An Empirical Model for Geopolymer Reactions Involving Fly Ash and GGBS

Numerous works are reported in literature regarding the enhancement of compressive strength of fly ash-GGBS geopolymer combinations with addition of alkali activators of varying concentrations. However, a limited study has been chronicled, revealing the specific role of alkali or alkaline earth contributed by the fly ash-GGBS combinations on the compressive strength development. It is well known that the strength of a geopolymer is dependent on gel formation from Al/Si ratio, Ca/Si ratio, and Ca/(Si + Al) ratio but their exact role when cured for various extended periods is unknown as yet. In the present study, alkali concentration in a fly ash-GGBS geopolymer combination was varied from 6 M to 12 M with increments of two mol in six different fly ash-GGBS combinations with a minimum of 20 percent and a maximum of 70 percent GGBS. The correlation coefficients between compressive strength and Al/Si, Ca/Si, and Ca/(Si + Al) ratios exhibited values higher than 0.95 taken individually. Multiple linear regression analysis with compressive strength (as dependent parameter) and individual values of Al/Si, Ca/Si, and Ca/(Si + Al) ratios (as independent parameters) was effectuated. It was observed that, depending on the composition, the compressive strength circumstantiated a changeover from Ca/Si to Ca/(Si + Al) ratio in the intermediate composition range. Such a detailed analysis is considered supportive of developing a suitable composition which will provide the optimum compressive strength of the combination.

Advanced Light Weight Thixotropic Lost Circulation Cement Solution for Vugular and Natural Fractured Limestone Formations: UAE Offshore Case History

Lost circulation while drilling across vugular or naturally fractured limestone formations is a costly challenge and has financial impacts including nonproductive time and remedial operational expenses. Many fields in the UAE are encountering notorious lost circulation complications, which are difficult to control with conventional lost circulation solutions while drilling surface sections. Novel lightweight thixotropic cement has proven beneficial to take control of severe losses in these vugular and naturally fractured limestone formations. The main challenge while drilling across the surface section in UAE offshore field is the heavy or total loss of returns. Drilling performance is affected due to poor hole cleaning, a risk of stuck pipe, surface fluid handling problems, and well control risks. Conventional extended cement slurries have been widely used to cure losses while drilling but with limited success. A new lost circulation solution combines lightweight (10.5- lbm/galUS) high solids fraction cement (trimodal system) and a thixotropic agent, which develop fast gels with high compressive strength. Thus, it enables plugging of large voids and fractures to deliver the wellbore integrity required to continue drilling with enhanced performance and efficiency. Intensive laboratory qualification tests focusing on static gel strength and compressive strength development was performed to tailor the new solution. The results were promising with more than 100 lbf/100 ft2 of static gel strength in 10 minutes and compressive strength development of 1,000 psi within 24 hours at low surface temperature. In addition, a transition time (TT) on-off-on test demonstrated more rapid gel strength development when the shear is reduced and regained fluidity with reapplication of shear. In one of the wells, heavy losses were encountered while drilling across surface section. The lightweight thixotropic solution was pumped for the first time worldwide and it was shown that the innovative lost circulation solution was effective in significantly reducing the losses and enabled the operator to continue drilling to section TD. This case study demonstrates that this advanced system is effective in curing losses and reducing nonproductive time. The unique properties of faster rapid gel strength and high compressive strength make this solution effective for treating a wide range of lost circulation events while drilling. Furthermore, the advanced lightweight thixotropic cement lost circulation solution exhibits strong performance in curing heavy losses and establishing well integrity with reliability.

Model-Based Methods to Produce Greener Metakaolin Composite Concrete

Metakaolin is reactive and is widely used in the modern concrete industry. This study presents an integrated strength–sustainability evaluation framework, which we employed in the context of metakaolin content in concrete. First, a composite hydration model was employed to calculate reactivity of metakaolin and cement. Furthermore, a hydration-based linear equation was designed to evaluate the compressive strength development of metakaolin composite concrete. The coefficients of the strength evaluation model are constants for different mixtures and ages. Second, the sustainability factors—CO2 emissions, resource consumption, and energy consumption—were determined based on concrete mixtures. Moreover, the sustainability factors normalized for unit strength were obtained based on the ratios of total CO2 emissions, energy consumption, and resource consumption to concrete strength. The results of our analysis showed the following: (1) As the metakaolin content increased, the normalized CO2 emissions and resource consumption decreased, and the normalized energy first decreased and then slightly increased. (2) As the concrete aged from 28 days to three months, the normalized CO2 emissions, resource consumption, and energy consumption decreased. (3) As the water/binder ratio decreased, the normalized CO2 emissions, resource consumption, and energy consumption decreased. Summarily, the proposed integrated strength–sustainability evaluation framework is useful for finding greener metakaolin composite concrete.

The influence of calcium sulfate content on the hydration of belite-calcium sulfoaluminate cements with different clinker phase compositions

The influence of different amounts of gypsum on the hydration of a belite-rich and a ye'elimite-rich belite-calcium sulfoaluminate clinker (BCSA) was investigated. The hydration kinetics, phase assemblages and compressive strength development of cements prepared using ye’elimite/ calcium sulfate molar ratios of 1, 1.5 and 2 were studied. Besides ettringite and monosulfate, aluminium hydroxide, strätlingite, C−S−H, iron-containing siliceous hydrogarnet and hydrotalcite were present as hydration products. Increasing the amount of gypsum increased the ratio of ettringite to monosulfate formed in the cement paste, lowered the amount of pore solution, delayed the dissolution of belite and ferrite, decreased the formation of strätlingite and, in the case of the ye’elimite-rich BCSA, led to an increase in compressive strength. Increased amounts of belite in the clinker led to the formation of higher quantities of C–S–H, at the expense of strätlingite and a lower compressive strength, as belite has a lower degree of reaction than ye’elimite and due to the formation of more C–S–H and strätlingite compared to the more space-filling ettringite. The thermodynamic model established for BCSA cement hydration agrees well with the experimental data. Compressive strength directly correlated with bound water from thermogravimetric analyses and inversely correlated with the porosity calculated from thermodynamic modelling.

Influence of Mechanical and Mineralogical Activation of Biomass Fly Ash on the Compressive Strength Development of Cement Mortars

Biomass combustion is a significant new source of green energy in the European Union. The adequate utilization of byproducts created during that process is a growing challenge for the energy industry. Biomass fly ash could be used in cement composite production after appropriate activation of that material. This study had been conducted to assess the usefulness of mechanical and physical activation methods (grinding and sieving), as well as activation through the addition of active silica in the form of silica fume, as potential methods with which to activate biomass fly ash. Setting time, compressive strength, water absorption and bulk density tests were performed on fresh and hardened mortar. While all activation methods influenced the compressive strength development of cement mortar with fly ash, sieving of the biomass fly ash enhanced the early compressive strength of cement mortar. The use of active silica in the form of silica fume ensured higher compressive strength results than those of control specimens throughout the entire measurement period.

Heavy Weight Cement System for Corrosive Environment: Preventing Strength Retrogression and H2S Corrosion

Well cementing in high temperature and hydrogen sulfide (H2S) corrosive environment presents challenges in preventing cement compressive strength retrogression and selecting weighting agents inert to H2S. This paper presents the development of a cementing system for high pressure high temperature (HPHT) well with bottom hole static temperature in excess of 165°C, a drilling fluid density of 2.19 SG and a high concentration of H2S. A major operator in the Caspian Sea region accepted the cement design and successfully used it on the production liner section of the HPHT well. Cementing of the production liner was complex due to the requirement for a high-density cement system, narrow margin between the pore pressure and frac gradient, HPHT conditions and 18% H2S concentration in the formation fluid. Comprehensive laboratory testing was performed to evaluate the properties of the cement system including measurements of thickening time and compressive strength evaluation using a UCA and destructive method using ultra-HPHT curing chamber for cube sample curing. The presence of H2S limited the use of conventional weighting agents such as hematite and hausmannite, and the high temperature environment dictated the need for quartz silica. These factors required a nonstandard approach to cement blend formulation and flowability assessment. During cement system optimization, the target slurry density was achieved using barite which has a lower density compared to other common weighting agents and significantly reduces cement content in the blend but also is inert to H2S corrosion. A further challenge encountered during cement system optimization was strength retrogression that could not be prevented by the conventional approach of adding 30-40% quartz silica by weight of cement into the system. To overcome strength retrogression, much higher concentrations of silica were required. As a result, the low cement content led to insufficient compressive strength development at liner hanger depth. A solution was found by adding a Vinylamide/Vinylsulfonated polymer (VA/VS) polymer in a certain proportion to the slurry design. Thus, at elevated temperatures, it was observed that the VA/VS polymer tended not to delay compressive strength development while still extending the slurry thickening time. The developed heavy weight cement system was successfully implemented to isolate the 7-in liner on HPHT well. All the stages of job planning, design and execution, along with the slurry optimization process are presented.