Organic–Inorganic Hybrid Gel Microspheres as a Plugging Agent for Ultra-High Temperature and High-Salinity Water-Based Drilling Fluids

With the continuous expansion of ultra-deep and deep well drilling toward complex geological formations, the performance stability of water-based drilling fluids and wellbore stability under ultra-high temperature and high-salinity conditions have become critical challenges. High temperature and salt contamination can induce the degradation or failure of drilling fluid additives, while the development of pores and fractures in complex formations further increases the risk of filtrate invasion. Conventional polymer and inorganic plugging agents often suffer from insufficient thermal stability, poor salt tolerance, or limited adaptability to complex pore structures. In this study, an organic–inorganic hybrid gel microsphere plugging agent (HGP) with a core–shell structure was developed by in situ polymerization of AMPS, styrene (St), and sodium styrene sulfonate (SSS) on KH570-modified nano-SiO2. The hybrid microspheres consisted of a rigid SiO2 core and a flexible polymer shell, providing synergistic thermal stability, mechanical strength, and deformation capability. Structural characterization confirmed the successful formation of the designed organic–inorganic hybrid structure. After aging at 240 °C, HGP maintained stable morphology and dispersion characteristics, while exerting minimal influence on drilling fluid rheological properties. The addition of 3 wt% HGP reduced API fluid loss by approximately 30% and decreased sand bed invasion by approximately 50% after high-temperature aging. Under 35 wt% NaCl and 5 wt% CaCl2 contamination, HGP maintained effective filtration control, reducing fluid loss by more than 50% compared with the base fluid. Furthermore, HGP achieved core plugging efficiencies above 94% and reduced mud cake permeability by over 70%, demonstrating superior plugging performance compared with polymer microspheres NF-1 and SiO2 particles. The enhanced performance was considered to arise from the synergistic effects of stable dispersion, pore-throat bridging, deformation filling, and structural stabilization. This study provides a rigid–flexible hybrid strategy for designing high-performance plugging agents for ultra-high temperature and high-salinity water-based drilling fluids.