Development of a High-Performance Epoxy Resin Plugging Agent for High-Temperature and High-Pressure Drilling Operations.

In deep and ultradeep oil and gas wells, lost circulation control remains a significant technical challenge. Traditional sealing materials often exhibit insufficient high-temperature and high-pressure resistance and low sealing efficiency. In this study, a resin-based plugging material was prepared via melt polymerization, using bisphenol A epoxy resin E-03 as the matrix and HYB as the curing agent. Fourier-transform infrared (FTIR) analysis confirmed cross-linking reactions, and testing showed a compressive strength of 300.28 MPa, an initial thermal decomposition temperature of 355 °C, and a density of 1.07 g/cm3. Leak sealing tests demonstrated that the material could withstand pressures up to 14 MPa in cracks 1-4 mm wide. Scanning electron microscopy (SEM) images revealed a polyhedral rhombic structure, enhancing anchoring and sealing performance. This study provides theoretical and experimental support for the design and application of high-performance leak sealing materials in complex deep well formations.