Influence of calcium content on the atomic structure and phase formation of alkali-activated cement binder
Abstract not provided
Si, Ruizhe↗
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Spirulina-laden cements for green construction materials: effects of algae incorporation on the mechanical properties and environmental impact of cement
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Lin, Meng-Yen↗
Using NASA Life Support Technology to Reduce Cement Industry CO2 Emissions While Improving Cement and Concrete Products
No abstract available
Abney, Morgan↗
Design of Fit-for-Purpose Cement to Restore Cement-Caprock Seal Integrity.
Abstract not provided.
Matteo, Edward N↗
Influence of Cement Concentration on Gas Migration in a Cement Slurry
American Physical Society (APS) March Meeting 2023, Virtual, March 20-22, 2023
Konan, Arthur↗
Effective Permeability Change in Wellbore Cement with Carbon Dioxide Reaction
Portland cement, a common sealing material for wellbores for geological carbon sequestration was reacted with CO{sub 2} in supercritical, gaseous, and aqueous phases at various pressure and temperature conditions to simulate cement-CO{sub 2} reaction along the wellbore from carbon injection depth to the near-surface. Hydrated Portland cement columns (14 mm diameter x 90 mm length; water-to-cement ratio = 0.33) including additives such as steel coupons and Wallula basalt fragments were reacted with CO{sub 2} in the wet supercritical (the top half) and dissolved (the bottom half) phases under carbon sequestration condition with high pressure (10 MPa) and temperature (50 C) for 5 months, while small-sized hydrated Portland cement columns (7 mm diameter x 20 mm length; water-to-cement ratio = 0.38) were reacted with CO{sub 2} in dissolved phase at high pressure (10 MPa) and temperature (50 C) for 1 month or with wet CO{sub 2} in gaseous phase at low pressure (0.2 MPa) and temperature (20 C) for 3 months. XMT images reveal that the cement reacted with CO{sub 2} saturated groundwater had degradation depth of {approx}1 mm for 1 month and {approx}3.5 mm for 5 month, whereas the degradation was minor with cement exposure to supercritical CO{sub 2}. SEM-EDS analysis showed that the carbonated cement was comprised of three distinct zones; the innermost less degraded zone with Ca atom % > C atom %, the inner degraded zone with Ca atom % {approx} C atom % due to precipitation of calcite, the outer degraded zone with C atom % > Ca atom % due to dissolution of calcite and C-S-H, as well as adsorption of carbon to cement matrix. The outer degraded zone of carbonated cement was porous and fractured because of dissolution-dominated reaction by carbonic acid exposure, which resulted in the increase in BJH pore volume and BET surface area. In contrast, cement-wet CO{sub 2}(g) reaction at low P (0.2 MPa)-T (20 C) conditions for 1 to 3 months was dominated by precipitation of micron-sized calcite on the outside surface of cement, which resulted in the decrease in BJH pore volume and BET surface area. Cement carbonation and pore structure change are significantly dependent on pressure and temperature conditions as well as the phase of CO{sub 2}, which controls the balance between precipitation and dissolution in cement matrix. Geochemical modeling result suggests that ratio of solid (cement)-to-solution (carbonated water) has a significant effect on cement carbonation, thus the cement-CO{sub 2} reaction experiment needs to be conducted under realistic conditions representing the in-situ wellbore environment of carbon sequestration field site. Total porosity and air permeability for a duplicate cement column with water-to-cement ratio of 0.38 measured after oven-drying by Core Laboratories using Boyle's Law technique and steady-state method were 31% and 0.576 mD. A novel method to measure the effective liquid permeability of a cement column using X-ray micro-tomography images after injection of pressurized KI (potassium iodide) is under development by PNNL. Preliminary results indicate the permeability of a cement column with water-to-cement ratio of 0.38 is 4-8 mD. PNNL will apply the method to understand the effective permeability change of Portland cement by CO{sub 2}(g) reaction under a variety of pressure and temperature conditions to develop a more reliable well-bore leakage risk model.
36 MATERIALS SCIENCE↗
Printable Fiber Reinforced Cement Composites – Feasibility Study
Additive manufacturing is enabling the manufacturability of structures with previously unattainable complexity or functionality, and there is growing interest in additive manufacturing of “printed” concrete structures. The focus of this Phase 1 Technical Collaboration (TC) project was to evaluate feasibility of printing hybrid cement composite structures reinforced with textile carbon fibers (tCF). This project leverages other (non-IACMI) projects on cement formulation and printing process development, as well as on the production process for tCF. This project’s primary focus was to explore cement composite mix design with textile carbon fibers to be manufactured by MonteFibre (TC partner) and evaluate suitable fiber-matrix interface or sizing for cement composites working with Michelman (TC Partner). This project supports IACMI’s goal of reducing the cost and embodied energy of carbon fiber composites. Cost is one of the fundamental challenges to carbon fiber reinforced cement composites. Cement is an extremely inexpensive material (approximately $\$$0.05/lb). Adding 1 wt% of conventional carbon fiber to cement quadruples its cost. Therefore, the need to use low-cost carbon fiber and ensure that the additional cost of the carbon fiber has a greater cost benefit to the final product. This was the first preliminary evaluation to integrate tCF reinforcement in cement composites, and such potential tCF utilization should significantly reduce materials cost. Cement composite production is energy and emissions intensive, thus by strengthening it less material will be required. Hence, the embodied energy and production time of the resulting structures will be reduced. Additionally, integrating these new materials into additive processes can enable selective use of the material in high load or stress areas. It is noteworthy that past work in this field of fiber reinforced cement composites did not consider the optimization of fiber-matrix interface using suitable sizing. Carbon fiber reinforcement offers potential added benefits of thermal conductivity (which affects cure rate) and flow behavior that could provide opportunities for site specific utilization of carbon fiber on hybrid cement structures (e.g. use the fiber reinforcement on outer surfaces to enhance strength and modulus and then infiltrating the internal structures with conventional concrete). MonteFibre was the industry lead and planned on supplying the tCF for this project. However, during the short Phase-1 duration of this project, MonteFibre was unable to produce tCF for this project due to manufacturing plant being off-line throughout the course of the project. The project team decided to pursue an alternate option which involved demonstrating printable concrete with steel fibers by the ORNL lead, Dr. Brian Post. The University of Tennessee collaboration team focused on evaluating the suitable chemical sizing for carbon fibers working with Michelman and also developed methods for material characterization of cement-based composites to evaluate the material response for compression, shear, flexure, and tension. The two milestones for University of Tennessee, Knoxville were realized related to identification of one sizing suitable for carbon fiber reinforced cement composite and developing data associated with mechanical behavior of unreinforced (neat) and carbon fiber reinforced cement composites. ORNL could not complete the task of carbon fiber reinforced printed cement composites due to the reasons mentioned earlier, but was able to replace tCF with steel fibers to demonstrate the feasibility of printing with fiber reinforced cement composites. The Project team reviewed possible sizing chemistry available in collaboration with Michelman for use on carbon fiber reinforcement in cement composites and concrete applications. Our initial goal was to identify a sizing most promising for formulation with textile carbon fibers (tCF) to deliver excellent mechanical properties in composite material state. Since tCF was not available for this project as originally envisioned, the team continued this task to identify a suitable sizing for carbon fiber applications by applying such sizing to lower cost carbon fibers currently available commercially from Zoltek called Panex fibers. At a future time this can be optimized for textile carbon fibers from Montefibre. The bulk of previous work on carbon fiber reinforced cement has neglected the importance of fiber-matrix adhesion on mechanical properties of the cement composite and identifying this missing link was an important accomplishment for future research. Tensile behavior of fiber reinforced concrete is important to evaluate in order to realize the dream of concrete products that do not need reinforcing steel. Important sample preparation and testing procedures were addressed in this study and it was concluded that substantial improvements in tensile behavior, without compromising compressive strength, and improved ductility can result from the use of carbon fiber reinforcement.
36 MATERIALS SCIENCE↗
Bond Durability of Carbon-Microfiber-Reinforced Alkali-Activated High-Temperature Cement Adhering to Carbon Steel
The study aims at evaluating the bond durability of a carbon microfiber (CMF)-reinforced alkali-activating calcium aluminate cement (CAC)/fly ash F (FAF) blend cementitious material adhering to carbon steel (CS) under stresses induced by a 350°C heat-25°C water cooling cycle. This cementitious material/CS joint sample was originally prepared in an autoclave at 300°C under a pressure of 8.3 MPa. For comparison, two reference geothermal well cements, Class G modified with silica (G) and calciumaluminum phosphate (CaP), were employed as well reinforced with CMF. In the CAC/FAF blending cement systems, the CAC-derived cementitious reaction products preferentially adhered to CS surfaces, rather than that of FAF-related reaction products. CMF played a pivotal role in creating tough interfacial bond structure of cement layer adhering to CS. The bond toughness also was supported by the crystalline cementitious reaction products including sodalite, brownmillerite, and hedenbergite as major phases, and aragonite, boehmite, and garronite as minor ones. The brownmillerite as an interfacial reaction product between cement and CS promoted the chemical bonding of the cement to CS, while the other phases served in providing the attractive bonding of the cement to CS. The post-stress-test joint samples revealed the formation of additional brown-millerite, aragonite, and garronite, in particular brownmillerite as the major one. The combination of chemical bonding and self-advancing adherence behavior of the cement was essential for creating a better interfacial bond structure. A similar interfacial bond structure was observed with CaP. The crystalline phase composition of the autoclaved cement revealed apatite, zeolite, and ferrowyllieite as major reaction products, and aragonite and al-katoite as the minor ones. Ferrowyllieite was identified as cement/CS interfacial reaction product contributing to the chemical bond of cement, while the other phases aided in providing the attractive bond of cement. After a stress test, two phases, ferrowyllieite and aragonite, promoted the self-advancing adherence of cement to CS. However, the effectiveness of these phases in improving adherence performance of cement was less than that of CAC/FAF blend cement, reflecting the fact that the bond durability of CAC/FAF blend cement was far better than that of the CaP. In contrast, the autoclaved silica-modified G cement consisting of xonotlite, and 0.9 nm-to-bermorite and riversideite, with calcite as the crystalline reaction products, had no significant effect on improving the shear bond strength and the bond’s toughness. No interaction product with CS was found in the cement adhering to CS. After a stress test, the calcite phase acted only to promote the self-advancing adherence of cement, but its extent was minimal compared with that of the other cements, thereby resulting in poor bond durability.
15 GEOTHERMAL ENERGY↗
Foamed Cement Interactions with CO 2
Geologic carbon storage (GCS) is a potentially viable strategy to reduce greenhouse emissions. Understanding the risks to engineered and geologic structures associated with GCS is an important first step towards developing practices for safe and effective storage. The widespread utilization of foamed cement in wells may mean that carbon dioxide (CO 2 )/brine/foamed cement reactions may occur within these GCS sites. Characterizing the difference in alteration rates as well as the physical and mechanical impact of CO 2 /brine/foamed cement is an important preliminary step to ensuring offshore and onshore GCS is a prudent anthropogenic CO 2 mitigation choice. In a typical oil and gas well, cement is placed in the annulus between the steel casing and formation rock for both zonal isolation and casing support. The cement must have sufficient strength to secure the casing in the hole and withstand the stress of drilling, perforating, and fracturing (e.g. API, 1997, 2010 Worldwide Cementing Practices). As such, measuring the mechanical and properties of cement is an important step in predicting cement behavior under applied downhole stresses (Nelson, 2006). Zonal isolation is the prevention of fluids migrating to different zones outside of the casing and is strongly impacted by the permeability of the wellbore cement (Nelson, 2006). Zonal isolation depends on both the mechanical behavior and permeability (a physical property) of the cement (Mueller and Eid, 2006; Nelson, 2006). Long-term integrity of cement depends on the mechanical properties of the cement sheath, such as Young’s Modulus (Griffith et al., 2004). The cement sheath’s ability to withstand the stresses from changes in pressure and temperature is predominantly determined by the mechanical properties, including Young’s modulus, Poisson’s ratio, and tensile strength. Any geochemical alteration may impact both the mechanical and physical properties of the cement, thus ultimately impacting the structural integrity of the wellbore. In this study, atmospheric foamed cements were generated using a neat cement and three foam qualities (volume of entrained gas in the cement) - 10%, 20%, and 30 % gas volume. The samples were immersed in a 0.25 M NaCl brine followed by the injection of supercritical CO 2 at 28.9 MPa and 50°C. Petrophysical properties were examined for representative samples using computed tomography (CT) and scanning electron microscopy (SEM). CT scanning of representative samples across the range of reacted cements revealed macroscopic changes in structure due to brine/CO 2 /cement interactions. The high foam quality samples resulted in more CO 2 -saturated brine infiltrating radially deeper into the cement and thus were more susceptible to alteration. After 56 days of exposure, the 30% foam quality sample had the most reaction resulting in an alteration depth of 8.35 ± 0.13 mm with a calculated 34.6 ± 0.2% reacted area and 5.76 ± 0.2% reacted pore space area. The neat sample on the other hand, had a reaction depth of 0.31 ± 0.13 mm with a calculated 0.15 ± 0.08% reacted area and 0.57 ± 0.05% reacted pore area. Physical measurements of the exposed samples were consistent with this degree of alteration having 47.02% porosity and the highest permeability of 0.041 mD. These results indicate that the greater surface area provided by the increase of pore space in the higher quality foam coupled with carbonate diffusion reactions enabled greater alteration.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Experimental study of potential wellbore cement carbonation by various phases of carbon dioxide during geologic carbon sequestration
Hydrated Portland cement was reacted with carbon dioxide (CO2) in supercritical, gaseous, and aqueous phases to understand the potential cement alteration processes along the length of a wellbore, extending from deep CO2 storage reservoir to the shallow subsurface during geologic carbon sequestration. The 3-D X-ray microtomography (XMT) images displayed that the cement alteration was significantly more extensive by CO2-saturated synthetic groundwater than dry or wet supercritical CO2 at high P (10 MPa)-T (50°C) conditions. Scanning electron microscopy with energy dispersive spectroscopy (SEM-EDS) analysis also exhibited a systematic Ca depletion and C enrichment in cement matrix exposed to CO2-saturated groundwater. Integrated XMT, XRD, and SEM-EDS analyses identified the formation of extensive carbonated zone filled with CaCO3(s), as well as the porous degradation front and the outermost silica-rich zone in cement after exposure to CO2-saturated groundwater. The cement alteration by CO2-saturated groundwater for 2-8 months overall decreased the porosity from 31% to 22% and the permeability by an order of magnitude. Cement alteration by dry or wet supercritical CO2 was slow and minor compared to CO2-saturated groundwater. A thin single carbonation zone was formed in cement after exposure to wet supercritical CO2 for 8 months or dry supercritical CO2 for 15 months. Extensive calcite coating was formed on the outside surface of a cement sample after exposure to wet gaseous CO2 for 1-3 months. The chemical-physical characterization of hydrated Portland cement after exposure to various phases of carbon dioxide indicates that the extent of cement carbonation can be significantly heterogeneous depending on CO2 phase present in the wellbore environment. Both experimental and geochemical modeling results suggest that wellbore cement exposure to supercritical, gaseous, and aqueous phases of CO2 during geologic carbon sequestration is unlikely to damage the wellbore integrity because cement alteration by all phases of CO2 is dominated by carbonation reaction. This is consistent with previous field studies of wellbore cement with extensive carbonation after exposure to CO2 for 3 decades. However, XMT imaging indicates that preferential cement alteration by supercritical CO2 or CO2-saturated groundwater can occur along the cement-steel or cement-rock interfaces. This highlights the importance of further investigation of cement degradation along the interfaces of wellbore materials to ensure permanent geologic carbon storage.
Calcite↗
Development of an Improved Cement for Geothermal Wells
After an oil, gas, or geothermal production well has been drilled, the well must be stabilized with a casing (sections of steel pipe that are joined together) in order to prevent the walls of the well from collapsing. The gap between the casing and the walls of the well is filled with cement, which locks the casing into place. The casing and cementing of geothermal wells is complicated by the harsh conditions of high temperature, high pressure, and a chemical environment (brines with high concentrations of carbon dioxide and sulfuric acid) that degrades conventional Portland cement. During the 1990s and early 2000s, the U.S. Department of Energy’s Geothermal Technologies Office (GTO) provided support for the development of fly-ash-modified calcium aluminate phosphate (CaP) cement, which offers improved resistance to degradation compared with conventional cement. However, the use of CaP cements involves some operational constraints that can increase the cost and complexity of well cementing. In some cases, CaP cements are incompatible with chemical additives that are commonly used to adjust cement setting time. Care must also be taken to ensure that CaP cements do not become contaminated with leftover conventional cement in pumping equipment used in conventional well cementing. With assistance from GTO, Trabits Group, LLC has developed a zeolite-containing cement that performs well in harsh geothermal conditions (thermal stability at temperatures of up to 300°C and resistance to carbonation) and is easy to use (can be easily adjusted with additives and eliminates the need to “sterilize” pumping equipment as with CaP cements). This combination of properties reduces the complexity/cost of well cementing, which will help enable the widespread development of geothermal energy in the United States.
15 GEOTHERMAL ENERGY↗
TCF - Sustainable Well Cement for Geothermal, Thermal Recovery, and Carbon Storage wells
Primary cementing is the most important operation performed on a subterranean well. Cement, placed in the annulus between the casing and the formations, serves as a hydraulic seal preventing fluids and gas migrations, protecting steel casing from corrosion, and supporting the well structure. Poor cementing jobs can be directly responsible for wells not reaching their full capacity, casing corrosion, compromised well integrity and, in the worst-case scenarios, well collapse. Geothermal, thermal recovery, and carbon storage wells offer environments that are especially difficult for cements to survive while the required lifespan of these wells can be years. In these wells currently used cements cannot provide durable well integrity, and new solutions are necessary. The necessity of stabilizing the electric grid, increasing its flexibility, and providing energy on demand will further expand the market of durable cement solutions for applications in high-temperature underground reservoir thermal energy storage wells (HT RTES). The design challenges of special cement systems for such wells originate from chemistry limitations of currently used well cements, aggressive environments, temperature and repeated shock conditions associated with them, and very weak formations that are not uncommon in these wells. During the last 70 years the most common systems for thermal-well construction have been Ordinary Portland Cement (OPC) (absolute majority of the wells), silica-lime system, and high aluminum cement-containing formulations. The major issues of calcium-silicate hydrates, that form during the hydration of OPC resulting in hardened material, are their poor chemical resistance to acids due to the calcium interactions with acid anions followed by its eventual dissolution, even in mild acids, such as carbonic acid from CO 2 dissolution, and inadequate bonding to the steel causing serious casing corrosion problems (Sugama & Pyatina, 2019). Performance of OPC-based cement may be significantly improved with organic additives; however, those are limited by their temperature stability. An alternative to calcium-silicate cement was developed by BNL and commercialized by Halliburton as ThermaLock TM cement. Calcium-aluminate-phosphate-based chemistry of the material allowed overcoming acid-resistance problems of OPC, especially in CO 2 -rich geothermal environments. In 2012-2015, building upon this experience, BNL developed Thermal Shock Resistant Cement (TSRC) with the support of Geothermal Technology Office (GTO) of DOE. TSRC has high-temperature stable chemistry, superior properties of cement-metal casing bond and corrosion protection (4-times better than currently used OPC-based formulation), significantly outperforms common well-cements in thermal-shock tests, has self-healing properties, and like ThermaLock TM is CO 2 resistant incorporating carbonate ions into stable hydrates (Gill et al., 2012).
15 GEOTHERMAL ENERGY↗
Air Pollutant Emissions Projections for the Cement and Steel Industry in China and the Impact of Emissions Control Technologies
China’s cement and steel industry accounts for approximately half of the world’s total cement and steel production. These two industries are two of the most energy-intensive and highest carbon dioxide (CO 2 )-emitting industries and two of the key industrial contributors to air pollution in China. For example, the cement industry is the largest source of particulate matter (PM) emissions in China, accounting for 40 percent of its industrial PM emissions and 27 percent of its total national PM emissions. The Chinese steel industry contributed to approximately 20 percent of sulfur dioxide (SO 2) emissions and 27 percent of PM emissions for all key manufacturing industries in China in 2013. In this study, we analyzed and projected the total PM and SO 2 emissions from the Chinese cement and steel industry from 2010–2050 under three different scenarios: a Base Case scenario, an Advanced scenario, and an Advanced EOP (end-of-pipe) scenario. We used bottom-up emissions control technologies data and assumptions to project the emissions. In addition, we conducted an economic analysis to estimate the cost for PM emissions reductions in the Chinese cement industry using EOP control technologies, energy efficiency measures, and product change measures. The results of the emissions projection showed that there is not a substantial difference in PM emissions between the Base Case and Advanced scenarios, for both the cement and steel industries. This is mainly because PM emissions in the cement industry caused mainly by production process and not the fuel use. Since our forecast for the cement production in the Base Case and Advanced scenarios are not too different from each other, this results in only a slight difference in PM emissions forecast for these two scenarios. Also, we assumed a similar share and penetration rate of control technologies from 2010 up to 2050 for these two scenarios for the cement and steel industry. However, the Advanced EOP scenario showed significantly lower PM emissions for the cement industry, reaching to 1.7 million tons of PM in 2050, which is less than half of that in the other two scenarios. The Advanced EOP scenario also has the lowest SO 2 emissions for the cement industry in China, reaching to 212,000 tons of SO 2 in 2050, which is equal to 40 percent of the SO 2 emissions in the Advanced scenario and 30 percent of the emissions in the Base Case scenario. The SO 2 emission is mainly caused by fuel (coal) burning in cement kiln or steel processes. For the steel industry, the SO 2 emissions of the Advanced EOP scenario are significantly lower than the other scenarios, with emissions declining to 323,000 tons in 2050, which is equal to 21 percent and 17 percent of the emissions of Advanced and Base Case scenarios in 2050, respectively. Results of the economic analysis show that for the Chinese cement industry, end-of-pipe PM control technologies have the lowest abatement cost per ton of PM reduced, followed by product change measures and energy efficiency measures, respectively. In summary, in order to meet Chinese national and regional air quality standards, best practice end-of-pipe emissions control technologies must be installed in both cement and steel industry and it must be supplemented by implementation of energy efficiency technologies and reduction of cement and steel production through structural change in industry.
54 ENVIRONMENTAL SCIENCES↗
Defining the Difference Between Laboratory and Field-Generated Foamed Cement
Foamed cement has been used extensively across a variety of applications for oil and gas well cementing, including deepwater riserless cementing, low fracture gradient cementing, horizontal well cementing, steam injection well cementing, and high-pressure/high-temperature (HP/HT) cementing. When using foamed cement, laboratory testing is used to estimate the performance characteristics of foamed cement slurries that are designed for well applications. It is well known that significant differences exist between the methods used to generate foamed cement in the laboratory and those used to generate foamed cement for field applications. The implications of these differences on foamed slurry characteristics (e.g., bubble size distribution) and performance properties (e.g., stability, permeability, mechanical properties) has not been well analyzed or well understood. This paper documents a project that was undertaken through a joint effort between API Sub-Committee 10 and the National Energy Technology Laboratory (NETL) to examine the differences between foamed slurries generated with laboratory equipment and field foamed cementing equipment. Methods for generating and capturing foamed cement samples using field equipment are discussed, as well as analytical methods for evaluating the characteristics of foamed cements. References to the resulting data are provided. Finally, conclusions and recommendations are presented that were developed during the course of the project.
02 PETROLEUM↗
Investigation of Possible Wellbore Cement Failures During Hydraulic Fracturing Operations
We model and assess the possibility of shear failure, using the Mohr-Coulomb model ? along the vertical well by employing a rigorous coupled flow-geomechanic analysis. To this end, we vary the values of cohesion between the well casing and the surrounding cement to representing different quality levels of the cementing operation (low cohesion corresponds to low-quality cement and/or incomplete cementing). The simulation results show that there is very little fracturing when the cement is of high quality.. Conversely, incomplete cementing and/or weak cement can causes significant shear failure and the evolution of long fractures/cracks along the vertical well. Specifically, low cohesion between the well and cemented areas can cause significant shear failure along the well, but the same cohesion as the cemented zone does not cause shear failure. When the hydraulic fracturing pressure is high, low cohesion of the cement can causes fast propagation of shear failure and of the resulting fracture/crack, but a high-quality cement with no weak zones exhibits limited shear failure that is concentrated near the bottom of the vertical part of the well. Thus, high-quality cement and complete cementing along the vertical well appears to be the strongest protection against shear failure of the wellbore cement and, consequently, against contamination hazards to drinking water aquifers during hydraulic fracturing operations.
02 PETROLEUM↗
Cementation of Nuclear Wastes: From Past to Future in a Sustainable Approach - 18266
Cementation of nuclear wastes is a widespread technology due to several factors such as excellent feedback from past experience, simplicity of implementation and versatility. Indeed, as nuclear wastes come in many physical states (bulk wastes, powders, sludges), cementation is the immobilisation process that can easily accommodate this large range of wastes provided the appropriate mixing technology is used: heterogenous cementation (grouting of bulky wastes) or homogenous cementation (intermixing process between the powder or the sludge and the cementitious material). However, nuclear wastes equally present an important chemical variability. This is especially true as New Areva's range of nuclear activities covers the entire fuel cycle: mining, conversion, enrichment and recycling and dismantling and decommissioning. The chemical interactions between the waste and the cement matrix are carefully studied by New Areva's R and D teams in order to provide comprehensive solutions by developing cement formulations which are adapted to wastes characteristics. The aim of the studies is to obtain cement waste-forms that meet the waste acceptance criteria, the final product being thus in perfect adequacy with the disposal requirements. For over 30 years New Areva has been developing cement formulations adapted to the physical and chemical specificities of the wastes accounting for constrains imposed by waste characteristics. The overall approach includes the definition of the appropriate cement composition at laboratory scale, engineering design, equipment manufacturing, testing and commissioning of the cementation facilities. With this strong technical background, a specific methodology has been developed by New Areva teams in order to allow a rapid screening of possible solutions for a given waste (in terms of cement chemistry adapted to the waste) in a learn-fast approach that is based on theoretical analysis and small-scale tests. The methodology was applied for wastes presenting a complex nature (such as reactive metals, ion exchange resins, oils and solvents, mercury, etc), known to interact with Portland cement from a chemical point of view and leading to durability issues of the wasteform (swelling, strength reduction, leaching) and thus reducing the final waste loading. Once the screening process is over, the main drivers for choosing the most appropriate solution to be further developed at pilot scale are: reducing the overall volume and the impact of the final waste package, ensure the waste package performance as defined by the disposal requirements and control the long-term behaviour in final disposal. Moreover, a modelling approach is addressed, aiming to develop a thermo-chemo-mechanical (THM) concrete models that are able to predict the behaviour of the structure (waste form) in time. The aim of the present paper is to describe the main principles within the developed methodology and illustrate it by using a few specific examples. Several distinct cement formulations are developed for complex wastes, limiting the chemical interaction between the cement matrix and the given wastes, obtaining better waste loadings and better overall durability behaviour which facilitates long term behaviour demonstration. (authors)
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Development of an Advanced Finite Element Model and Parametric Study to Evaluate Cement Sheath Barrier
Cement failure is known as one of the major causes for loss of well control events. Cement design is considered as one of the top technological knowledge gaps in high-pressure high-temperature oil and gas exploration. The primary objective of this paper is to perform a parametric analysis and identify critical parameters affecting the mechanical integrity of the set cement sheath. To achieve the objective, three-dimensional finite element models consisting of concentric casings and annular cement sheath were created. The finite element model was validated by analytical calculations. Performance of cement sheath was assessed by analyzing radial, hoop, and maximum shear stresses at different loading conditions. A parametric study was conducted by individually varying influencing factors such as cement material properties, sheath dimensions, and wellbore pressure loads. Values of all parameters were normalized and represented on the same plot against mechanical stresses. Such response curves can be used to estimate whether cement will structurally fail because of various operational loads or material aging. The plot can also be utilized to rank various factors in terms of influence on cement’s performance. Sensitivity response reveals that wellbore pressure, cement material properties, and annulus pressure are major parameters influencing mechanical stresses in neat class G cement. The order of importance depends on the type of stress. Results indicate interfacial bond failure and radial cracking to be the more likely modes of failure for class G cement. Cement response curves can help design engineers and regulators alike in quickly evaluating short-term or long-term fitness-for-service of cement sheath from the perspective of structural integrity. Industry standards and guidelines can be improved by adding performance curves for standard cement recipes.
Energy & Fuels↗
Experimental Evaluation of Geopolymer, Nano-Modified, and Neat Class H Cement by Using Diametrically Compressive Tests
Abstract Cement is the prime barrier material to maintain zonal isolation during wellbore life-cycle. Different types of the cement have different performances on sealability. The primary objective of this study is evaluation of three types of cement systems, neat Class H, nano-synthetic graphite, and rock-based geopolymer cements, on interfacial bond integrity. Diametrical compressive tests are used on casing–cement–formation systems. Cement performances are tested in a conventional configuration (Berea Sandstone). A universal testing system is utilized to analyze the relationship applied load–axial strain and the digital image correlation (DIC) technique is used to generate the strain field maps. Based on the relationship and DIC results, bond strengths in different cement systems are evaluated. Additionally, microscope images provide insight explanations of the bond from micro-view. Based on the experimental results, failures of all cases initiate and propagate from the casing–cement interface. Then, radial cracks develop through the formation. This is because the mechanical interlocking bonds are formed only at the cement–sandstone interface to enhance the bond strength. The comparison of geopolymer and nano-modified cements with the conventional cement (neat Class H) shows that the unconventional cements have a lower maximum load and higher axial strain before failure of the samples. It indicates that both the two kinds of cements are more ductile than conventional cement and can support more deformation before the initiation of cracks.
Energy & Fuels↗