Styrene-Lauryl Acrylate Rubber Nanogels as a Plugging Agent for Oil-Based Drilling Fluids with the Function of Improving Emulsion Stability

With the exploration and development of unconventional oil and gas, the use frequency of oil-based drilling fluid (ODF) is increasing gradually. During the use of ODFs, wellbore instability caused by invasion of drilling fluid into formation is a major challenge. To improve the plugging property of ODFs, nano-sized poly(styrene-lauryl acrylate) (PSL) rubber nanogels were synthesized using styrene and lauryl acrylate through soap-free emulsion polymerization method and were characterized using FTIR, NMR, SEM, TEM, particle size analysis and TGA. The results show that, due to good dispersion stability and oil-absorbing expansion ability, the PSL rubber nanogels have a wide range of adaptations for nano-scale pores to deposit a layer of dense filter cake on the surface of filter paper with various pore diameters, reducing the filtration of mineral oil and W/O emulsion significantly. Due to the unique wettability, the PSL rubber nanogels can be adsorbed stably at the oil–water interface and form a dense granular film to prevent droplets coalescing, which improves the emulsification stability of W/O emulsion. Furthermore, the PSL rubber nanogels are soap-free and compatible with ODFs without foaming problems. The PSL rubber nanogels can increase the hole-cleaning performance of ODFs by raising viscosity and yield point. The PSL rubber nanogels outperformed hydrophobic modified nano silica and polystyrene nanospheres in plugging and filtration reduction. Therefore, the PSL rubber nanogels are expected to be used as a new plugging agent in oil-based drilling fluid. This research provide important insights for the use of organic nanogels in ODFs and the optimization of plugging conditions.