Imaging wellbore cement degradation by carbon dioxide under geologic sequestration conditions using X-ray computed microtomography

A Numerical Simulation Study of the Impact of Microchannels on Fluid Flow through the Cement–Rock Interface

Microchannels located at the cement–rock interface can form potential pathways for formation fluid leakage in oil and gas wells. The effects of geometric shape, quantity, and the inclination angle of microchannels on the flow through cemented rock samples were explored. Finite element 3D models were established based on modified micro-CT images obtained from physical samples. The volume flow rate through different sections of cemented rock samples was extracted after the fluid flow simulations. The numerical results showed that with the presence of a single microchannel, the total volume flow rate could be higher than that of the base case by as much as 9%. Microchannel contact and cross-sectional areas were found to be the two most important factors affecting the total volume flow rate. The overall volume flow rate increased with the increasing cross-sectional area, contact area, and inclination angle of the microchannel. The total volume flow rate for the cases with microchannels having the same cross-sectional area but different shapes increased with the decreasing number of sides of the shape (from circular to triangular) due to the increased contact area. The simulation results also revealed that the relative magnitude of the rock permeability may influence the volume flow rate through each section.

Carbonation Reaction Mechanisms of Portlandite Predicted from Enhanced Ab Initio Molecular Dynamics Simulations

Geological carbon capture and sequestration (CCS) is a promising technology for curbing the global warming crisis by reduction of the overall carbon footprint. Degradation of cement wellbore casings due to carbonation reactions in the underground CO2 storage environment is one of the central issues in assessing the long-term success of the CCS operations. However, the complexity of hydrated cement coupled with extreme subsurface environmental conditions makes it difficult to understand the carbonation reaction mechanisms leading to the loss of well integrity. In this work, we use biased ab initio molecular dynamics (AIMD) simulations to explore the reactivity of supercritical CO2 with the basal and edge surfaces of a model hydrated cement phase—portlandite—in dry scCO2 and water-rich conditions. Our simulations show that in dry scCO2 conditions, the undercoordinated edge surfaces of portlandite experience a fast barrierless reaction with CO2, while the fully hydroxylated basal surfaces suppress the formation of carbonate ions, resulting in a higher reactivity barrier. We deduce that the rate-limiting step in scCO2 conditions is the formation of the surface carbonate barrier which controls the diffusion of CO2 through the layer. The presence of water hinders direct interaction of CO2 with portlandite as H2O molecules form well-structured surface layers. In the water-rich environment, CO2 undergoes a concerted reaction with H2O and surface hydroxyl groups to form bicarbonate complexes. We relate the variation of the free-energy barriers in the formation of the bicarbonate complexes to the structure of the water layer at the interface which is, in turn, dictated by the surface chemistry and the degree of nanoconfinement.

Characterization of the Pore Structure of Well Cement under Carbon Capture and Storage Conditions by an Image-Based Method with a Combination of Metal Intrusion

To more quantitatively and subtly analyze effects of carbonation on the pore structure of well cement by supercritical CO₂ under carbon capture and storage (CCS) conditions, a digital scanning electron microscopy-backscattered electron (SEM-BSE) image analysis with a combination of nontoxic low-melting point metal intrusion is used to characterize the exposed cements to humid supercritical CO₂ for 10 and 20 days. The porous area fraction (PAF) and pore size distribution (PSD) profiles obtained by slicing operation are used to describe the pore structure variation along the corrosion direction in a two-dimensional (2D) plane. The results show that the image-based method with the combination of metal intrusion is an effective method for characterizing the layer structure of exposed cement and getting quantitative information about the pore structure. From the surface to the core, the main altered layers in exposed cement for 10 days include the partially leached layer, the carbonated layer, and the calcium hydroxide (CH)-dissolved layer. For the exposed cement for 20 days, the main altered layers include the porous leached layer, the partially leached layer, the carbonated layer, and the carbonated transition layer. The nonporous carbonated layer can effectively block the flow parallel to the corrosion direction, while the porous leached layer can facilitate the flow perpendicular to the corrosion direction. Findings from this study will provide valuable information for understanding the effects of carbonation on the pore structure of well cement under CCS conditions.

Digital Cement Integrity: A Methodology for 3D Visualization of Cracks and Microannuli in Well Cement

Leakages of greenhouse gases, such as methane and carbon dioxide from wells, may have considerable environmental consequences. Although much emphasis is currently put on understanding well barrier failures, and thus, preventing well leakages, especially for an important barrier material as cement, there are still several knowledge gaps and unknowns. However, a step-change in well integrity understanding may be obtained by applying advanced characterization techniques and scientific approaches to studying well barrier materials and their failure mechanisms. This paper describes the development of an experimental methodology that uses X-ray computed tomography to obtain 3D visualizations of cracks and microannuli in annular cement sheaths. Several results are included that demonstrate the value of using such digital methods to study well cement, and it is shown that such experimental studies provide an improved understanding of cement sheath integrity. For example, it is seen that radial cracks do not form in symmetrical patterns and that microannuli do not have uniform geometries. Such experimental findings can potentially be used as benchmark to validate and improve cement integrity simulation tools.

Incorporating Nanoscale Effects into a Continuum-Scale Reactive Transport Model for CO2-Deteriorated Cement

Wellbore cement deterioration is critical for wellbore integrity and the safety of CO₂ storage in geologic formations. Our previous experimental work highlighted the importance of the portlandite (CH)-depleted zone and the surface dissolution zone in the CO₂-attacked cement. In this study, we simulated numerically the evolution of the CH-depleted zone and the dissolution of the cement surfaces utilizing a reduced-dimension (1D) reactive transport model. The approach shows that three nanoscale effects are important and had to be incorporated in a continuum-scale model to capture experimental observations: First, it was necessary to account for the fact that secondary CaCO₃ precipitation does not fill the pore space completely, with the result that acidic brine continues to diffuse through the carbonated zone to form a CH-depleted zone. Second, secondary precipitation in brine begins via nucleation kinetics, and this could not be described with previous models using growth kinetics alone. Third, our results suggest that the CaCO₃ precipitates in the confined pore space are more soluble than those formed in brine. This study provides a new platform for a reduced dimension model for CO₂ attack on cement that captures the important nanoscale mechanisms influencing macroscale phenomena in subsurface environments.

Characterization of reactive flow-induced evolution of carbonate rocks using digital core analysis- part 1: Assessment of pore-scale mineral dissolution and deposition

The application of X-ray micro-computed tomography (μ-CT) for quantitatively characterizing reactive-flow induced pore structure evolution including local particle detachment, displacement and deposition in carbonate rocks is investigated. In the studies conducted in this field of research, the experimental procedure has involved alternating steps of imaging and ex-situ core sample alteration. Practically, it is impossible to return the sample, with micron precision, to the same position and orientation. Furthermore, successive images of a sample in pre- and post-alteration states are usually taken at different conditions such as different scales, resolutions and signal-to-noise ratios. These conditions accompanying with subresolution features in the images make voxel-by-voxel comparisons of successive images problematic. In this paper, we first address the respective challenges in voxel-wise interpretation of successive images of carbonate rocks subject to reactive flow. Reactive coreflood in two carbonate cores with different rock types are considered. For the first rock, we used the experimental and imaging results published by Qajar et al. (2013) which showed a quasi-uniform dissolution regime. A similar reactive core flood was conducted in the second rock which resulted in wormhole-like dissolution regime. We particularly examine the major image processing operations such as transformation of images to the same grey-scale, noise filtering and segmentation thresholding and propose quantitative methods to evaluate the effectiveness of these operations in voxel-wise analysis of successive images of a sample. In the second part, we generalize the methodology based on the three-phase segmentation of normalized images, microporosity assignment and 2D histogram of image intensities to estimate grey-scale changes of individual image voxels for a general case where the greyscale images are segmented into arbitrary number of phases. The results show that local (voxel-based) porosity changes can be decomposed into local mineral dissolution and deposition. Moreover, it is found that the microporosity evolutions are differently distributed in the samples after the reactive coreflood experiments. In the last part of the paper, for the case of quasi-uniform dissolution, we combine the tomographic images with numerical calculations of permeability along the core to characterize the relationship between changes in permeability and the fractions of the mineral dissolved and deposited. A consistency is found between the calculated longitudinal permeability changes and the quantified distribution of mineral dissolved and deposited along the sample.

Numerical Simulation of Permeability Change in Wellbore Cement Fractures after Geomechanical Stress and Geochemical Reactions Using X-ray Computed Tomography Imaging

X-ray microtomography (XMT) imaging combined with three-dimensional (3D) computational fluid dynamics (CFD) modeling technique was used to study the effect of geochemical and geomechanical processes on fracture permeability in composite Portland cement-basalt caprock core samples. The effect of fluid density and viscosity and two different pressure gradient conditions on fracture permeability was numerically studied by using fluids with varying density and viscosity and simulating two different pressure gradient conditions. After the application of geomechanical stress but before CO2-reaction, CFD revealed fluid flow increase, which resulted in increased fracture permeability. After CO2-reaction, XMT images displayed preferential precipitation of calcium carbonate within the fractures in the cement matrix and less precipitation in fractures located at the cement-basalt interface. CFD estimated changes in flow profile and differences in absolute values of flow velocity due to different pressure gradients. CFD was able to highlight the profound effect of fluid viscosity on velocity profile and fracture permeability. This study demonstrates the applicability of XMT imaging and CFD as powerful tools for characterizing the hydraulic properties of fractures in a number of applications like geologic carbon sequestration and storage, hydraulic fracturing for shale gas production, and enhanced geothermal systems.

Defining the Brittle Failure Envelopes of Individual Reaction Zones Observed in CO2-Exposed Wellbore Cement

To predict the behavior of the cement sheath after CO2 injection and the potential for leakage pathways, it is key to understand how the mechanical properties of the cement evolves with CO2 exposure time. We performed scratch-hardness tests on hardened samples of class G cement before and after CO2 exposure. The cement was exposed to CO2-rich fluid for one to six months at 65 °C and 8 MPa Ptotal. Detailed SEM-EDX analyses showed reaction zones similar to those previously reported in the literature: (1) an outer-reacted, porous silica-rich zone; (2) a dense, carbonated zone; and (3) a more porous, Ca-depleted inner zone. The quantitative mechanical data (brittle compressive strength and friction coefficient) obtained for each of the zones suggest that the heterogeneity of reacted cement leads to a wide range of brittle strength values in any of the reaction zones, with only a rough dependence on exposure time. However, the data can be used to guide numerical modeling efforts needed to assess the impact of reaction-induced mechanical failure of wellbore cement by coupling sensitivity analysis and mechanical predictions.

Effects of Sulfate during CO2 Attack on Portland Cement and Their Impacts on Mechanical Properties under Geologic CO2 Sequestration Conditions

To investigate the effects of sulfate on CO2 attack on wellbore cement (i.e., chemical and mechanical alterations) during geologic CO2 sequestration (GCS), we reacted cement samples in brine with 0.05 M sulfate and 0.4 M NaCl at 95 °C under 100 bar of either N2 or supercritical CO2. The results were compared to those obtained from systems without additional sulfate at the same temperature, pressure, salinity, and initial brine pHs. After 10 reaction days, chemical analyses using scanning electron microscopy with a backscattered electron detector (SEM-BSE) and inductively coupled plasma optical emission spectrometry (ICP-OES) showed that the CO2 attack in the presence of additional sulfate was much less severe than that in the system without additional sulfate. The results from three-point bending tests also indicated that sulfate significantly mitigated the deterioration of the cement's strength and elastic modulus. In all our systems, typical sulfate attacks on cement via formation of ettringite were not observed. The protective effects of sulfate on cement against CO2 attack resulted from sulfate adsorption, coating of CaSO4 on the CaCO3 grains in the carbonated layer, or both, which inhibited dissolution of CaCO3. Findings from this study provide new, important information for understanding the integrity of wellbores at GCS sites and thus promote safer GCS operations.

Chemical Reactions of Portland Cement with Aqueous CO2 and Their Impacts on Cement's Mechanical Properties under Geologic CO2 Sequestration Conditions

To provide information on wellbore cement integrity in the application of geologic CO2 sequestration (GCS), chemical and mechanical alterations were analyzed for cement paste samples reacted for 10 days under GCS conditions. The reactions were at 95 °C and had 100 bar of either N2 (control condition) or CO2 contacting the reaction brine solution with an ionic strength of 0.5 M adjusted by NaCl. Chemical analyses showed that the 3.0 cm × 1.1 cm × 0.3 cm samples were significantly attacked by aqueous CO2 and developed layer structures with a total attacked depth of 1220 μm. Microscale mechanical property analyses showed that the hardness and indentation modulus of the carbonated layer were 2-3 times greater than for the intact cement, but those in the portlandite-dissolved region decreased by ∼50%. The strength and elastic modulus of the bulk cement samples were reduced by 93% and 84%, respectively. The properties of the microscale regions, layer structure, microcracks, and swelling of the outer layers combined to affect the overall mechanical properties. These findings improve understanding of wellbore integrity from both chemical and mechanical viewpoints and can be utilized to improve the safety and efficiency of CO2 storage.

Determination of diffusion profiles in altered wellbore cement using X-ray computed tomography methods

The development of accurate, predictive models for use in determining wellbore integrity requires detailed information about the chemical and mechanical changes occurring in hardened Portland cements. X-ray computed tomography (XRCT) provides a method that can nondestructively probe these changes in three dimensions. Here, we describe a method for extracting subvoxel mineralogical and chemical information from synchrotron XRCT images by combining advanced image segmentation with geochemical models of cement alteration. The method relies on determining "effective linear activity coefficients" (ELAC) for the white light source to generate calibration curves that relate the image grayscales to material composition. The resulting data set supports the modeling of cement alteration by CO2-rich brine with discrete increases in calcium concentration at reaction boundaries. The results of these XRCT analyses can be used to further improve coupled geochemical and mechanical models of cement alteration in the wellbore environment.

Characterization of the mechanisms controlling the permeability changes of fractured cements flowed through by CO2-rich brine

Experiments were conducted to assess the potential impact of fractured well-cement degradation on leakage rate. Permeability was monitored while CO2-enriched reservoir-equilibrated brine was flowed at constant rate through a single fracture in a class G cement core under conditions mimicking geologic sequestration environments (temperature 60 °C, pressure 10 MPa). The results demonstrate that, at least for the conditions used in the experiment, an initial leakage in a 42 μm aperture fracture (permeability = 1.5 × 10(-10) m(2)) can be self-mitigated due to the decrease of the fracture hydraulic aperture after about 15 h. This decrease results from the development of continuous highly hydrated amorphous Si-rich alteration products at the edge of the fracture and the dense carbonation of the bulk cement that mitigate the penetration of the alteration front.