This paper presents an economical type of mechanical breaking foam method for foam drilling during drilling operations. Laboratory experiments on foam volume breaking and experiment set-up with a new geometrical design of foam breaking device has been done. Simplified symmetrical two dimension model and simulated calculation study by using K- ε model (2 equations) and steady time on changing air pressure fields inside the bursting foam device is presented. Results of simulated calculation and laboratory experiments have been shown a good agreement with Binary Equation. Foam bubbles expansion and rupture is driven by the different pressures inside the foam bubbles during the fluid circulation which is higher and the ambient pressure inside the foam breaking device which is very low in comparison, on the other hand, performed of different foam fluid velocities through the foam bursting device and increasing of air pressure on the foam fluid flow led to different bursting foam volume bubbles. Decreasing the foam volume during circulation when drilling operation is desirable and will provides less impact on environment in comparison. To confirm the efficiency of the bursting foam device, experiments have been done on different foam agents ABS and SDS; results ranging from 71 to 80% and from 64 to 69.4% respectively are obtained. Process model is accomplished via the solution of designing the device and simulated by fluent program. It is demonstrated that the amount of air volume, pressure and the fluid velocity in the device are the dominant control mechanism for the final result of foam bursting. Calculation of the changing field pressures and the results computed and discussed.
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