This study provides a detailed characterization and evaluation
of Claytone-EM as a rheological additive to enhance the performance
of oil-based drilling fluids (OBDFs) under high-pressure, high-temperature
(HPHT) conditions. It also offers a comparative evaluation of the
effectiveness of Claytone-EM with an existing organoclay, analyzing
their mineral and chemical compositions, morphologies, and particle
sizes. A series of experiments are performed to evaluate Claytone-EM’s
influence on crucial drilling mud properties, such as mud density,
electrical stability, sagging tendency, rheology, viscoelastic properties,
and filtration properties, to formulate a stable and high-performing
OBDF. Results indicated that Claytone-EM had no significant impact
on mud density but remarkably enhanced emulsion stability. Claytone-EM
effectively mitigated sagging issues under both static and dynamic
conditions, leading to improvements in the plastic viscosity (PV),
yield point (YP), apparent viscosity (AV), and YP/PV ratio. The PV,
YP, AV, and YP/PV ratios were improved by 11, 85, 28, and 66% increments,
respectively, compared with those of the drilling fluid formulated
with MC-TONE. The addition of Claytone-EM resulted in enhancing gel
strength and improving the filtration properties of the drilling fluid.
The filtration volume was reduced by 2% from 5.0 to 4.9 cm3, and the filter cake thickness had a 13% reduction from 2.60 to
2.26 mm. These findings highlight Claytone-EM as a valuable additive
for enhancing OBDF performance, particularly under challenging HPHT
conditions. Its ability to provide emulsion stability, reduce static
and dynamic sag, and control filtration holds the potential to enhance
drilling operations, minimize downtime, and bolster wellbore stability.
This study acknowledges certain limitations, including its temperature
range, which could benefit from exploration at extreme temperatures.
Additionally, the absence of flow experiments limits a comprehensive
understanding of sag effects, and further research and field-scale
evaluations are recommended to validate and optimize the application
of Claytone-EM in OBDFs.