Targeting the incompatibility issue between traditional Portland cements and non-aqueous drilling muds, a mud solidification technique based on geopolymer cements was recently introduced to the industry. This technique was achieved by incorporating non-aqueous fluids (NAF) such as synthetic-based or oil-based drilling mud in a geopolymer cement that is formed by blending an aluminosilicate powder with an alkaline activating solution. In a previously completed study, the consolidated mud, or "geopolymer hybrid", was evaluated for its compressive strength, thickening time and stability for applications including primary cementing as well as lost circulation control. In an effort to further develop the geopolymer hybrid system as a new generation well cementing material, the present work comprehensively studies their mechanical properties, self-healing capabilities and cement-to-pipe bond strength.
One of the concerns currently preventing the use of geopolymers for well cementing is its low early compressive strength. This study shows that although the early age uniaxial compressive strength of geopolymer is lower than that of Portland cement, with an applied confining stress, geopolymers have more than sufficient strength for primary cementing applications.
Furthermore, the abilities of cement to properly bond with steel casing and rock formations, as well as to withstand subsurface stress changes over time are of paramount importance for long-term cement integrity. The triaxial tests performed in this study show that geopolymers are less brittle than Portland cement, and can therefore accommodate stress changes without localized failure. The geopolymer bond strength measurements showed that geopolymer could bond to steel even in presence of non-aqueous drilling muds. In addition, the triaxial tests revealed that geopolymers exhibit true self-healing capabilities, characterized by samples fully regaining their mechanical competence with 28 day post-failure strength exceeding the native 7-day strength. Portland cement, in comparison, retained lower ultimate strength than its 7-day strength. The self-healing capability of geopolymers is ideally suited to adapt to subsurface stress changes, making such materials ideally suited for use as permanent barriers in plug and abandonment operations.