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Steam-Water Relative Permeability European Geothermal Congress 2019 Den Haag, The Netherlands, 11-14 June 2019 PROPERTIES OF WELL CEMENTS FOR HIGH TEMPERATURE GEOTHERMAL WELLS Jan ter Heege1, Marcel Naumann2, Penny Pipilikaki3, Frank Vercauteren4, Jens Wollenweber1 1 TNO Applied Geosciences, Princetonlaan 6, Utrecht, the Netherlands 2 Equinor ASA, Sandsliveien 90, Sandsli, Norway 3 TNO Structural reliability, Stieltjesweg 1, Delft, the Netherlands 4 TNO Material Solutions, High Tech Campus 25, Eindhoven, the Netherlands [email protected] Keywords: high temperature wells, well cement, the production casing may regain stiffness and strength experimental data, mineralogy, mechanical data. after exposure at temperatures above ~400°C. Promising options for improved cement formulations ABSTRACT with reduced water content use a combination of high Maintaining long term wellbore stability in high shear mixing, and addition of superplasticisers and temperature environments one of the key challenges nano-particles. determining the success of geothermal wells. Changes in cement mineralogy and associated mechanical 1. INTRODUCTION properties critically affect the integrity of high Geothermal drilling environments are often hostile to temperature wells. In this study, the relation between well materials, especially in magmatic settings where changes in mineralogy, microstructure and mechanical properties of well casing and cements may rapidly properties of cement samples was investigated. change as a result of high temperatures and chemically Laboratory-made synthetic cement samples consisting reactive formation fluids. Maintaining long term of API class G cement with 40% silica flour were wellbore stability in high temperature environments is exposed to temperatures of 60°C (curing only) up to one of the key challenges for the commercial success of 420°C (curing and exposure) for exposure times of 3 high enthalpy geothermal projects (Kaldal et al 2016). days (curing time) to 4 weeks (HT exposure). The effect Recent wells target super-hot reservoirs containing of mineralogical changes on mechanical properties was supercritical fluids, such as the IDDP-1 and IDDP-2 investigated using a combination of (1) chemical well (Iceland Deep Drilling Project) with envisaged analysis using X-ray diffraction (XRD), (2) reservoir temperatures and pressures reaching up to microstructural analysis using scanning electron above 400°C and 300 bars (Friðleifsson et al 2015). microscopy (SEM) and optical microscopy, and (3) Long term wellbore integrity at these conditions is mechanical properties (failure stress, Young’s critically affected by changing mechanical properties of modulus) using triaxial strength tests at confining well materials that may ultimately lead to casing pressures of 2-15 MPa. The mineralogy was compared rupture or collapse (Kaldal et al 2016). Moreover, with cement samples from the excavated top section of properties of interfaces between different casing the IDDP-1 well that were exposed to in-situ conditions components, cement sheaths and rock formation play a for a prolonged time. It was found that the relation crucial role. To withstand such conditions, tailored between mineralogy, microstructure and mechanical high-temperature cements need to be developed and behavior of synthetic cement samples is complex and tested that ensure the plugging of loss zones during due to the combined effect of changing porosity, drilling, proper anchoring, corrosion protection of microstructure and strength of mineral phases. The casing strings, zonal isolation and well integrity at these most important mineralogical changes are the elevated temperatures and pressures (HPHT formation of stronger xonotlite and wollastonite phases conditions). with higher density. The cement is more brittle deformation at low confining pressures and more The integrity of wellbore cement is particularly ductile deformation at high confining pressures with a important in high temperature geothermal wells as considerable residual strength that may be able to carry cement damage promotes migration of reactive fluids large differential loads even after cement failure. along and through the cement sheath, and reduces Geothermal wells targeting super-hot reservoirs thermal isolation of the casing by the cement sheath. containing supercritical fluids may be critically The resulting reduction in zonal isolation, enhanced affected by changing mechanical properties of well casing corrosion, and elevated thermo-mechanical cement between 120 and 250°C during thermal stresses may significantly reduce the lifetime of recovery after drilling, while cement sheaths close to geothermal wells. 1 Ter Heege et al. In this study, the relation between changes in favored. The lime-rich alpha-dicalcium silicate hydrate mineralogy, microstructure and mechanical properties (α-C2SH) is denser than the usual calcium silicate of cement samples was investigated. Laboratory-made hydrate (C-S-H gel) product. Bulk volume decrease, synthetic cement samples were compared with samples and cement shrinkage or porosity increase is associated from the excavated top section of the IDDP-1 well that with this reaction, which results in a decrease in cement were exposed to in-situ conditions for a prolonged time. strength and increase in permeability (Patchen 1960; Synthetic samples consist of API class G cement with Pernites and Santra 2016). All types of OPC and other 40% silica flour. The synthetic samples were exposed types of well cements with similar composition show to temperatures of 60°C (curing only) up to 420°C lower strengths when cured above 110°C, compared to (curing and exposure) for exposure times of 3 days curing at 93°C. (curing time) to 4 weeks (HT exposure). The effect of mineralogical changes on mechanical properties was Elevated curing temperatures are commonly reached by investigated using a combination of (1) chemical geothermal wells in areas with moderate to high analysis using X-ray diffraction (XRD), (2) geothermal gradients. Changes in cement properties microstructural analysis using scanning electron need to be accounted in the design of cement microscopy (SEM) and optical microscopy, and (3) formulations as well as cementation of these wells to mechanical properties (failure stress, Young’s ensure the plugging of loss zones during drilling, proper modulus) using triaxial strength tests at confining anchoring, corrosion protection of casing strings, zonal pressures of 2-15 MPa. isolation and well integrity at elevated temperatures and pressures (HPHT conditions). Common practice is to Results show that the formation of high temperature use Portland-type cements with added silica (such as fly mineral phases in the cement such as tobermorite, ash, silica fume or quartz flour) to stabilize cement to xonotlite and wollastonite is associated with marked higher temperature. Reactions of Ca(OH)2 with added changes in elastic properties and failure behaviour. silica at elevated temperatures result in a C-S-H with a Critical conditions for the changes in mineralogy and lower C/S ratio. Addition of 35 to 40% by weight of mechanical behaviour are determined, and compared to cement is enough to prevent the reaction forming α- IDDP-1 conditions. The implications for well integrity C2SH. Instead, cement phases such as tobermorite or and design of new cement formulations are discussed. xonotlite are formed (Patchen 1960). Moreover, for a To counter embrittlement of the cement due to water to solids ratio of 0.4, a formulation with added mineralogical changes at high temperature, cement silica results in 91% of the water being chemically formulations need to be modified. Enhanced cement bound against only 39 % of the available water in the flexibility is required to account for extreme OPC. Addition of ~40% silica flour thereby favours mechanical loads caused by casing deformation during formation of high strength and low permeability temperature cycles. In addition, the residual water, mineral phases. required for cement placement rather than for hydration, in the hydrated cement or in pockets needs Despite the importance for well integrity of high to be reduced as this can result in (over)pressures that temperature wells, data on mineralogical and eventually trigger casing collapse during the warm-up mechanical changes during exposure of well cements to period(s). The main challenge remains to optimize HPHT conditions is limited. Some relevant laboratory cement properties for prolonging the integrity of studies are available (Taylor 1990; Gabrovšek et al cement at high temperatures while maintaining low 1993; Meller et al 2009; Pernites and Santra 2016), but viscosity of cement slurry during well cementation. investigations of the relation between mineralogical and mechanical changes at different exposure times and 2. BACKGROUND temperatures are sparse. Standard cement formulations have been reported to 3. EXPERIMENTAL APPROACH reach their mechanical and chemical (stability) limits due to the harsh conditions and extreme cyclic Synthetic cement samples, Dyckerhoff HT Basic Blend temperature loads in geothermal wells (Kaldal et al of cement clinker (API class G cement) with 40 % silica 2016). For standard curing conditions, hydration of flour was used as a starting material (Papaioannou, ordinary Portland cement (OPC, e.g., class G well 2018). Specimens are prepared using the Dyckerhoff cement) with a calcium oxide to silicon dioxide (C/S) blend and demineralized water with a water to solid ratio close to 3.1 produces the
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