Scaling Up Geopolymer Cement-Free Technology from the Laboratory to the Field: Multiple Case Studies

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🔬研究者:Demonstrates scalable low-carbon cement alternative for well construction with field validation.

🏢実務担当者:Provides operational evidence that geopolymer can replace OPC in well cementing with existing equipment and lower emissions.

🏛政策担当者:Supports decarbonization of oil and gas sector with proven technology; consider for regulatory incentives.

An innovative approach is required in the oilfield cementing process to minimize the carbon footprint. Although Ordinary Portland Cement (OPC) has been used and continuously developed for more than a hundred years, it is no longer a sustainable solution for the industry to achieve its net-zero goals. Geopolymer is a technology that can be tailored for different well conditions, reducing carbon emissions by up to 85%. The objective of this paper is to present several cases of this low-carbon geopolymer technology while meeting diverse job requirements based on well conditions and applications. Details from the design phase, including its challenges, as well as the preparation and execution of yard tests, are discussed. Geopolymer slurries ranging from 11.0 to 15.8 lb/galUS were optimized following the American Petroleum Institute Recommended Practice (API RP 10B-2) for testing well cements. Properties of geopolymer slurries, such as rheology, free fluid, thickening time, compressive strength development, and fluid loss, were evaluated across multiple laboratories to meet specific job requirements. Bottomhole circulating temperature (BHCT) varied from 77°F to 185°F. Once optimized in the laboratory, the scalability of the geopolymer technology was assessed by bulk mixing and pumping these new fluids using conventional cementing equipment in seven different countries. Both continuous (on-the-fly) mixing and batch mixing were evaluated. The flowability and homogeneity of bulk plant scale-up blends of varying designs were verified by collecting multiple samples for analysis and comparison with laboratory-prepared blends. In total, seven low-carbon geopolymer slurries using local raw material sources were optimized in laboratories across seven countries. These case studies addressed key challenges, including developing early compressive strength under low BHCT conditions, achieving a three-hour stop in thickening time to simulate liner jobs (go/no-go), and maintaining fluid loss below 50 mL. To validate these designs in practice, seven yard tests were performed across the world. The trials confirmed that geopolymer slurries can be mixed and pumped with the same equipment and infrastructure used for conventional cement jobs, across a wide range of densities, temperatures, and job types. Beyond these operational results, the system provides a significant sustainability benefit: by relying on materials with lower embodied carbon, it helps reduce the footprint of well construction. Overall, the findings demonstrate that geopolymer can deliver the required field performance while supporting long-term decarbonization goals. The case studies have demonstrated that geopolymer slurries can easily be designed and customized to different well conditions, similar to traditional cement slurries. Replacing OPC with geopolymer technology is instrumental in achieving a sustainable future for wellbore barrier materials and mitigating environmental impact, while maintaining the necessary high performance of the fluids and ease of operations in the field. Geopolymer technology is a novel solution supporting the decarbonization of the well construction industry.

• semanticscholar https://doi.org/10.2118/230757-msfirst seen 2026-06-29 07:20:32