Partial Replacement of Saudi Class G Cement with Red Mud for 15.8 ppg Cement Slurries
Authors: Mahmoud Ahmed Abdulhamid , Ahmed Abdulmalek , Alsabaa Ahmed , Elkatatny Salaheldin 
Published: August 2024

This study focuses on investigating the potential integration of red mud, a by-product from aluminum production, as a component in the oil well cementing process, with the aim to contribute to the oil and gas industry's sustainability efforts. A variety of experimental approaches were undertaken to develop cement slurries by blending Saudi Class G cement with red mud in a ratio of 90/10. The purpose of this specific blend was to determine the feasibility of using red mud as a sustainable, quality-maintaining alternative in cement formulations. The study included a detailed analysis, adjusting the content of viscosifying agents and fluid loss prevention additives to refine the properties of the slurry, seeking ideal cement properties. The objective was to engineer a cement slurry with a density of 15.8 ppg. Rigorous assessments scrutinized the slurry's rheological properties and the duration required to reach the thickening time. Preliminary results revealed that blends of only Class G cement with red mud fell short of meeting the industry benchmarks. Conversely, when retarders and viscosifiers were precisely incorporated into the mixture, enhanced performance of the slurry was achieved that complied with the exacting oil well cementing standards. These advancements are noteworthy as they indicate red mud's capacity to support environmentally sustainable cementing methods without compromising the essential attributes of performance. Consequently, the study advocates for red mood as a viable and responsible choice for inclusion within the repertoire of materials used by the oil and gas industry.

1. INTRODUCTION

The rising levels of carbon dioxide (CO2), a significant contributor to the Earth's greenhouse effect, are causing widespread concern due to their role in exacerbating global warming and the resulting shifts in climate patterns (Markewitz et al., 2012). This troubling trend has highlighted the urgent need for effective CO2 management strategies to address the growing environmental impact. Consequently, the international community is increasingly focusing on how to best dispose of this potent greenhouse gas (Ahmed Ali et al., 2020; Lal, 2004; Patrinos & Bradley, 2009; Weiss, 2021).

The oil and gas industry stands at a crossroads, compelled by environmental concerns and economic imperatives to seek innovative solutions that balance sustainability with operational efficiency (Chernova et al., 2021; Jafarinejad, 2017; Skea, 1992). Cement plays a critical role in oil well construction, providing structural integrity and zonal isolation. However, conventional cement production methods rely heavily on finite natural resources, often resulting in significant environmental impact (Al-Dadi et al., 2014; Chen et al., 2010; Habert, 2014; Mohamad et al., 2022). In this context, the exploration of alternative raw materials becomes imperative to mitigate environmental degradation and enhance resource efficiency (Ali et al., 2023; Fakher et al., 2023; Mahmoud & Elkatatny, 2020).