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Drilling fluids manufactured by LPM

4. Wahal high shear mixers and Homogenization:

Thorough mixing is crucial at each stage to ensure all components are evenly distributed and the fluid has consistent properties. Various types of mixers are used, including:

  • Low-speed agitators by Wahal: For general mixing and maintaining uniformity in storage tanks.
  • Wahal High shear mixers/homogenizers: Essential for rapid dispersion of powders (like clays and barite) and achieving stable emulsions in oil-based muds. These work by creating intense mechanical forces that break down agglomerates and reduce droplet size. Inline mixers can also be used for continuous processing.
  • Wahal liquid Powder mixing systems: Specialized systems for quickly and efficiently incorporating and hydrating large volumes of powders into liquids, often used for bentonite and other additives.

5. Quality Control and Testing:

Throughout the manufacturing process and before the drilling fluid is used downhole, rigorous quality control tests are performed to ensure it meets the required specifications. These tests include measuring:

  • Density (Mud Weight)
  • Viscosity (Plastic Viscosity, Apparent Viscosity, Yield Point, Gel Strength)
  • Filtration Rate (Fluid Loss)
  • pH
  • Salinity and Ion Content
  • Solids Content
  • Electrical Stability (for oil-based muds)
  • Alkalinity and Hardness
  • Specific additive concentrations

The manufacturing of drilling fluids is a complex and critical process that requires careful selection of raw materials, precise mixing techniques supplied by Wahal and thorough quality control using automated systems to ensure the fluid performs effectively and safely in the demanding environment of oil and gas wells. Please contact us for more info.

Drilling fluids manufactured by liquid powder mixers

Wahal manufactures turnkey customised processing systems for manufacturing of drilling fluids.

Manufacturing drilling fluids, often called drilling muds, is a multi-step process that involves combining various components to achieve the desired properties for a specific drilling operation. The exact recipe and manufacturing steps will vary significantly based on the type of drilling fluid (water-based, oil-based, synthetic-based, or pneumatic) and the specific downhole conditions.

Here’s a general overview of the manufacturing process for liquid-based drilling fluids:

1. Base Fluid Preparation:

  • Water-Based Muds (WBM): The process typically starts with a large volume of water (freshwater, seawater, or brine) in mixing tanks.
  • Oil-Based Muds (OBM) and Synthetic-Based Muds (SBM): These begin with the chosen base oil (diesel, mineral oil, synthetic oil, esters, etc.) in the mixing tanks.

2. Addition and Dispersion of Solids using Wahal high shear mixers:

  • Clays (e.g., Bentonite): Clay, often bentonite, is a primary component for viscosity and suspension. It needs to be properly dispersed and hydrated in the base fluid. High shear mixers are crucial here to break down agglomerates and ensure maximum surface area exposure for gelling. This step can sometimes require pre-hydration in separate tanks for several hours using conventional mixers.
  • Weighting Agents (e.g., Barite, Hematite, Calcium Carbonate): These are added to increase the density of the drilling fluid to control formation pressure. Efficient incorporation and dispersion are vital to maintain a uniform density throughout the mud. Advanced mixing systems beyond basic rotor/stator mixers might be needed for materials like barite.
  • Drilled Solids: During the drilling process, the fluid picks up cuttings. While not intentionally added during manufacturing, the management and potential reprocessing of returned drilling fluid containing these solids is a continuous aspect of the overall fluid system. Solids control equipment at the surface (shakers, desanders, desilters) removes these cuttings before the fluid is recirculated.
  • 3. Addition of Chemical Additives:A wide variety of chemical additives are incorporated to achieve specific functions. These are typically added and mixed in stages:
    • Viscosifiers (e.g., Polymers like Xanthan Gum, Guar Gum, CMC, PAC): These increase the fluid’s viscosity for cuttings transport and suspension. Wahal high shear mixers helps to properly dissolve and hydrate these polymers.
    • Fluid Loss Control Agents (e.g., Cellulose derivatives, Starches, Resins): These minimize the loss of fluid into permeable formations.
    • Shale Inhibitors (e.g., Salts like KCl, Glycols, Amines): These prevent swelling and disintegration of reactive shales.
    • Emulsifiers and Wetting Agents: Essential for oil-based and synthetic-based muds to create stable emulsions of oil and water/brine and to ensure solids remain oil-wet.
    • Thinners and Dispersants (e.g., Lignosulfonates, Tannins): Used to control viscosity and prevent flocculation of solids.
    • Lubricants (e.g., Beads, Esters, Graphite): Reduce friction between the drill string and the borehole.
    • Corrosion Inhibitors: Protect the drilling equipment from chemical attack.
    • pH Control Agents (e.g., Lime, Caustic Soda, Soda Ash): Maintain the desired pH for optimal fluid performance and to activate certain additives.
    • Defoamers: Prevent or reduce foaming of the drilling fluid.
    • Biocides/Preservatives: Prevent microbial growth in water-based muds.

  • This commitment to customer service underscores Wahal’s reputation for reliability and excellence.
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