High-Performance Lightweight Cements: A Review
Authors: Matovu Stewart , Mahmoud Ahmed Abdulhamid , Al Shafloot Talal 
Published: August 2024

The pursuit of high-performance lightweight formulations in well cementing plays a crucial role in the oil and gas sector. This paper provides a comprehensive examination of the development and practical application of lightweight cement formulations, focusing on their essential attributes and impact on the industry. Through research findings and real-world case studies, the paper investigates the formulation process, material selection, and application techniques. It highlights the promising advantages of lightweight cement formulations, emphasizing their effectiveness in reducing hydrostatic pressure and stabilizing wellbores during cementing operations. Additionally, the study underscores their role in enhancing drilling efficiency by mitigating wellbore instability and maintaining zonal isolation. The paper's observations reveal the utility of lightweight cement in addressing lost circulation issues, contributing to efficient drilling and reduced operational downtime. By effectively sealing lost circulation zones, these formulations improve overall well integrity and safety. This paper represents the first comprehensive exploration of high-performance lightweight cement formulations and their practical application in the oil and gas sector. It combines detailed insights into the formulation process with real-world case studies, offering a holistic perspective on this emerging technology and its adaptability in various industrial contexts. Overall, lightweight cement formulations hold significant promise for improving the safety, efficiency, and integrity of oil well operations.

1. INTRODUCTION

Oil well cementing is a crucial process in drilling operations, cement placement in the annulus between the wellbore and casing (Ikinya Ng ‘ang ‘a, 2014). It secures the casing, isolates subsurface formations, and prevents fluid migration (Lavrov & Torsaeter, 2016). Proper cementing is essential for maintaining well structural integrity, protecting groundwater resources, and ensuring efficient hydrocarbon extraction. (R. J. Davies et al., 2014).

Circulation losses are common in oil and gas drilling and cementing, causing prolonged drilling and requiring fluid replenishment, lost circulation treatments, remedial cementing, and even well abandonment (Lavrov, 2017). Lost circulation frequently requires more casing strings or multi-stage cementing, which raises costs (Turki & Mackay, 1983). Lightweight cement slurries are commonly used nowadays to reduce circulation loss (Anya, 2018). These slurries have a lower density compared to conventional cement which reduces the hydrostatic pressure exerted on the formation, (Smith et al., 1980). This lower pressure minimizes the risk of fracturing the formation and losing circulation fluid into it, (Labenski et al., 2003). Using lightweight slurries maintains the integrity of the surrounding geological structures, preventing fluid loss and ensuring more efficient and safer drilling operations (Sweatman et al., 1999). Short-waiting cement slurries gel quickly, minimizing fluid loss in high-permeability zones. Thixotropic cements solidify rapidly in large void spaces, preventing cement from flowing into wellbores. This helps maintain well integrity and control fluid migration during cementing operations. Researchers have improved conventional and unconventional lightweight cement to reduce wellbore losses caused by a weak formation fracture gradient over the past 40 years, (Larki et al., 2019; Smith et al., 1980). These lightweight cement systems include the use of water-expanded lightweight particles and foamed lightweight cements, (Marriott et al., 2005). Foamed cements absorb gas, usually nitrogen, to create a gas-liquid mixture that is lightweight and has a very low specific gravity while maintaining the desired mechanical properties.