Using foams to drill in low pore pressure reservoirs is attractive because of their low density, high viscosity, and ability to transport cuttings. However, in high temperature reservoirs (240 °F) with H2S gas present, there are concerns with the long-term stability of a foam drilling fluid. In this work, we highlight a lab program to develop a stable drilling foam for drilling in a low pore pressure, high temperature reservoir. The work also includes pilot-scale experiments to evaluate foam performance. Aqueous nitrogen-in-water foams were stabilized with a preferred foaming surfactant formulation, and the rheology and stability of the foams were measured at representative drilling conditions (temperature and pressure) at the lab and pilot-scale. The foams were also evaluated for their compatibility with current drilling fluids used on site and for stability in the presence of H2S gas (at 1900 psi and 140 °F). The drilling foam was also evaluated using a pilot-scale flow loop comprised of a rheology flow loop and a model drilling wellbore. The experiments included measuring the foam rheology, foam stability in the model wellbore, and gas migration tests to understand how the foam suppresses upwardly migrating gas bubbles. We successfully developed a surfactant stabilized foam designed for a high-temperature reservoir with H2S gas present. We found that H2S can negatively impact foam stability if proper surfactants are not selected. Our foam showed less than 10% liquid drainage after 12 hours at 240 °F and showed no significant degradation upon contact with 17 mol% H2S gas. Additionally, the foam was compatible with all drilling fluids (both water-based and oil-based) currently used at the drill site and demonstrated good stability in a model pilot-scale drilling wellbore. Interestingly, when the wellbore was angled at 30 degrees from vertical with the eccentric drill pipe rotating at 100 RPM, the foams were susceptible to degradation compared to an equivalent scenario of a vertical wellbore with concentric rotating drill pipe. The gas migration tests at the pilot-scale showed the foam was capable of significantly slowing down an upwardly moving gas bubble with and without pipe rotation.

It has been shownthat injecting surfactants into unconventional hydraulically fractured wells can improve oil recovery. It is hypothesized that oil recovery can be further improved by more efficiently distributing surfactants into the reservoir using foam. The challenge is that in high temperature applications (e.g., 240 F) many of these formulations may not make stable foams as they have only moderate foaming properties (short half-life). Therefore, we are evaluating polymers that can be used to improve foam stability in high temperature wells which has the potential to improve oil recovery beyond surfactant only injection.Surfactant stabilized nitrogen foams were evaluated using a foam rheometer at pressures and temperatures representative of a field pilot well. The evaluation process consisted of measuring baseline properties (foam viscosity and stability) of a surfactant stabilized foam without any added stabilizer. Next, conventional enhanced oil recovery polymers (HPAMs, modified-HPAMs, and nonionic polymers) were added at different concentrations to determine their impacts on foam stability. Our results demonstrate that inclusion of a relatively low concentration (0.05 wt% – 0.2 wt%) of polymer has a pronounced impact on foam stability. It was determined that reservoir temperature plays a key role in selecting astabilizing polymer. For example, at higher temperatures (>240 F), sulfonated HPAM polymers at just 0.2 wt% more than doubled the stability of the foam. The polymer that was selected from this lab work was tested in a foam field trial in an unconventional well. It is thought that improved foam stability could potentially help improve the distribution of surfactants in fracture network and further improve oil recovery.

There has been increasing interest in different greenhouse gas (GHG) management strategies including the reduction of methane emissions and carbon sequestration. It has been proposed that reinjection of excess produced natural gas can mitigate GHG emissions without compromising oil production. Foam has been used as a method to reduce gas mobility, delay gas breakthrough, and improve sweep efficiency. However, industrial production of petroleum-based chemicals or surfactants to generate foam can be dependent on fossil-based resources that can be scarce or expensive. The main objective of this work was to reduce chemical cost and oil-based chemical dependency by developing an alternative biosurfactant formulation to generate high quality foam. Biosurfactant blends were ranked in comparison to single component anionic and nonionic surfactants and other commercially available surfactant blends. Bulk stability "shake tests" were done to look at initial foamability and stability of the different candidates and then corefloods in sandpacks and surrogate rocks were completed to look at if formulations would generate foam in porous media with methane gas and in the presence of crude oil. Experiments showed success in replicating chemical performance by replacing traditional oil-based surfactants with bio-based lignin derived surfactants even at reservoir conditions. High-quality biosurfactant foams reduced chemical costs, provided an alternative method to dispose of large amounts of hydrocarbon gas, and improved oil recovery through foam displacement.