Description:TECHNICAL FIELD
[0001] The present invention relates to the field of drilling fluid additives, specifically to loss circulation materials (LCMs) used in oil and gas drilling operations. More particularly, the invention pertains to a cellulose fiber composition derived from almond shells, combined with a bulk density adjuster, for effectively controlling fluid loss during drilling. The invention further relates to a method for producing such cellulose fiber compositions by grinding, classifying, and processing almond shells into eco-friendly, sustainable grades suitable for various drilling conditions.

BACKGROUND ART
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] In oil and gas drilling operations, loss of drilling fluids into subsurface formations, also known as loss circulation, is a persistent and costly problem. Drilling fluid loss can lead to reduced drilling efficiency, increased operational costs, wellbore instability, and even environmental hazards. To mitigate such losses, materials known as loss circulation materials (LCMs) are added to drilling fluids to seal fractures, voids, and porous formations, thereby maintaining wellbore integrity.
[0004] Traditionally, a variety of LCMs have been used, including calcium carbonate, mica, nut shells, wood fibers, and synthetic materials. While these materials have shown effectiveness to some extent, many suffer from limitations such as inconsistent quality, high costs, poor environmental sustainability, or limited availability. Furthermore, the growing emphasis on eco-friendly and sustainable drilling practices has created a demand for LCMs derived from renewable or waste materials that minimize environmental impact.
[0005] Almond shells are an abundant agricultural by-product of almond processing industries, particularly in countries such as the USA and in parts of Europe. These shells are typically discarded or used for low-value purposes despite their fibrous, strong, and biodegradable nature. Given their high cellulose content and structural integrity, almond shells present a promising raw material for producing an effective LCM.
[0006] US9920233B2 drilling fluid for wellbore strengthening having nanoparticles and granular particles. In one aspect described herein, the drilling fluid is an invert emulsion based fluid. In a further aspect, the nanoparticles are iron hydroxide or calcium carbonate, and in a further aspect from about 1 to 30 nm in size. In one aspect described herein, the granular particles are graphite or calcium carbonate and in a further aspect, up to 250 μm in size. The nanoparticles and granular particles plug fractures in the wellbore to strengthen the wellbore.
[0007] CA2734032C disclosed for reducing lost circulation in drilling wells, employing composite materials as lost circula-tion materials. The composites comprise a thermoplastic polymer and cellulosic fibers. Optionally the composites may include other components such as calcium carbonate, clay, oil and other blending agents.
[0008] However, the use of almond shells in LCM applications has not been widely adopted, primarily due to the lack of a standardized and scalable process for converting them into a form that meets the stringent particle size and quality requirements of the oil and gas industry.
[0009] Accordingly, there exists a need to develop a sustainable, cost-effective, and efficient cellulose fiber-based LCM derived from almond shells, with well-defined particle size distribution and grading, which can be produced consistently and meet international quality standards for use in oil and gas drilling operations.
[0010] The present invention addresses this need by providing a novel cellulose fiber composition derived from almond shells and a method for its preparation, which overcomes the drawbacks of existing LCMs and leverages a renewable, eco-friendly resource.
[0011] OBJECTS OF THE INVENTION
[0012] The principal object of the present invention is to overcome the disadvantages of the prior art.
[0013] An object of the present invention is to provide an eco-friendly and sustainable cellulose fiber composition for use as a loss circulation material (LCM) in oil and gas drilling operations.
[0014] Another object of the present invention is to utilize almond shells an agricultural by-product as the primary raw material for producing the cellulose fiber, thereby promoting environmental sustainability and value-added use of waste material.
[0015] Another object of the present invention is to offer a cellulose fiber composition with controlled particle size distribution, classified into at least three grades coarse, medium, and fine to effectively seal fractures and voids and minimize drilling fluid loss.
[0016] Another object of the present invention is to develop a method for producing the cellulose fiber composition that is efficient, scalable, and cost-effective, ensuring high-quality output suitable for export markets.
[0017] Another object of the present invention is to provide a method of production that includes sourcing almond shells, mixing with bentonite and proprietary ingredients, grinding, separating, sieving, and packaging the cellulose fiber in a reproducible and standardized manner.
[0018] Another object of the present invention is to enable customization of the particle size distribution of the cellulose fiber grades to meet specific customer requirements and drilling conditions.
[0019] Another object of the present invention is to deliver a light-brown, export-ready LCM that meets international quality standards and is packaged in user-friendly laminated paper bags for ease of handling and transport.
[0020] Another object of the present invention is to improve the efficiency of oil and gas drilling operations by offering a reliable LCM that reduces downtime and operational costs associated with fluid loss control.
SUMMARY
[0021] The present invention provides a cellulose fiber composition and a method for producing the same, specifically designed as a loss circulation material (LCM) for oil and gas drilling operations.
[0022] In one aspect, the invention relates to a light-brown, eco-friendly, and sustainable cellulose fiber composition derived from almond shells an agricultural by-product. The cellulose fiber is carefully graded based on particle size distribution to effectively control drilling fluid losses. The composition is classified into at least three grades: i) Coarse grade, containing approximately 90% of material above 50 mesh; ii) Medium grade, containing approximately 95% of material between 50 and 100 mesh; and iii) Fine grade, comprising 100% of material that passes through 100 mesh.
[0023] These grades may be customized based on customer specifications and are suitable for improving drilling efficiency and maintaining wellbore integrity by sealing fractures and voids.
[0024] In another aspect, the invention provides a method for producing the cellulose fiber composition, which involves sourcing almond shells from almond processing operations, mixing them with bentonite powder and other proprietary ingredients, grinding the mixture using a hammer mill, and passing it through a cyclone separator to remove fines. The ground material is then sieved through a vibrating shifter equipped with 50 mesh, 50–100 mesh, and 100 mesh sieves to produce the coarse, medium, and fine grades of the material. The finished product is collected, packaged preferably in 25-pound laminated paper bags and prepared for export, meeting international quality standards.
[0025] These and other features will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings. While the invention has been described and shown with reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.
BRIEF DESCRIPTION OF DRAWINGS
[0026] The accompanying illustrations are incorporated into and form a part of this specification in order to aid in comprehending the current disclosure. The pictures demonstrate exemplary implementations of the current disclosure and, along with the description, assist to clarify its fundamental ideas.
[0027] Fig.1 illustrates the method of the invention in terms of drawings.
[0028] It should be noted that the figures are not drawn to scale, and the elements of similar structure and functions are generally represented by like reference numerals for illustrative purposes throughout the figures. It should be noted that the figures do not illustrate every aspect of the described embodiment sand do not limit the scope of the present disclosure.
[0029] Other objects, advantages, and novel features of the invention will become apparent from the following detailed description of the present embodiment when taken in conjunction with the accompanying drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0030] While the present invention is described herein by way of example using embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for ease of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and the detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claim.
[0031] As used throughout this description, the word "may" is used in a permissive sense (i.e. meaning having the potential to), rather than the mandatory sense, (i.e. meaning must). Further, the words "a" or "an" mean "at least one” and the word “plurality” means “one or more” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein are solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers, or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents acts, materials, devices, articles, and the like are included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.
[0032] In this disclosure, whenever a composition or an element or a group of elements is preceded with the transitional phrase “comprising”, it is understood that we also contemplate the same composition, element, or group of elements with transitional phrases “consisting of”, “consisting”, “selected from the group of consisting of, “including”, or “is” preceding the recitation of the composition, element or group of elements and vice versa.
[0033] The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, several materials are identified as suitable for various facets of the implementations.
[0034] The present invention relates to a novel cellulose fiber composition derived from almond shells and a method for its preparation. The composition is designed for use as a loss circulation material (LCM) in oil and gas drilling operations. The invention provides an eco-friendly, sustainable, and efficient material with tailored particle size distributions to meet various operational needs.
[0035] In an embodiment of the present invention discloses to a cellulose fiber composition for use as a loss circulation material (LCM) in oil and gas drilling operations, wherein the cellulose fiber is derived from almond shells and comprises a light-brown, eco-friendly, sustainable material classified into at least three grades based on particle size distribution: i) a coarse grade containing approximately 90% of material above 50 mesh; ii) a medium grade containing approximately 95% of material between 50 and 100 mesh; and iii) a fine grade comprising 100% of material that passes through 100 mesh.
[0036] In another embodiment of the present invention a cellulose fiber composition for use as a loss circulation material (LCM) in oil and gas drilling operations, comprises i) almond shells; and ii) A bulk density adjuster.
[0037] In another embodiment of the present invention the method for producing cellulose fiber as a loss circulation material from almond shells, the method comprising: i) sourcing almond shells as a by-product from almond processing operations; ii) mixing the almond shells with bentonite powder and one or more additional ingredients according to a proprietary formula; iii) grinding the mixture using a hammer mill to produce particulate material; iv) passing the ground material through a cyclone separator; v) sieving the separated material through a vibrating shifter equipped with 50 mesh, 50–100 mesh, and 100 mesh sieves to classify the material into at least three grades: coarse, medium, and fine; and vi) collecting, packaging, and preparing the cellulose fiber for export in laminated paper bags.
[0038] According to another aspect of the present invention, the method for producing the cellulose fiber from almond shells includes the following steps: i) Almond shells are collected as a by-product from almond processing operations, where the nuts are separated from the shells.
[0039] According to another aspect of the present invention the collected almond shells are mixed with bentonite powder and one or more additional proprietary ingredients. The bentonite powder contributes to the binding and structural integrity of the final material. The quantities and proportions of the mixture are determined according to a proprietary formulation optimized for performance.
[0040] According to another aspect of the present invention the mixture it is subjected to grinding using a hammer mill to produce particulate material of desired size. In preferred embodiments, the grinding is carried out in a batch system, processing approximately 1 ton per batch.
[0041] According to another aspect of the present invention the ground material is passed through a cyclone separator, which removes fines and ensures uniformity of particle size.
[0042] According to another aspect of the present invention the material is further classified by passing through a vibrating shifter, approximately six feet in length, equipped with three different sieves: 50 mesh, 50–100 mesh, and 100 mesh. This step produces the three distinct grades: coarse, medium, and fine. The vibrating shifter provides precise separation and grading, ensuring each product grade meets its specified particle size distribution.
[0043] According to another aspect of the present invention the classified cellulose fiber is collected, packaged in 25-pound laminated paper bags, and prepared for storage or export. The material is light brown in color and ready for international shipment, meeting industry quality standards.
[0044] Optionally, the particle size distribution of each grade can be customized based on specific customer requirements by adjusting sieve sizes and processing parameters.
[0045] Advantages
[0046] According to one aspect of the invention, the cellulose fiber composition is derived from almond shells, which are an agricultural by-product of almond processing. The material exhibits a light-brown color and is environmentally sustainable, leveraging a renewable raw material that would otherwise be discarded.
[0047] The cellulose fiber is classified into at least three distinct grades, based on particle size distribution:
[0048] Coarse Grade: comprising approximately 90% of material above 50 mesh.
[0049] Medium Grade: comprising approximately 95% of material between 50 and 100 mesh.
[0050] Fine Grade: comprising 100% of material that passes through 100 mesh.
[0051] These grades can be provided individually or blended as required to suit specific drilling conditions. The particle size distribution is carefully controlled to effectively seal fractures and voids in subsurface formations, thereby reducing drilling fluid loss and improving drilling efficiency.
[0052] The product is light brown in color, has excellent compatibility with drilling fluids, and is export-ready, conforming to international quality standards. In preferred embodiments, the composition is packaged in 25-pound laminated paper bags for ease of handling and storage.
[0053] In an exemplary embodiment, the almond shells used are sourced from almonds imported from the USA and European countries, where almonds are extensively cultivated. The kernels and shells are separated in Mumbai, India, and the shells are collected in large quantities as a by-product for further processing.
[0054] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
[0055] Thus, the scope of the present disclosure is defined by the appended claims and includes both combinations and sub-combinations of the various features described hereinabove as well as variations and modifications thereof, which would occur to persons skilled in the art upon reading the foregoing description. , Claims:1. A cellulose fiber composition for use as a loss circulation material (LCM) in oil and gas drilling operations, comprising:
i) Almond shells; and
ii) A bulk density adjuster.
2. The composition as claimed in claim 1, wherein almond shells and comprises a light-brown, eco-friendly, sustainable material classified into at least three grades based on particle size distribution: i) a coarse grade containing approximately 90% of material above 50 mesh; ii) a medium grade containing approximately 95% of material between 50 and 100 mesh; and iii) a fine grade comprising 100% of material that passes through 100 mesh.
3. The composition as claimed in claim 1, wherein said bulk density adjuster can be atleast one or more from bentonite powder, ash, sand, dust, charcoal, residue, soot, amber or combinations thereof.
4. The composition as claimed in claim 1, wherein the product is light brown in color and suitable for controlling loss circulation and improving drilling efficiency in oil and gas well operations.
5. The method for producing cellulose fiber as a loss circulation material from almond shells, as claimed in claim 1, the method comprising:
i) sourcing almond shells as a by-product from almond processing operations;
ii) mixing the almond shells with density adjuster;
iii) grinding the mixture using a hammer mill to produce particulate material;
iv) passing the ground material through a cyclone separator;
v) sieving the separated material through a vibrating shifter equipped with 50 mesh, 50–100 mesh, and 100 mesh sieves to classify the material into at least three grades: coarse, medium, and fine; and
vi) collecting, packaging, and preparing the cellulose fiber for export in laminated paper bags.
6. The method as claimed in claim 5, wherein the grinding is performed in a batch system of about 1 ton per batch.
7. The method as claimed in claim 5, wherein the vibrating shifter is approximately six feet in length and provides precise separation of coarse, medium, and fine grades.