Study on Gel–Resin Composite for Losting Circulation Control to Improve Plugging Effect in Fracture Formation

Lost circulation, a prevalent challenge in drilling engineering, poses significant risks including drilling fluid loss, wellbore instability, and environmental contamination. Conventional plugging materials often exhibit an inadequate performance under high-temperature, high-pressure (HTHP), and complex formation conditions. To address that, this study developed a high-performance gel–resin composite plugging material resistant to HTHP environments. By optimizing the formulation of bisphenol-A epoxy resin (20%), hexamethylenetetramine (3%), and hydroxyethyl cellulose (1%), and incorporating fillers such as nano-silica and walnut shell particles, a controllable high-strength plugging system was constructed. Fourier-transform infrared spectroscopy (FTIR) and thermogravimetric analysis (TGA) confirmed the structural stability of the resin, with an initial decomposition temperature of 220 °C and a compressive strength retention of 14.4 MPa after 45 days of aging at 140 °C. Rheological tests revealed shear-thinning behavior (initial viscosity: 300–350 mPa·s), with viscosity increasing marginally to 51 mPa·s after 10 h of stirring at ambient temperature, demonstrating superior pumpability. Experimental results indicated excellent adaptability of the system to drilling fluid contamination (compressive strength: 5.04 MPa at 20% dosage), high salinity (formation water salinity: 166.5 g/L), and elevated temperatures (140 °C). In pressure-bearing plugging tests, the resin achieved a breakthrough pressure of 15.19 MPa in wedge-shaped fractures (inlet: 7 mm/outlet: 5 mm) and a sand-packed tube sealing pressure of 11.25 MPa. Acid solubility tests further demonstrated outstanding degradability, with a 97.69% degradation rate after 24 h in 15% hydrochloric acid at 140 °C. This study provides an efficient, stable, and environmentally friendly solution for mitigating drilling fluid loss in complex formations, exhibiting significant potential for engineering applications.