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<p>Ensuring long-term wellbore integrity in the oil and gas industry remains a significant challenge due to the mechanical and chemical limitations of Portland cement (PC) under downhole conditions. In this study, a geopolymer was formulated using locally sourced kaolin, magnesite, and waste glass cullets, aiming to enhance durability and sustainability. Sodium metasilicate synthesized from waste glass was used as an alkaline hardener. A dual-curing approach, CO<sub>2</sub>-assisted carbonation followed by brine immersion, was employed to simulate thermochemically aggressive and ion-rich wellbore environments. XRF, XRD, FTIR, and BET analyses confirmed the development of an aluminosilicate matrix with a high amorphous content (66.4%) and a surface area of up to 310.23 m<sup>2</sup>/g. Carbonation curing led to a 10.34% mass gain and improved compressive strength by 19.35%. The highest compressive strength recorded was 36.72 ± 0.22&#xa0;MPa after 28&#xa0;days of brine curing at 80&#xa0;°C. Water absorption remained low at 1.36 ± 0.06%, and the concentration of leached Mg<sup>2</sup>⁺, Al<sup>3</sup>⁺, Si<sup>4</sup>⁺, and Ca<sup>2</sup>⁺ ions in brine was minimal, indicating strong chemical stability. Thermogravimetric analysis showed a total mass loss of 22.6%, confirming thermal resilience of the geopolymer up to 850&#xa0;°C. These results demonstrate that the synthesized geopolymer offers enhanced short-term mechanical and chemical performance under deep-well-relevant conditions, while valorizing industrial waste and reducing carbon emissions. The formulation aligns with the industry’s growing shift toward ultra-deep exploration, where hypersaline environments are increasingly encountered. Overall, the study supports the feasibility of deploying geopolymer as a sustainable alternative to PC in oil and gas sector.</p>

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Formulation of Geopolymer with Assisted Carbonation and High-Salinity Brine Curing to Strengthen Wellbore Integrity in Deep Oil and Gas Wells

  • 期刊论文

  • 发表日期：

    2025年11月17日

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  • Catherine Y. Msomba,
  • Makungu M. Madirisha,
  • Kessy F. Kilulya

摘要

Ensuring long-term wellbore integrity in the oil and gas industry remains a significant challenge due to the mechanical and chemical limitations of Portland cement (PC) under downhole conditions. In this study, a geopolymer was formulated using locally sourced kaolin, magnesite, and waste glass cullets, aiming to enhance durability and sustainability. Sodium metasilicate synthesized from waste glass was used as an alkaline hardener. A dual-curing approach, CO2-assisted carbonation followed by brine immersion, was employed to simulate thermochemically aggressive and ion-rich wellbore environments. XRF, XRD, FTIR, and BET analyses confirmed the development of an aluminosilicate matrix with a high amorphous content (66.4%) and a surface area of up to 310.23 m2/g. Carbonation curing led to a 10.34% mass gain and improved compressive strength by 19.35%. The highest compressive strength recorded was 36.72 ± 0.22 MPa after 28 days of brine curing at 80 °C. Water absorption remained low at 1.36 ± 0.06%, and the concentration of leached Mg2⁺, Al3⁺, Si4⁺, and Ca2⁺ ions in brine was minimal, indicating strong chemical stability. Thermogravimetric analysis showed a total mass loss of 22.6%, confirming thermal resilience of the geopolymer up to 850 °C. These results demonstrate that the synthesized geopolymer offers enhanced short-term mechanical and chemical performance under deep-well-relevant conditions, while valorizing industrial waste and reducing carbon emissions. The formulation aligns with the industry’s growing shift toward ultra-deep exploration, where hypersaline environments are increasingly encountered. Overall, the study supports the feasibility of deploying geopolymer as a sustainable alternative to PC in oil and gas sector.