Development of a Polyurethane Lost Circulation Material Suitable for Malignant Leakage of Drilling Fluid

Abstract

A malignant leakage presents a significant challenge in drilling engineering, particularly within carbonate formations, where such a leakage is frequently encountered. Currently, there is no effective solution to this problem. In this study, a water-reactive polyurethane sealing agent was developed using multifunctional polypropylene glycol and 1,4-butanediol (BDO) as soft segments, diphenylmethane diisocyanate (MDI) as the hard segment, and a composite catalyst consisting of N, N-dimethyl cyclohexylamine (PC-8) and dibutyltin dilaurate (T-12). The material reacts rapidly with water to form a high-strength gel, with the reaction time being controllable. Through experimental optimization, it was determined that the BDO mass fraction was 1%, and the molar ratio of isocyanate group to hydroxyl group was 1.8. Additionally, the gelation time can be controlled by adjusting the mass fraction of the composite catalyst. Experimental results from sand-bed and fracture-plate tests indicated that the material could withstand pressures exceeding 3 MPa at 93 °C and exhibited resistance to saturated NaCl and CaCl2 environments. The plugging mechanism was investigated using scanning electron microscopy (SEM), thermogravimetric analysis (TGA), and Fourier-transform infrared (FTIR) spectroscopy. The results demonstrated that the agent formed a compact, micron-scale porous structure upon reacting with water, exhibiting excellent thermal stability and dual plugging performance through both physical and chemical mechanisms. Due to its water-reactive characteristics, a multi-stage injection process was adopted for field application design. This material shows promising potential for mitigating large-fracture-type malignant leakages in drilling operations.