Abstract
The substitution of Ordinary Portland Cement (OPC) by geopolymer materials for sealing oil and gas wells has the potential to reduce the associated carbon footprint and provide more flexibility and durability at downhole conditions compared to OPC. However, geopolymer materials have chemical incompatibilities when mixed with those drilling muds commonly used. Thus, careful use of spacers is needed. In this work, we present a case study that explores the process of designing compatible spacers for sealing a wellbore with a geopolymer. To ensure negligible mud-geopolymer contamination, the spacer design is backed-up by the results of 2D-gap averaged simulations of annular displacements. Simulation results are post-processed into maps of displacement efficiency for the cementing operation. The results show a broad operating window of eccentricities, density, and rheology for an effective spacer design, i.e. producing near-perfect displacement of the bulk fluids. While qualitatively the results conform to best practices (high standoff, positive density, and rheology hierarchies), the use of simulation allows for quantitative prediction. This highlights the benefits of using 2D flow simulations, in particular reducing the risk of deployment of new materials.
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