Optimum particle size distribution design for lost circulation control and wellbore strengthening

- Optimum PSD is critical to maximize the strengthening benefits.
- A bimodal PSD has a clear strengthening advantage over a unimodal PSD.
- We introduced a new method to generate the optimum PSD for LCM blends.
- The introduced method employs a bimodal PSD which provides appropriately sized fine and coarse particles.

In this paper, we have experimentally studied the impact of particle size distribution (PSD) on the fracture sealing capability of lost circulation material (LCM) blends. Our primary aim was to determine the PSD which maximizes the Wellbore Strengthening (WBS) benefits obtained from fracture sealing. High-pressure borehole fracturing experiments were conducted on Berea sandstone samples under atmospheric pore pressure and various confining pressures to investigate the WBS effects of several LCM blends. Post-fracturing methods such as Computerized Axial Tomography (CAT) scan and thin-section imaging were used to investigate the geometry of induced fractures and formed seals within them. Based on the conducted experiments and post-fracturing analyses, we have evaluated and re-assessed well-known theories applicable to the design of LCM blends, such as the one-third rule, the ideal packing theory, and the Vickers criteria. Our experiments indicate that for any rock with a given set of rock strength and failure parameters, there exists an optimum PSD to maximize WBS benefits. Optimum PSD appears to be of primary importance, almost independent of LCM type. In addition, we have shown that the optimum PSD should have a bimodal structure, with sufficient concentrations of properly sized fine and coarse particles. Although the one-third rule, the ideal packing theory, and the Vickers criteria may provide some basic PSD guidelines, these theories are mainly empirical relationships based on conventional particle plugging experiments. As shown here, they do not properly represent the physics of fracture sealing. To remedy this situation, we are introducing a new family of design curves for optimum PSD, based on the underlying physics of fracture sealing observed in the WBS experiments.