Hydrothermal reactions in the system sepiolite/H2O have been examined between 149° and 316°C. Approximately 10–20% of the starting sepiolite was converted to a smectite (stevensite) at 204°C within 24 hr. Similar results were obtained when CaCl2, NaOH, Ca(OH)2, or Mg(OH)2 was added to the system. In the presence of NaCl, about 60% of the sepiolite was converted to stevensite, whereas, only 5% stevensite formed in the presence of MgCl2. Greater amounts of stevensite formed at 260°C in these systems. Above 316°C, 60–80% of the sepiolite was converted to stevensite in 24 hr, regardless of the presence or absence of salts. Within the experimental conditions used, temperature is the most important factor in the sepiolite-to-stevensite conversion.

At or below 216°C, sepiolite appears to transform into stevensite by dislocations involving c12 glides that are triggered by the stresses of the hydrothermal conditions. Above this temperature, stevensite seems to form by direct precipitation after dissolution of sepiolite.

The rheological properties of three Na-activated, trioctahedral Mg-bentonites (hectorite clay from the CMS Source Clay Project repository, saponite clay from Spain and stevensite clay from Rhassoul, Morocco) and a sepiolite clay from Greece were examined after dynamic ageing at temperatures up to 230°C. The 5% w/v suspensions were prepared by dispersing the clay mineral samples in distilled water. The suspensions underwent dynamic, thermal ageing for 16 h before determination of the viscosity, filtration loss, filter cake thickness and pH and the concentration of dissolved Na+ and Mg2+. Thermal ageing contributed to the dispersion of clay particles, with a direct effect on plastic and apparent viscosity, introducing pseudoplastic behaviour. With the exception of the stevensite clay at 230°C that displayed limited dissolution at 230°C and partial conversion to kerolite, the clays were stable at high temperatures. The Na-activation of all clays except for stevensite was not adversely affected by thermal ageing. Thermal ageing of stevensite at 230°C facilitated Na exchange and yielded suspension with high viscosity and low filtrate loss. Only the suspensions of hectorite and those of stevensite aged at 230°C met with American Petroleum Institute specifications. The thermal behaviour and rheological properties of the clays might be interpreted according to the intrinsic properties of the clay minerals, such as layer charge and charge distribution.

The rheological properties of sepiolite gels in relation to solution chemistry, fiber charge, and microstructure are poorly understood. The purpose of this study was to bring more clarity to this topic by quantifying the effects of solution pH, ionic strength, and adsorbed tetrasodium pyrophosphate (TSPP) additive on rheological properties. The electrical charge on sepiolite fibers was investigated to explain the fiber interaction configuration observed in the microstructure. Fiber interaction forces and dynamics explained the ageing behavior of the gel. Sepiolite gels of only a few percent solids displayed long-time ageing behavior, which was manifested by an increasing yield stress with wait time and continued for weeks. The gel microstructure showed randomly orientated rigid fibers with cross configuration attraction. Each fiber experiences both attractive (van der Waals and heterogeneous charge) and repulsive (electric double layer) forces, and initially a net force. The repulsive force causes these fibers to orientate or move continually to achieve a state of force equilibrium and this process takes a long time. The Leong model describes this ageing behavior. For good fiber separation, high intensity probe sonication of the suspension was required. The yield stress increased with sonication time, solids loading, and temperature. The yield stress was absent at pH > 11 and increased to a maximum value at pH < 8. This maximum was insensitive to pH between 4 to 8, and ionic strength up to 1 M KCl. TSPP reduced this maximum and shifted the zero yield stress region to a lower pH, ~7. The zero yield stress state corresponded to a zeta potential with a minimum magnitude of 30 mV.

The addition of clay minerals in drilling fluids modifies the dispersion's viscosity. In this article, scientific advances related to the use of clays and clay minerals (bentonite, palygorskite, sepiolite and mixtures of clay minerals) in drilling fluids are summarized and discussed based on their specific structure, rheological properties, applications, prevailing challenges and future directions. The rheological properties of drilling fluids are affected by the temperature, type of electrolytes, pH and concentration of clay minerals. Bentonites are smectite-rich clays often used in drilling fluids, and their composition varies from deposit to deposit. Such variations significantly affect the behaviour of bentonite-based drilling fluids. Palygorskite is suitable for use in oil-based drilling fluids, but the gelation and gel structures of palygorskite-added drilling fluids have not received much attention. Sepiolite is often used in water-based drilling fluids as a rheological additive. Dispersions containing mixtures of clays including bentonite, kaolin, palygorskite and sepiolite are used in drilling fluids requiring specific features such as high-density drilling fluids or those used in impermeable slurry walls. In these cases, the surface chemistry–microstructure–property relationships of mixed-clay dispersions need to be understood fully. The prevailing challenges and future directions in drilling fluids research include safety, ‘green’ processes and high-temperature and high-pressure-resistant clay minerals.

Drilling fluids are essential for the operation and productivity of petroleum wells. This study compares the efficiency of a salted water-based mud for which the viscosity has been enhanced with polymeric compounds with that of a new salted water-based mud containing palygorskite clay, which mainly functions as a viscosity enhancer. The experiment measured the density, apparent viscosity, plastic viscosity, yield point, American Petroleum Institute filtrate and pH of the samples. The results indicate that the rheological properties of the fluids containing greater amounts of palygorskite were not affected significantly by the addition of salt. However, when the concentration of palygorskite was low, the rheological behaviour of the samples was appropriate to the drilling operation only with lesser amounts of salt. In addition to its good rheological properties, the filtrate volume obtained for samples containing greater concentrations of palygorskite was lower, which suggests that the filtration properties at the bottoms of the wells were controlled appropriately.