The use of gels in oil production processes has become a regular practice in oilfield operations and is constantly developing in all oil-producing countries of the world, as evidenced by the growth of publications and patent activity on this topic. Many oil production processes, such as hydraulic fracturing, conformance control, water, and gas shutoff, cannot be imagined without the use of gel technologies. Inorganic, organic, and hybrid gels are used, as well as foams, gel-forming, and gel-dispersed systems. The possibility of a broad control of structural and mechanical properties, thermal stability, and shear resistance by introducing microscale and nanoscale additives made hydrogels and hydrocarbon-based gels indispensable tools for oil engineers.

The application of nanocomposites based on polyacrylamide hydrogels as well as silica nanoparticles in various tasks related to the petroleum industry has been rapidly developing in the last 10–15 years. Analysis of the literature has shown that the introduction of nanoparticles into hydrogels significantly increases their structural and mechanical characteristics and improves their thermal stability. Nanocomposites based on hydrogels are used in different technological processes of oil production: for conformance control, water shutoff in production wells, and well killing with loss circulation control. In all these processes, hydrogels crosslinked with different crosslinkers are used, with the addition of different amounts of nanoparticles. The highest nanoparticle content, from 5 to 9 wt%, was observed in hydrogels for well killing. This is explained by the fact that the volumes of injection of block packs are counted only in tens of cubic meters, and for the sake of trouble-free workover, it is very important to preserve the structural and mechanical properties of block packs during the entire repair of the well. For water shutoff, the volumes of nanocomposite injection, depending on the well design, are from 50 to 150 m³. For conformance control, it is required to inject from one to several thousand cubic meters of hydrogel with nanoparticles. Naturally, for such operations, service companies try to select compositions with the minimum required nanoparticle content, which would ensure injection efficiency but at the same time would not lose economic attractiveness. The aim of the present work is to develop formulations of nanocomposites with increased structural and mechanical characteristics based on hydrogels made of partially hydrolyzed polyacrylamide crosslinked with resorcinol and paraform, with the addition of commercially available nanosilica, as well as to study their thermal degradation, which is necessary to predict the lifetime of gel shields in reservoir conditions. Hydrogels with additives of pyrogenic (HCSIL200, HCSIL300, RX380) and hydrated (white carbon black grades: ‘BS-50’, ‘BS-120 NU’, ‘BS-120 U’) nanosilica have been studied. The best samples in terms of their structural and mechanical properties have been established: nanocomposites with HCSIL200, HCSIL300, and BS-120 NU. The addition of hydrophilic nanosilica HCSIL200 in the amount of 0.4 wt% to a hydrogel consisting of partially hydrolyzed polyacrylamide (1%), resorcinol (0.04%), and paraform (0.09%) increased its elastic modulus by almost two times and its USS by almost three times. The thermal degradation of hydrogels was studied at 140 °C, and the experimental time was converted to the exposure time at 80 °C using Van’t Hoff’s rule. It was found that the nanocomposite with HCSIL200 retains its properties at a satisfactory level for 19 months. Filtration studies on water-saturated fractured reservoir models showed that the residual resistance factor and selectivity of the effect of nanocomposites with HCSIL200 on fractures are very high (226.4 and 91.6 for fracture with an opening of 0.05 cm and 11.0 for porous medium with a permeability of 332.3 mD). The selectivity of the isolating action on fractured intervals of the porous formation was noted.

We propose a complex sealing compound for increasing the efficiency of shutoff operations based on natural materials processing for materials such as sand, peat, rice, and husks. We studied the influence of mechanical activation processes on the mechanical and rheological properties of the developed sealants. Through mechanochemical activation, sand dissolution in a low-concentrated alkali solution was possible, and gelling the resulting sodium silicate while reinforcing it with undissolved sand particles to obtain a sealant composition. We used this approach to produce a hybrid sealing compound based on activated rice husks with up to 20% biogenic silicon dioxide combined with mechanically activated peat: the maximum shear strain of the hybrid sealant was 27.7 ± 1.7 Pa. We produced hydrogels based on sodium silicate, polyacrylamide, and chromium acetate, reinforced with mechanically activated rice husks. We studied the sealants’ rheological and filtration properties and observed the respective viscoplastic and viscoelastic properties. An increase in the dispersion concentration from 0 to 0.5% increased the maximum strain value of undestroyed hydrogel’s structure in the range 50–91 Pa and the maximum shear strain from 104 to 128 Pa. The high residual resistance factor values of the ideal fracture model make the natural and plant-renewable raw materials very promising for repair and sealing work.

Gas inflow control in oil wells is one of the most challenging types of repair and sealing operations, the success rate of which does not exceed, as a rule, 30%. Conventional shutoff methods are often ineffective for this purpose. For instance, cement solutions cannot be injected into wells in the required volumes, while gel screens can only temporarily block the breakthrough zones, as gas easily seeps through the gel, forming new channels for gas inflow. Technology for the two-stage injection of gas-insulating gel systems for gas control in horizontal wells was developed. At the first stage, a self-generating foam gel composition (FGC), consisting of gel-forming and gas-forming compositions, was used. A foam gel structure with enhanced rheological and flow characteristics was formed over a controlled time as a result of the interaction between the gel-forming and gas-forming compounds. A PAM-based hydrogel crosslinked with an organic crosslinker was added to the FGC at the second stage of treatment. The laboratory experiments substantiated the technology of well gas and water shutoff by the sequential injection of self-generating foam gel composition and hydrogel. Field tests confirmed the correctness of the chosen concept. It is very important to clearly identify the sources of gas inflow for the success of this well intervention and take into account the well design, as well as the reservoir geological structure and characteristics. The gas shutoff operation can be properly designed for each well only by comparing all these factors. The validity of the selected technology was tested through a series of laboratory experiments. Successful laboratory tests allowed for the application of the studied technology in a field setting, where the gas shutoff agent was injected into three horizontal wells. As a result of the field application, the gas inflow was successfully isolated in two wells. However, the application of the technology failed in the third well which gave an opportunity to revisit the technology’s design and to review the sources of gas inflow. Overall, the achieved success rate of 66% demonstrated the high efficiency of the studied technology and supported its wider application in the field.

Well-killing operations in water-sensitive hydrophilic formations are often complicated by extended well clean-up periods and, in some cases, failure to restore the well’s production potential post-kill. Typical development targets exhibiting these properties include the Neocomian and Jurassic deposits of fields in Western Siberia and Western Kazakhstan. This paper proposes a well-killing method incorporating simultaneous near-wellbore treatment. In cases where heavy oil components (asphaltenes, resins, or paraffins) are deposited in the near-wellbore zone, their removal with a solvent results in post-operation flow rates that exceed pre-restoration levels. For wells not affected by asphaltene, resin, and paraffin deposits, killing is performed using a blocking pill of invert emulsion stabilized with an emulsifier and hydrophobic nanosilica. During filtration into the formation, this emulsion does not break but rather reforms according to the pore throat sizes. Flow rates in such wells typically match pre-restoration levels. The described engineering solution proves less effective when the well fluid water cut exceeds 60%. For wells exhibiting premature water breakthrough that have not yet produced their estimated oil volume, the water source is identified, and water shutoff operations are conducted. This involves polymer-gel systems crosslinked with resorcinol and paraform, reinforced with inorganic components such as chrysotile microdispersions, micro- and nanodispersions of shungite mineral, and gas black. Oscillation testing identified the optimal additive concentration range of 0.6–0.7 wt%, resulting in a complex modulus increase of up to 25.7%. The most effective polymer-inorganic composite developed by us, incorporating gas black, demonstrates high water shutoff capability (residual resistance factor ranges from 12.5 to 65.0 units within the permeability interval of 151.7 to 10.5 mD). Furthermore, the developed composites exhibit the ability to selectively reduce water permeability disproportionately more than oil permeability. Filtration tests confirmed that the residual permeability to oil after placing the blocking composition with graphene is 6.75 times higher than that to water. Consequently, such treatments reduce the well water cut. Field trials confirmed the effectiveness of the developed polymer-inorganic composite systems.