NOVEL CHEMICALLY BONDED PHOSPHATE CERAMIC BOREHOLE SEALANTS FOR ARCTIC ENVIRONMENT
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Transcript of NOVEL CHEMICALLY BONDED PHOSPHATE CERAMIC BOREHOLE SEALANTS FOR ARCTIC ENVIRONMENT
NOVEL CHEMICALLY BONDED NOVEL CHEMICALLY BONDED PHOSPHATEPHOSPHATE
CERAMIC BOREHOLE SEALANTS FOR CERAMIC BOREHOLE SEALANTS FOR
ARCTIC ENVIRONMENT ARCTIC ENVIRONMENT
Presented ByPresented By : Nilesh Limaye, UAF. : Nilesh Limaye, UAF.
Principal InvestigatorPrincipal Investigator : Shirish Patil, UAF. : Shirish Patil, UAF. Partner Principal InvestigatorPartner Principal Investigator : Arun Wagh, : Arun Wagh,
ANL.ANL. Industrial ParticipantIndustrial Participant : Jeff Dawson, BJ : Jeff Dawson, BJ
services. services.
January 23, 2007January 23, 2007
Fairbanks, AK.Fairbanks, AK.
INTRODUCTION:
• Unique cementing difficulties in permafrost and gas hydrate zone at ANS.
• Problems associated with Conventional Portland cement concretes.
• Development of Ceramicrete.
• Advantages of Ceramicrete over Conventional Portland cement.
• Various tests carried out at ANL, regarding Ceramicrete properties.
• “Argonne Phosphate cement”.
Tests done at BJ: Flash setting of Ceramicrete
Void spaces
Tasks Achieved (09/05-12/06):
• Ceramicrete application for cementing oil
wells in ANS
• Economic Analysis of well cementing.• Determination of radius of thawed-permafrost zone and temperature distribution in thawed zone around well bore at ANS.
Task remaining:• laboratory tests at ANL, regarding flash setting
of mixture of Ceramicrete (95%) and Conventional
Portland cement(5%).
Tests at BJ services
Ceramicrete application for Cementing oil wells : Ceramicrete formulation used : (Banerjee,2005)
Ceramicrete Formulation
Weight %
MgO 25%
KH2PO4 27.20%
C-Class fly Ash 10.20%
Wollastonite 10.20%
Boric Acid 0.09%
Water 27.20%
Total 100%
Economics of well cementing :
1. Example of a typical oil well at ANS .
2. Calculation of annular volume between casing and bore hole for different zones.
3. Calculation of amount of Ceramicrete required for cementing oil well.
4. Calculation of raw material cost and thus, cost of production.
Consider a typical oil well that is to be drilled at ANS at a depth of 3500 feet.
Typical oil well configuration at ANS:
Well depth 3500 Ft.
Permafrost Zone 1800 Ft.
Stable Hydrate Zone 1700 Ft.
Diameter Size
open hole in permafrost Zone 26’’
Surface Casing in permafrost Zone
20’’
hydrate zone 22’’
intermediate casing 14’’
Permafrost zone1800 feet.
Stable Hydrate Zone1700 feet
Ceramicrete
Dia.20”
Dia.26”
Dia.14”
Dia.22”
Surface Casing
Casing shoe
Intermediate Casing
Annular volume between casing and zones:
Annular volume between Surface casing and
permafrost
zone or Intermediate casing and Stable hydrate zone
Annular Volume = 0.785 * (Dh2 – Dc2) *H.
Where, Dh = Diameter of permafrost zone or Stable hydrate
Zone
Dc= Diameter of casing
H = Depth of each zone (permafrost & stable hydrate). Total annular volume = annular volume between surface casing / permafrost zone + Intermediate casing / Stable hydrate zone
Thus, Total annular volume for given well = 152.34 m3.
Ceramicrete requirement for cementing given well: The Ceramicrete slurry density for formulation used is
found out to be 1.9 gm/cc or 1900 kg/m3. (Banerjee, 2005)
Amount of Ceramicrete = Density * Volume
= 152.34 (m3) * 1900( Kg/m3)
= 285.45 MT.
Calculation of raw material cost: Amount of Ceramicrete required for cementing 1well = 285.45 MT. We consider 8% more cement production considering
various loses involved in actual cementing application.
i.e. Amount of cement production = 308.28MT.Ceramicrete Formulation:
Weight %
Tones $
MgO 25% 0.25 76.9538,475.0
0
KH2PO4 27.20% 0.272 83.72115,906.
10
C-Class fly Ash 10.20% 0.102 31.39 784.89
Wollastonite 10.20% 0.102 31.3918,837.3
6
Boric Acid 0.09%0.000
90.2770
2 218.29
Water 27.20% 0.273 84.02
Total 100% 1.00308.2
8174,221
.64
Now, if we consider 10,20,30,…. such oil wells to be drilled at ANS (Ceramicrete Production on bulk basis), the Raw material cost would be: Number of
wellsProduction (tones)
Raw material cost ($)
1 308.28 174,221.64
10 3,078.00 1,853,910.79
20 6,156 3,695,505.28
30 9234.00 5,528,413.39
40 12,312.00 7,364,041.12
50 15,390.00 9,199,193.36
60 17,100.00 10,217,638.26
70 19,950.00 11,911,844.45
80 24,621.53 14,701,080.44
Problems associated with current formulation of Phosphate cement: (@ Tomball meeting)
1. Failure in consolidation test.
2. Cement contamination / flash setting.
“Argonne Phosphate cement”
1.Composition without cement contamination
2.Composition with cement contamination
• Range of amount of fly ash.
• 10% Portland Cement.
• Water to cement ratio :33.12%
Powder Components
24-h compressive strength
Argonne's novel phosphate Binder
Class C fly ash
Boric acid(% binder)
OPC(Type I)
50 50 3.75 0 1024
40 50 3.75 10 657
40 50 2.5 10 657
45 45 3.75 10 657
50 40 3.75 10 1052
Test Results:
Compression strength in consolidation tests.
Powder Component
s
Argonne novel
phosphate binder
Class C fly ash
Boric acid (%
binder)
OPC(Type
I)
24-h compressive strength (psi)
50 50 3.75 0 823
50 40 3.75 10 756
Composition and compressive strength of sample mixed in the Consistometer:
Compressive strength values are slightly lower than those found in consolidation tests due to oil contamination during the consistency test.
Consistency graph without Portland
cement
Consistency graph with 10% Portland
cement
Project Schedule:Completed tasks:
Task 1 Literature search.
Task 2 Optimization of sealants and Testing for niche applicationsEvaluation of pumping characteristics, physical and mechanical properties
Optimization of thermal properties Bonding Characteristics
Formulation in presence of down-hole gases
Remaining Tasks (Tasks for next quarter): Task 4 laboratory tests at ANL, regarding flash setting of mixture of Ceramicerete(95%) and Portland cement(5%) followed by tests at BJ
Task 3-A Economics of oil well cementing
Task 3-B Determination of thawed-permafrost zone and temperature profile in thawed region.