a new understanding of the

importance of the SiO2:Na2O ratio along with more
advanced polymers and the use of monovalent
brines, allowed these limitations to be overcome.
 SILICATE SYSTEM

Silicate Muds

• Utilizes soluble sodium silicate or potassium

silicate

• Is designed to drill in highly reactive clays and

shales, in highly dispersible formations, and
in unconsolidated or rafted zones

• Provides “Near Oil Mud” performance and

hole calipers
 SILICATE SYSTEM

Shales
• More than 75% of formations drilled are Shale or Clay

• More than 90% of wellbore instability problems are related

to drilling Shale or Clay

• Estimated US$500 MM/year cost to the industry from

Shale related problems

• Silicates are designed to provide protection against

problems related to unconsolidated formations and highly
reactive clays and shales
 SILICATE SYSTEM

Factors in Shale Instability

• Shale strength and deformation

• Shale porosity
• Shale composition (water, clays, chemistry)
• Formation in-situ stresses and pore pressure
• Downhole temperature and pressure
• Surrounding geological environment (tectonic stresses,
salt domes)
• Chemical & physical properties of drilling fluid
• Time of exposure of shale to drilling fluid
• Depth and length of exposed interval
 SILICATE SYSTEM

Controllable Factors
• Shale strength
 generally increased by a fluid which dehydrates - OBM or
Membrane Efficient WBM (Silicates)
 decreased by a fluid which hydrates - traditional WBM
• Shale porosity: diminished effects with the use of
blocking/sealing agents
• Time of exposure: affect compounds exponentially with
conventional WBM
• Chemistry/additives of continuous phase: WBM
• Composition and type of internal phase: OBM
 SILICATE SYSTEM

Hydration Forces in Wellbore

P mud = Hydrostatic Pressure

P = Pore Pressure
P
sh

mud
U = Chemical Potential (Salinity)
_ _ _ _ _ _ _ _
_ _ _ _ _ _
_ _ _ _ _ _ _ _
_ _ _ P mud _ _ _Psh
__ _ _ _ _ _
Umud
_ _ _ _ _ Ush
_ _ _ _ _ _ _ _
_ _ _ _ _ _
Q = f [(P - P )+(U  U )]
mud sh mud sh
 SILICATE SYSTEM

How Do Silicates Work?

• Provide a semi-permeable membrane to enable

dehydration of formation clays, similar to OBM

• Supply an effective plastering or cementation

mechanism, precipitated / gelled silicates
 SILICATE SYSTEM

Silicate Muds

Silicate muds are composed of the following:

• Silicate - primary shale inhibitor (provides water barrier)

• Potassium - secondary shale inhibitor (reduces
swelling)
• Bio-polymer - rheology control.
• PAC/Starch - provides fluid loss control
• Compatible with conventional anionic and non-ionic
fluid additives
• Used with monovalent salts (KCL & NaCl)
 SILICATE SYSTEM

Silicate Muds
• Silicates gel with reducing pH
• Silicates precipitate with divalent cation
• The presence of solutes such as NaCl and KCl is synergistic, as
solutes will balance the mud and shale activities to reduce the net flow
of ions into the shale.
• The presence of K+ is useful as it will exchange for Ca++ and Mg++ at
the clay surface, making these ions available to form precipitates.
• Precipitated/gelled silicates will bridge shale
• Silicates have affinity was metallic ions
• Silicate fluids more stable with salts
• Optimum inhibition at 7-10 v/v% silicate alone
• Optimum inhibition at 5-8 v/v% silicate with salt
• Soluble silicates unlike OBM and SBM have the ability to fill small
cracks and pressure-seal them.
 SILICATE SYSTEM

Silicate Attachment Mechanism

Na -

OH
O O

Ca++
OH
OH

O
O

OH
Na -

OH
SiO2 OH
O O

Ca++
OH
OH O
O Mg++
Ca++
O
OH
O
OH

OH
SiO2 OH
O
OH
O

Ca
++

O
O Mg++
Ca++
OH
OH

O O
OH
Ca++

Silicates associate with each other, aided by divalent

ions, as well as clay surfaces and tubulars
 SILICATE SYSTEM

Structure of Gelled Silicates

 SILICATE SYSTEM

Sealing of Microfractured Shales by Silicates

Fracture propagation

Mp Fp
Mp FLUID Fp Non-
Non inhibitive Fluid
INGRESS

Mp > Fp Mp = Fp = Mechanical Failure

Silicate gel/precipitate

Mp
Mp FLUID Fp HYDRO-
HYDRO-FOIL S8 Fluid
INGRESS Fp

Mp > Fp Mp > Fp = Mechanical Stability

 SILICATE SYSTEM

Inhibition Mechanisms of Silicates

H2O May Penetrate But Ions Are Excluded

Ca
Ca

H2O Ca Ca
SHALE PORE
Ca
Ca

~ GELLED/PRECIPITATED SILICATES
 SILICATE SYSTEM

Silicate Cementation of Rafted or Unconsolidated Formation

~ GELLED/PRECIPITATED SILICATES
 SILICATE SYSTEM

Silicate Manufacture

FURNACE PROCESS
Sand
Caustic Solution

1400+ oC Lump Glass

Silicate Liquor

Soda Ash

HYDROTHERMAL PROCESS
Sand Caustic Solution

Na2CO3 + nSiO2 Na2O .nSiO2 + CO2

n is Molar Ratio

Silicate Liquor
 SILICATE SYSTEM

Typical Formulation of a HYDRO-FOIL S8 system

HYDRO-FOIL
Product Function HYDRO-FOIL S8
S8
Drillwater (bbl/bbl) Base Fluid 0.74 0.65
Water Activity &
KCl (lb/bbl) Cation 30 25
Exchange
Caustic Soda / Potash Alkalinity Control
to pH 12 – 12.5 to pH 12 – 12.5
(lb/bbl)
Soda Ash Hardness Control to < 400 mg/L to < 400 mg/L

XC-EED (lb/bbl) Viscosifier 0.75 – 1.0 0.75 – 1.25

HYDRO-PAC UL (lb/bbl) Fluid Loss Control 2.5 2.5
HYDRO-STAR CMS Fluid Loss Control
2.0 2.0
(lb/bbl)
SILIC-8S (v/v%) Shale Stabilisation 11.0 9.0

SCAV-OX (lb/bbl) Oxygen Scavenger 1.0 – 1.5 1.0 – 1.5

DRILL-BAR (lb/bbl) Weighting Agent 155 340

 SILICATE SYSTEM

Typical Properties of a HYDRO-FOIL S8 system

Properties

Density (ppg) 12 15

Plastic Viscosity (cP) 20 - 30 25 - 35

Yield Point (lb/100ft2) 15 - 25 20 - 30

Gels (lb/100ft2) +/- 6 /10 +/- 8 / 14

API Fluid Loss

<6 <6
(cc/30min)

Pf/Mf 20/25 - 35/40 20/25 - 35/40

SiO2/Na2O 40-50 / 20-25 40-50 / 20-25

pH 12 – 12.5 12 – 12.5
 SILICATE SYSTEM

SILICATES - Optimum Silicate Concentration

100
90
80
Recovery 70
60
of
50
dispersive
40
clay (%) 30
20
10
0
1 2 3 4 5
Silicate concentration (% vol)
 SILICATE SYSTEM

SILICATES
100
90
80

% R ecovery
• Laboratory results
confirm the more 70
effective inhibition 60
performance of the 50
“higher ratio” silicate. 40
The selection of the 30
2.6 - 2.8 ratio is a 20
compromise to obtain 10
the maximum 0
inhibition with
optimum solubility.
Silicate ratio (SIO2:Na20)
 SILICATE SYSTEM

Temperature Stability With & Without Polyglycol

 SILICATE SYSTEM

Silicates - Engineering Guidelines

• Monitor SiO2 and Na2O via titration. Report depletion

rates and chart trends

• Monitor Pf/Mf/pH and chart trends

• Control LGS below 7% and MBT below 15 lb/bbl

• Monitor K+ and report. Report depletions rates and

chart trends

• Monitor and report all other standard WBM properties

 SILICATE SYSTEM

Silicates - Engineering Guidelines

• Rheology - Xanthan for 6/3 RPM readings. Variation with

Silicate concentration
• Fluid Loss - +/- 3.0 ppb PAC U/L & Reg (9-6cc)
• Silicate - 5-8 % by volume
• KCl - 25 - 35 ppb
• MBT - Generally low (highly inhibitive)
• pH - 11 - 12 (natural level)
• Hardness - Zero (positive Silicate)
• Corrosion - inhibitors not necessary
 SILICATE SYSTEM

Silicates - Engineering Guidelines

• Hole Cleaning - Integrity of cuttings requires optimising

LSRV’s & Flow Rates
• Wiper Trips - Recommended regularly to ensure no
packing-off (especially in deviated hole)
• Trips - Overpull on first trip through new hole due to +/-
gauge. Minimise backreaming to avoid stripping Silicate
“membrane”
 SILICATE SYSTEM

Silicates -Engineering Guidelines

• Normally 5-7 % by vol. Of Na Silicate (Less in Chalks/

low reactive Clays)
• Normally 25-35 ppb KCl (Less in chalk)
• pH run high (11 to 12) - must be kept well above 10.5
(Na Silicate base @ +/- 12.2)
• Ca++/Mg++ contamination - May affect rheology but
definitely depletes Silicate
• API Fluid Loss test not directly related to wellbore
filtration levels
 SILICATE SYSTEM

Silicate Depletions

• Low to moderate in clays, shales, chalk, cured cement

• Severe in anhydrite, green cement, divalent salts

• Severe with carbon dioxide contamination

• Severe in chalk at BHST > 190o


If desired, controlled depletions may be performed
using gypsum
 SILICATE SYSTEM

Drilling Practices
• Pump Rate: Adequate circulation volume is important to
ensure that BHAs do not become fouled.

• Mud Density: Silicate cementation will aid in dealing with

tectonic stresses, however adequate mud density is
necessary to balance interstitial pressures.

• Drill Pipe Rotation: Aids in preventing BHA fouling

• Limit Rate of Penetration: Maintain a minimum annular

cuttings concentration. Cuttings tend to be large and
therefore difficult to remove from around the BHA
 SILICATE SYSTEM

Drilling Practices
• Mud Rheology Parameters: Ensure that fluid rheology is
adequate to remove larger diameter cuttings from wellbore.
• Routine Monitoring of Cuttings Discharges: Ensure that an
equivalent volume of cuttings are being removed as to the
volume of formation being drilled.
• Sweeps: Frequent low viscosity / high viscosity sweeps are
helpful in minimizing BHA fouling.
• Wiper Trips: Aid in maintaining a clean BHA and workable
wellbore.
• Equipment Selection: Less BHA jewelry is less prone
to fouling
 SILICATE SYSTEM

Field Observations

• Stable hole conditions in reactive shales

• Stable mud properties
• Gauge or near-gauge hole : shale and chalk
• Firm, large, discrete cuttings
• Low dilution rates compared to other WBMs -
typically half
• Polyglycols provides temperature stability approaching
300oF
• No HSE-related incidents
 SILICATE SYSTEM

Field Observations

• Cuttings size - hole cleaning problems if not dealt

with
• Cuttings have tendency to attach to BHA, sweeps
and adequate circulation rates minimize effects
• Proper salinity is important for shale stability
• Swab/surge in near-gauge hole
• Occasional high torque/tight hole
• Torque at high hole angles
• Seepage/minor mud losses tend to heal - silicate
precipitates
 SILICATE SYSTEM

SILICATES: EXPERIENCE

• Maximum penetration rates

• Minimum down-time attributed to formation chemical instability
• Minimal “bit balling” problems
• Caliper wellbore geometry for optimum cement jobs
• Excellent cuttings integrity for geology interpretation and for effective
removal by the solids control equipment
• High solids removal efficiency, comparable of invert emulsion fluids
• Minimal environmental impact as a consequence of the use of all
“environmentally friendly” products
• Minimal environmental impact with reduced discharges to the sea
• Low dilution rates, which are also beneficial with regard to waste
control and management. This factor is extremely important with
regard to fluid design criteria for onshore application
 SILICATE SYSTEM

Comparative Performance

Performance
80
70 Mud Cost
60 $/ft
50
40
30
20
10
0
Silicate KCl PHPA Ligno
 SILICATE SYSTEM

Comparative Performance

Performance
100
90
Ave. ROP, ft/hr
80
70 Chemicals Used, lb/ft
60
50
40
30
20
10
0
Silicate KCL/Polymer PHPA Ligno
 SILICATE SYSTEM

Subject Well Results

Subject Well Depth vs Days

Time (days)
0 20 40 50
0
AFE
2,000
Actual
4,000

6,000
Depth (md)

8,000

10,000

12,000

13,500
 SILICATE SYSTEM

Caliper Log - Subject Well

Hole Caliper - Inches
6 7 8 9 10 11 12 13 14 15 16
5,550

5,650

5,750

5,850

5,950

6,050

6,150

6,250

6,350

6,450

6,550

6,650

6,750

6,850

6,950

7,050

7,150

7,250

7,350

7,450

12-1/4” Section