| Abstract: | Oil-bearing formations often consist of loose sandy material. In the production of oil from these formations sand tends to be carried to the well bore along with the oil. The flow of sand can be prevented by consolidating or cementing together the sand particles of the formation around the well bore. The cementing has to be accomplished in such a manner that fluid flow channels between particles remain open. This paper describes a new three-step process that was developed to consolidate oil well sand. The steps in the process involve injection of: (1) resin, (2) inert fluid, and (3) inert fluid containing a catalyst. In the first step of the process, resin in injected into the formation where it fully saturates the interstices between sand grains. Permeability is established in the second step by displacement of the excess resin from the interstices, thereby leaving a thin film of resin on the sand grains. In the third step, polymerization is activated by migration of catalyst from the inert fluid into the thin resin film on the sand. The process has the advantage that resin is placed and permeability is established before the resin is catalyzed. This avoids premature polymerization of the resin which might cause plugging of the formation or the tubing string used to inject resin. Desirable characteristics of a resin for the three-step process are: (1) viscosity of 25–200 cp. at well bore temperature; (2) stability for several days at well bore temperature; (3) high adhesion to sand in the presence of an inert flushing fluid; (4) polymerization by less than 10% catalyst; (5) the polymerized resin binds sand together with a strong bond that is not affected by well fluids. Five different resin types have been tested for use in the three-step sand consolidation process. These are: (1) epoxy–anhydride cured with a tertiary amine; (2) epoxy–epoxy diluent cured with a primary–tertiary amine mixture; (3) furan; (4) unsaturated polyester–vinylpyrrolidone; (5) unsaturated polyester–styrene. The two epoxy resins give strong, permeable consolidated sand which is resistant to well fluids such as brine and crude oil. The furan resin gives a weak consolidation. The unsaturated polyester–vinylpyrrolidone gives good strength and oil resistance but is sensitive to brine. The unsaturated polyester–styrene is difficult to apply. Many oil wells have been successfully treated in the Gulf Coast area and in California with the two epoxy resins. Almost all of these wells are producing free of sand, and, to date, more than five million barrels of oil have been produced from these wells. |
