Contribution based approach to increase the density and strength of current thixotropic loss control solutions

1. A method of producing a loss control blend, the method comprising:

determining a first density, a first compressive strength and a first thixotropic behavior of a first composition, wherein the first composition consists essentially of (i) a first blend of first active components and (ii) water, wherein the first blend is present in the first composition in an amount from about 50 wt % to 95 wt %;

selecting ingredients for the loss control blend so that the loss control blend comprises the first blend, a clay and/or a polymer and at least two additional components; and

combining the thus selected ingredients to produce the loss control blend,

wherein the loss control blend produces a second composition when combined with water, and when the lost control blend is present in the second composition in amount about equal to the amount of the first blend in the first composition, the second composition having a second density, a second set compressive strength and a second thixotropic behavior, and

wherein each additional component is selected to have at least one of three tailored attributes and at least one additional component is selected to have three of the tailored attributes, wherein the tailored attributes are:

(i) including the additional component increases thixotropic behavior such that the second thixotropic behavior is greater than the first thixotropic behavior,

(ii) including the additional component increases density such that the second density is greater than the first density, and

(iii) including the additional component increases set compressive strength such that the second set compressive strength is greater than the first set compressive strength.

2. The method of claim 1 , wherein at least one of the additional components is an active component.

3. The method of claim 1 , wherein the clay is present in an amount from 0.05 wt % to 5.0 wt % based on the total weight of the loss control blend, and the polymer is present in an amount from 0.05 wt % to 3.0 wt % based on the total weight of the loss control blend.

4. The method of claim 3 , wherein the clay is selected from the group consisting of hectorite, bentonite, sepiolite, kaolinite, montmorillonite, talc, vermiculite, halloysite, brucite, muscovite, smectite, chlorite and mixtures thereof, and the polymer is selected from a group consisting of borate crosslinked HEC, xanthan gum, welan gum, guar gum, HPG, CMHPG, cellulose, CMC, HEC, Diutan, polyacrymide, AMPS, and combinations thereof.

5. The method of claim 1 , wherein at least one of additional components includes a plurality of passive materials consisting of solid particles, the plurality of passive materials selected so as to have:

a particle size distribution for the plurality of passive materials and total surface area for the plurality of passive materials is sufficient for the passive materials to remain in suspension in the second composition without turbulence for a period of time sufficient to allow the second composition to set; and

an aggregate specific gravity of the plurality of passive material so as to maintain a solids to water ratio of at least 2 and so that the second composition does not have less thixotropic behavior than the first composition.

6. The method of claim 5 , wherein a particle size distribution for the plurality of passive materials and total surface area for the plurality of passive materials is sufficient for the passive materials to remain in suspension in the loss control blend without shearing at a temperature between 32° F. and 450° F. for a period of time sufficient to allow the loss control blend to set.

7. The method of claim 5 , wherein the particle size distribution of the plurality of passive materials is such that the size of the particles is from 1 μm to 100 μm.

8. The method of claim 7 , wherein the plurality of passive materials include passive materials selected from the group consisting of CaCo 3 , CaMg(Co 3 ) 2 , MnO 2 , Fe 2 O 3 , SiO 2 , BaSO 4 , and combinations thereof and wherein the passive materials are present in an amount from 10 wt % to 80 wt % based on the total weight of the loss control blend.

9. The method of claim 8 , wherein at least one of the additional components includes SiO 2 present in an amount in the range of 5 wt % to 40 wt % based on the total weight of the loss control blend, which serves as a coalescing material and is in the form of at least one of amorphous silica and crystalline silica.

10. The method of claim 5 , wherein the aggregate specific gravity of the plurality of passive materials is between 2.5 and 5.0.

11. The method of claim 1 , wherein the second density is greater than 15 ppg.

12. The method of claim 1 , wherein the loss control blend is configured for the conditions in a wellbore and is used in servicing the wellbore.

13. The method of claim 12 , wherein the second density is greater than 15 PPg.

14. The method of claim 13 , wherein the two or more components include one or more second active components, wherein the clay is selected from the group consisting of hectorite, bentonite, sepiolite, kaolinite, montmorillonite, talc, vermiculite, halloysite, brucite, muscovite, smectite, chlorite and mixtures thereof and is present in an amount from 0.05 wt % to 5.0 wt % based on the total weight of the loss control blend.

15. The method of claim 14 , wherein the polymer is selected from the group consisting of borate crosslinked HEC, xanthan gum, welan gum, guar gum, HPG, CMHPG, cellulose, CMC, HEC, Diutan, polyacrymide, AMPS, and combination thereof and is present in an amount from 0.05 wt % to 3.0 wt % based on the total weight of the loss control blend.

16. A method of producing a loss control blend, the method comprising:

determining a first density, a first compressive strength and a first thixotropic behavior of a first composition, wherein the first composition consists essentially of (i) a first blend of first active components and (ii) water, wherein the first blend is present in the first composition in an amount from about 50 wt % to 95 wt %;

selecting ingredients for the loss control blend so that the loss control blend comprises the first blend, a clay and/or a polymer and at least two additional components; and

combining the thus selected ingredients to produce the loss control blend,

wherein the loss control blend produces a second composition when combined with water, and when the lost control blend is present in the second composition in amount about equal to the amount of the first blend in the first composition, the second composition having a second density, a second set compressive strength and a second thixotropic behavior, and

wherein each additional component is selected to have at least one of three tailored attributes and at least one additional component is selected to have three of the tailored attributes, wherein the tailored attributes are:

(i) including the additional component increases thixotropic behavior such that the second thixotropic behavior is greater than the first thixotropic behavior,

(ii) including the additional component increases density such that the second density is greater than the first density, and

(iii) including the additional component increases set compressive strength such that the second set compressive strength is greater than the first set compressive strength; and

wherein at least one of the additional components include a plurality of passive materials consisting of solid particles, the plurality of passive materials selected so as to have:

a particle size distribution for the plurality of passive materials and total surface area for the plurality of passive materials is sufficient for the weighting agents to remain in suspension in the loss control blend without turbulence at a temperature between 32° F. and 450° F. for a period of time sufficient to allow the loss control blend to set;

an aggregate specific gravity of the plurality of passive material so as to maintain a solids to water ratio of at least 2 and so that the second composition does not have less thixotropic behavior than the first composition; and

the particle size distribution of the plurality of passive material is such that the particles have a diameter within the range of from 1 μm to 100 μm.

17. The method of claim 16 , wherein the plurality of passive material includes a passive material selected from the group consisting of CaCo 3 , MnO 2 , Fe 2 O 3 , SiO 2 , BaSO 4 , and combinations thereof and wherein the passive material is present in an amount from 10 wt % to 80 wt % based on the total weight of the loss control blend, and wherein the second active component includes a material selected from cement kiln dust, lime kiln dust, hydrated lime, zeolites, pumice, perlite, furnace slag, fly ash, natural pozzolan, amorphous silica and combinations thereof.

18. The method of claim 17 , wherein the at least two or more components include SiO 2 present in an amount in the range of 5 wt % to 40 wt % based on the total weight of the loss control blend, which serves as a coalescing material and is in the form of at least one of amorphous silica and crystalline silica.

19. The method of claim 18 , wherein the aggregate specific gravity of the plurality of passive material is between 2.5 and 5.0.

20. The method of claim 19 , wherein the loss control blend is introduced downhole by a pump system.