Fumed silica A-200 (or similar grades like Evonik's AEROSIL® 200) is widely valued in the oil and gas industry for its exceptional ability to control the rheology of drilling fluids. Its nanoscale particle size (typically around 12 nm) and high specific surface area (approximately 200 m²/g) make it a versatile additive for addressing various challenges in drilling operations. As following:

2. Application Examples

Example 1: HPHT Drilling Fluid Stabilization
Challenge: In a North Sea HPHT well (bottomhole temperature: 180°C), barite sagging caused density variations, increasing well control risks.
Solution: Added 1.5% fumed silica A-200 to a synthetic-based drilling fluid.

Result:
Zero free fluid and <0.1% density variance after static aging at 180°C for 16 hours.
Plastic viscosity stabilized at 45–50 cP, and gel strength improved to 8 lb/100 ft² (10-sec gel).

Example 2: Fractured Formation Drilling

Challenge: Severe fluid loss (>20 mL/30 min) in fractured carbonate formations in the Middle East.
Solution: Used 2% fumed silica A-200K with calcium carbonate bridging agents.
Result:
Fluid loss reduced to 12 mL/30 min (API filter test at 100°C).
Effective fracture plugging and reduced formation damage.

Example 3: Shale Stabilization

Challenge: Clay swelling and wellbore instability in U.S. Permian Basin shale formations.
Solution: Added 1% fumed silica A-200K to a KCl-polymer drilling fluid.

Result:
30% reduction in clay dispersion (per capillary suction time test).
Improved wellbore integrity and reduced torque/drag.

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