Improving the rheological properties of alkali-activated geopolymers using non-aqueous fluids for well cementing and lost circulation control purposes

Abstract

Typical alkali-activated low-calcium fly ash (AAF) geopolymer formulations are yet to deliver acceptable rheologies for applications such as oil and gas well cementing, where the cement slurry needs to be pumped, and few effective superplasticizers have been identified. The work reported here centers on the discovery that the rheological properties (mixability and pumpability) of AAFs can be significantly improved by incorporating an organic-based non-aqueous fluid (NAF). NAFs such as oil-based muds and synthetic-based muds are water/brine-in-oil invert emulsions that are widely used in the oil and gas industry for drilling and completion operations. Adding NAF can significantly improve the rheological properties of AAF geopolymers, to the point where the rheology of the mixture approaches that of a Portland cement slurry. Overcoming the poor pumpability issue of AAF opens up a large variety of well cementing applications for AAF slurries including primary cementation and plug cementing in severe lost circulation zones.To modify the gelation and setting characteristics multiple fly ash sources and activators were considered in this study. The alkali activators tested in this study were sodium hydroxide and sodium hydroxide with addition of liquid or solid form sodium silicates. Sodium hydroxide activated AAFs showed improved rheological properties with the addition of NAFs. The liquid sodium silicate activated AAFs resulted in unfavorable rheology readings, gel strength measurements and accelerated the pumping time in comparison to use of pure sodium hydroxide activator. The addition of NAF further accelerated the pumping time, increased the viscosity of the AAF, leading to an unpumpable slurry with a rapid setting behavior. In contrast, activation with solid sodium silicate did not negatively affect the rheological behavior of AAF in the presence or absence of NAF. The use of a solid activator showed an initial high consistency peak that broke down with continued shearing. This early high consistency behavior may be exploited to combat lost circulation problems on troublesome oil and gas wells.