The Use of the Granite Waste Material as an Alternative for Silica Flour in Oil-Well Cementing

Analytical Perspectives on Cement Sheath Integrity: A Comprehensive Review of Theoretical Research

The cement sheath, serving as the primary element of well barriers, plays a crucial role in maintaining zonal isolation, protecting the casing from corrosion, and providing mechanical support. As the petroleum industry shifts from conventional to deep unconventional resources, the service environment for cement sheaths has become increasingly complex. High temperatures, high pressures, cyclic loading, and thermal stresses in downhole conditions have significantly increased the risk of cement sheath failure. A growing trend toward theoretical analysis of stress distribution, failure modes, and control mechanisms within the casing-cement sheath-formation system is evident. This paper comprehensively reviews theoretical research on cement sheath integrity from four key perspectives: (1) the concept of cement sheath integrity failure, (2) cement sheath constitutive models, (3) analytical models of the cement sheath-casing-formation system, and (4) numerical simulations of the cement sheath-casing-formation system. Through these discussions, this review provides profound insights into cement sheath integrity failure and offers valuable guidance for future research and practices.

Properties and Performance of Oil Well Slurry and Cement Sheath Incorporating Nano Silica: A Review

The oil well cementing job is the operation in which a cement paste is pumped to fill the annulus behind the casing. Inclusion of nanomaterials in oil well cement results in improving the cement properties. This paper provides a comprehensive overview of incorporating nanosilica into oil well cement, addressing various aspects of the nanosilica manufacturing process, dispersion challenges, the impact on cement hydration and properties, as well as the operational challenges. The addition of nanosilica is found to enhance cement properties such as hydration rate, compressive strength at low temperatures, and resistance to deterioration at high temperatures. However, challenges arise, including increased viscosity and the need for higher water content. Dispersion of nanosilica into cement slurry remains a difficulty, compounded by the high manufacturing cost, limiting its practical application. The paper recommends further research to improve nanosilica dispersion, explore cost-effective raw materials, and overcome operational challenges for broader utilization in oil well cementing.

Mixed Micromax and hematite-based fly ash geopolymer for heavy-weight well cementing

Ordinary Portland cement (OPC) has introduced different environmental and technical issues. Researchers tried either adding new materials to cement or developing alternatives for both technical and environmental challenges. Hematite as a weighting agent is used to increase cement slurry density. Heavy particles sedimentation in cement and geopolymer slurries is a serious issue which creates heterogenous properties along the cemented section. This work presents a new class of geopolymers using both hematite and Micromax as weighting materials for high density well cementing applications. The first system used only hematite while the other system used both hematite and Micromax. The main goal behind using Micromax with hematite is to check the possibility of eliminating the sedimentation issue associated with hematite in geopolymers. Moreover, the effects of adding Micromax on different FFA geopolymer properties were also evaluated. Different mixtures of retarder, retarder intensifier and superplasticizer were introduced to increase the thickening times of the developed geopolymer systems. The results showed that adding Micromax to hematite decreased the average density variation from 12.5% to almost 3.9%. Micromax addition reduced plastic viscosity by 44.5% and fluid loss by 10.5%. Both systems had a close performance in terms of strength, elastic properties, and permeability. The thickening time was 390 min for the hematite system and 300 min for the mixed system using the proposed additives mixtures.

Development of Heavy-Weight Hematite-Based Geopolymers for Oil and Gas Well Cementing

In the petroleum industry, ordinary Portland cement (OPC) is utilized for different cementing applications. Yet, there are some technical and environmental issues for the usage of OPC in well cementing. The technical problems include gas invasion while setting, instability at corrosive environments, cement failure while perforation and fracturing due to high stiffness and brittleness, and strength reduction and thermal instability at elevated temperatures. Moreover, OPC production consumes massive energy and generates high greenhouse gas emissions. This study introduced the first hematite-based class F fly ash geopolymer formulation that can be used in oil and gas well cementing. Different properties of the designed slurry and hardened samples such as rheology, thickening time, strength, and elastic and petrophysical properties were evaluated. Moreover, mixability and pumpability challenges of heavy-weight geopolymer slurries were investigated. Unlike most of the studies in the literature, this work used 4 M NaOH solution only as an activator that can reduce the overall cost. The results showed that increasing the hematite percentage significantly decreased the thickening time. The developed formulation fell within the recommended fluid loss ranges for some cementing applications without using a fluid loss control additive. A proposed mixture of retarder and superplasticizer was introduced to enhance the thickening time by almost 5 times. The compressive strength increased by 49% and the tensile strength was enhanced by 27.4% by increasing the curing time from 1 to 7 days. The improvement in both compressive and tensile strength with curing time indicated that the geopolymerization reaction continued for extended time but with a smaller rate. The developed slurry acted more like a power law fluid at low temperatures and more like a Bingham plastic fluid at high temperatures. The elastic properties of the developed geopolymer samples proved that they are more flexible than some cement systems.

Effect of Graphite on the Mechanical and Petrophysical Properties of Class G Oil Well Cement

Casing cementing is one of the most crucial operations in the oil well drilling process since it determines the durability and stability of the well throughout its life. Different additives have been mixed into the oil well cement slurry to improve the properties of both the cement slurry and the solidified cement sheath. Graphite is a waste material with a huge potential to be utilized in cementing to improve the properties of the oil well cement and reduce the graphite waste content in the environment. This study intends to analyze the effect of graphite on alteration in properties of the cement compressive and tensile strength, Poisson's ratio, Young's modulus, porosity, and permeability for three days of curing. Based on the trend of the properties during the three days of curing, equations were established to describe the future change in cement properties with time. Two formulas of cement, the base (with no graphite) and graphite-based (with 0.2% by weight of cement graphite) were prepared in this study. The results showed that the graphite successfully increased the compressive strength, tensile strength, and Poisson's ratio of the cement sheath, throughout the curing process. Young's modulus was decreased after the incorporation of graphite which indicates an enhancement in cement resistance to shear forces. The porosity and permeability were also decreased indicating formation of a more densified cement sheath.

Experimental Investigation on the Potential Use of Magnetic Water as a Water Reducing Agent in High Strength Concrete

High-strength concrete is designed for a self-weight reduction structure and exhibits higher resistance to compressive loads. This paper proposes a novel technique to enhance concrete’s properties using Magnetic Field Treated Water (MFTW), describing the results of experimental studies to apprehend the fresh, hardened and microstructural behavior of concrete prepared with Magnetic Water (MW) using a permanent magnet with a field intensity of 0.9 Tesla. The novel scheme focuses on utilizing MW as a water-reducing agent instead of SP to improve the workability of fresh concrete with a 0.38 w/c ratio for achieving M40 grade concrete. Results show a 12% improvement in compressive strength and an 8.9% improvement in split tensile strength compared to normal water (NW) with 1% SP. At 30% cement volume reduction, Magnetic Water Concrete (MWC) performs better than Normal Water Concrete (NWC). Microstructure examination shows that a smaller Calcium Hydrate (CH) crystal is formed with MW and its mineral composition is observed through Energy Dispersive X-ray Analysis (EDAX).