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High-temperature (HT) geothermal wells can provide green power 24 hours a day, 7 days a week. Under harsh environmental and operational conditions, the long-term durability requirements of such wells require special cementitious composites for well construction. This paper reports a comprehensive assessment of geothermal cement composites in cyclic pressure function laboratory tests and field exposures in an HT geothermal well (300–350 °C), as well as a numerical model to complement the experimental results. Performances of calcium–aluminate cement (CAC)-based composites and calcium-free cement were compared against the reference ordinary Portland cement (OPC)/silica blend. The stability and degradation of the tested materials were characterized by crystalline composition, thermo-gravimetric and elemental analyses, morphological studies, water-fillable porosity, and mechanical property measurements. All CAC-based formulations outperformed the reference blend both in the function and exposure tests. The reference OPC/silica lost its mechanical properties during the 9-month well exposure through extensive HT carbonation, while the properties of the CAC-based blends improved over that period. The Modified Cam-Clay (MCC) plasticity parameters of several HT cement formulations were extracted from triaxial and Brazilian tests and verified against the experimental results of function cyclic tests. These parameters can be used in well integrity models to predict the field-scale behavior of the cement sheath under geothermal well conditions. [ABSTRACT FROM AUTHOR]

Low-enthalpy geothermal wells are considered a sustainable energy source, particularly for district heating in the Netherlands. The cement sheath in these wells experiences thermal cycles. The stability of cement recipes under such conditions is not well understood. In this work, thermal cycling experiments for intermediate- and low-temperature geothermal well cements have been conducted. The samples were cured either under ambient conditions or under realistic pressure and temperature for 7 days. The samples did not show any signs of failure after performing 10 cycles of thermal treatment between 100 °C and 18 °C. We also tested cement formulations under drying conditions. Drying shrinkage is caused by a reduction in the water content of cement, which leads to capillary forces that can damage cement. Such circumstances lead to tensile stresses causing radial cracks. Most samples exhibited cracks under low humidity conditions (drying). Fiber reinforcement, especially using short PP fibers, improved the cement's resilience to temperature and humidity changes. Such additives can improve the longevity of cement sheaths in geothermal wells. [ABSTRACT FROM AUTHOR]

Energy losses can be significantly reduced if thermally insulating cement is used for energy storage and recovery. The thermal conductivity (TC) of the currently used cement is between 1 and 1.2 W/mK. In this study we assessed the ability of polystyrene (PS)–polybutadiene (PB)–polyacrylic acid (PAA) terpolymer (cross-linked styrene–butadiene rubber, XSBR) latex to improve thermal insulating properties and thermal shock (TS) resistance of class G ordinary Portland cement (OPC) and fly ash cenosphere (FCSs) composites in the temperature range of 100–175 °C. The composites autoclaved at 100 °C were subjected to three cycles, one cycle: 175 °C heat → 25 °C water quenching). In hydrothermal and thermal (TS) environments at elevated temperatures in cement slurries the XSBR latex formed acrylic calcium complexes through acid–base reactions, and the number of such complexes increased at higher temperatures due to the XSBR degradation with formation of additional acrylic groups. As a result, these complexes offered the following five advanced properties to the OPC-based composites: (1) enhanced hydrophobicity; (2) decreased water-fillable porosity; (3) reduced TC for water-saturated composites; (4) minimized loss of compressive strength, Young's modulus, and compressive fracture toughness after TS; and (5) abated pozzolanic activity of FCSs, which allowed FCSs to persist as thermal insulators under strongly alkaline conditions of cement slurries. Additionally, XSBR-modified slurries possessed improved workability and decreased slurry density due to the air-entraining effect of latex, which resulted in further improvement of thermal insulation performance of the modified composites. [ABSTRACT FROM AUTHOR]

It is difficult for the commonly used Class G oil well cement to withstand the high-temperature environment of geothermal wells, and it is easy to deteriorate the mechanical properties and damage the integrity of the cement sheath. Industrial solid waste red mud can be used as supplementary cementing materials (SCMs) to improve its mechanical properties at high temperatures. In addition, compared to Class G oil well cement, high belite cement (HBC) has lower energy consumption and better mechanical properties at high temperatures. In this study, the mechanical properties of HBC as a gel material and quartz sand and red mud as SCMs were studied at high temperatures. The ratio of HBC to SCMs and the ratio of quartz sand to red mud in SCMs were optimized using the response surface method (RSM). The response surface was established using the three-level factorial design model, which fit well with the experimental data. The optimization results show that the best mass ratio of SCMs/HBC is 37.5% and that the best quality ratio of quartz sand/red mud is 9 under the curing conditions of 180 °C. However, the best mass ratio of SCMs/HBC is 49.3%, and the best quality ratio of quartz sand/red mud is 7 under 220 °C. With the addition of SCMs, the silicon-to-calcium ratio of HBC hydration products decreases, and high-temperature-stable xonotlite and tobermorite can be formed. After adding SCMs, the cement sample is denser without obvious cracks. [ABSTRACT FROM AUTHOR]

Conventional cements and plugs are challenged by corrosion in CO2-rich and extreme geothermal environments, due to the hostile chemistry and high temperatures. Thermite-based sealing and well intervention technologies are being applied in the oil and gas industry, combining the energy delivery capability of thermite materials with the sealing characteristics of low melt temperature alloys. The thermite reaction products (ceramics) and the sealing alloys used in these plugs both have very attractive corrosion properties, and their operating envelopes extend into geothermal conditions. Thermite plugs and platforms, without supplemental sealing materials, have been considered for nuclear waste isolation, carbon sequestration, and geothermal applications due to the geochemical stability of the ceramic product and its very high service temperature. This study addresses corrosion resistance of the thermite reaction products. A range of engineered thermite systems which yield thermite reaction products including pure aluminum oxide, feldspar, or aluminosilicate solid solutions (in addition to the iron produced in thermite reactions) was developed. These materials were evaluated for their strong acid resistance (pH 1), carbonate resistance (sodium carbonate) and thermal shock resistance (600 °C heating → cold water quenching repeated three times). Performance of different materials was evaluated based on the changes in mechanical properties, water-fillable porosity, phase changes under stress conditions. The aluminosilicate product exhibited very good corrosion resistance, both from material loss and strength perspectives, while the other products performed with varying degrees of stability. This paper presents the results of the thermite corrosion studies and describes the novel tools being deployed, and under development, to satisfy challenging barrier and intervention applications. [ABSTRACT FROM AUTHOR]

During geothermal energy development, the bottom high-temperature fluid continuously exchanges heat with the upper low-temperature wellbore and the stratum during its rising process. Thermal insulation cement (TIC) can increase the outlet temperature, thus effectively reducing the heat loss of the geothermal fluid and improving energy efficiency. In this study, vitrified microbubbles (VMB) were screened out by conducting an orthogonal test of compressive strength (CS) and thermal conductivity (TC) on three inorganic thermal insulation materials (VMB, expanded perlite (EP), and fly-ash cenosphere (FAC)). Fumed silica (FS) was introduced into the cement with VMBs, as its significant decreasing effect on the TC. Moreover, a cement reinforcing agent (RA) and calcium hydroxide [CH] were added to further improve the CS of TIC at 90 °C. The fresh properties, CS, TC, hydration products, pore-size distribution, and the microstructure of the cement were investigated. As a result, a TIC with a TC of 0.1905 W/(m·K) and CS of 5.85 MPa was developed. The main conclusions are as follows: (1) Increasing the mass fraction of the thermal insulation material (TIM) is an effective method to reduce TC. (2) The CH content was reduced, but the C–S–H gel increased as FS content increased due to the pozzolanic reaction of the FS. (3) As the C–S–H gel is the main product of both the hydration and pozzolanic reactions, the matrix of the cement containing 60% FS and VMBs was mainly composed of gel. (4) The 10% RA improved the cement fluidity and increased the CS of TIC from 3.5 MPa to 5.85 MPa by promoting hydration. [ABSTRACT FROM AUTHOR]

This study assessed the possibility of using polymethylhydrosiloxane (PMHS)-treated fly ash cenospheres (FCS) for formulating a thermally insulating and thermal shock (TS)-resistant cementitious blend with calcium aluminate cement. To prevent FCS degradation in an alkaline cement environment at high temperatures, the cenospheres were pre-treated with sodium metasilicate to form silanol and aluminol groups on their surface. These groups participated in a dehydrogenation reaction with the functional ≡Si–H groups within PMHS with the formation of siloxane oxygen-linked M-FCS (M: Al or Si). At high hydrothermal temperatures of 175 and 250 °C, some Si–O–Si and SiCH3 bonds ruptured, causing depolymerization of the polymer at the FCS surface and hydroxylation of the raptured sites with the formation of silanol groups. Repolymerization through self-condensation between the silanol groups followed, resulting in the transformation of siloxane to low crosslinked silicon-like polymer as a repolymerization-induced product (RIP) without carbon. The RIP provided adequate protection of FCS from pozzolanic reactions (PR), which was confirmed by the decline in zeolites as the products of PR of FCS. Cements with PMHS-treated FCS withstood both hydrothermal and thermal temperature of 250 °C in TS tests, and they also showed improved compressive strength, toughness, and water repellency as well as decreased thermal conductivity. The lubricating properties of PMHS increased the fluidity of lightweight slurries. [ABSTRACT FROM AUTHOR]