Geopolymer Implemented in Primary Casing Cementing
Authors: Carpenter Chris 
Published: May 2024

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This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper OTC 32218, “First Global Implementation of Geopolymer in Primary Casing Cementing,” by Mark Meade, SPE, Yeukayi Nenjerama, SPE, and Chris Parton, SPE, SLB, et al. The paper has not been peer reviewed. Copyright 2023 Offshore Technology Conference.

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Portland cements are integral components in the oilfield well-construction process; however, the confluence of various business drivers have created the need to find sustainable alternative materials. The complete paper presents the evaluation of geopolymer cementing for use in oil and gas wells, specifically the primary cementing of liner strings in the Permian Basin. Geopolymer cementing offers a unique opportunity for the oilfield industry to decrease CO2 emissions related to well construction and reduce dependence on the constrained supply of Portland cements.

Introduction

Manufacturing Portland cement emits approximately 1 ton of CO2 for every ton of cement produced. Additionally, the manufacturing of Portland cement is a complex process requiring specialized equipment. Thus, during spikes in demand of Portland cement, the supply of cement cannot be rapidly increased to meet demand.

Geopolymers are slurries that set to become a hard, durable solid that can withstand stresses and strains and are resistant to corrosion. Moreover, geopolymers can be made from a broad range of aluminosilicate raw materials sourced from waste products from other industries, mined materials, and biowaste. The low manufacturing and processing requirements reduce the carbon footprint of geopolymers to a fraction of that of manufacturing Portland cement.

Whereas Portland cement chemistry is driven by hydration of calcium aluminates and calcium silicates, geopolymer chemistry is based on the polymerization of aluminosilicates initiated by activators. The creation of geopolymers starts with dissolution of the aluminosilicate raw material into monomers by an increase in the pH of the fluid from the activator. Then, the activator provides a site for covalently bonded chains to form, and these chains undergo polycondensation to form the set 3D network of polymers. Implementation of this new material with such a different chemistry into the complex oilfield-construction process presents challenges that must be overcome.

Challenges

Existing geopolymer formulations typically are characterized as either two-step or one-step geopolymers. In two-step geopolymers, the activators are added into the mix fluid, whereas, in one-step geopolymers, the activators are dry blended with the aluminosilicate source. Implementation of two-step geopolymers would come with operational and logistical constraints impairing their scalability, along with increased service quality and health, safety, and environmental (HSE) risks. On the other hand, common existing one-step geopolymers are formulated with activator types that dissolve rapidly and disperse in the slurry. Therefore, development of novel chemistries for one-step geopolymers are required to introduce geopolymers into oilfield well construction.

Such applications expose geopolymers to temperatures and pressures significantly above ambient for extended periods of time during slurry placement within the wellbore. To ensure quality assurance of job placement, hydraulic simulators should be reliable predictors of the top of the placement, and geopolymers set within the wellbore must be detectable using established sonic logging tools.