Corrosion-Resistant Refractory Binder for Oil Well Cement Sheaths
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Solution Overview
Problem
Cement used in subterranean operations is prone to corrosion and heat degradation, especially in high-temperature environments, leading to premature failure and costly repairs due to reactions with carbonic acid and other corrosive agents, which increases permeability and allows harmful substances to pass through, causing interzonal communication and well casing corrosion.
Innovation Solution
A binder composition comprising high alumina cement, high-alumina refractory aluminosilicate material, and phosphorous material, which forms a corrosion-resistant and heat-stable cement sheath when set, reducing permeability and enhancing compressive strength, suitable for high-temperature applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cement is used in subterranean operations, then the cement sheath provides initial structural support and bonding, but the cement deteriorates due to corrosion from carbonic acid and other corrosive agents, leading to increased permeability and premature failure
Solution Approach 1:
The patent modifies the chemical composition parameters of the cement by incorporating specific corrosion-inhibiting additives and adjusting the cement formulation to resist carbonic acid and other corrosive agents, thereby improving long-term durability without sacrificing initial structural performance
Solution Approach 2:
The patent creates a composite cement material by combining conventional cement with specialized corrosion-resistant additives and modifiers, forming a multi-component system that provides both immediate structural support and long-term corrosion protection in harsh subterranean environments
2Temperature
If high temperature-resistant materials are used to withstand extreme conditions, then heat stability improves, but the complexity of the binder composition increases
Solution Approach 1:
The patent adjusts the chemical composition parameters of the binder to incorporate heat-resistant materials in optimized proportions, achieving high-temperature stability while controlling the complexity of the overall formulation through careful parameter selection and optimization
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The binder composition significantly improves corrosion resistance and heat stability, extending the lifespan of cement sheaths in subterranean formations by forming a durable, low-permeability barrier that withstands extreme conditions, reducing the risk of premature failure and costly repairs.
Implementation Method 1
The binder composition sets in the annular space, thereby forming therein an annular sheath of hardened cement (i.e., a cement sheath) that supports and positions the pipe string in the well bore and bonds the exterior surface of the pipe string to the walls of the well bore
Implementation Method 2
This could increase the permeability of the set cement, which could in turn allow permeation of compounds from a subterranean formation (e.g., chloride and hydrogen sulfide ions) through the cement
Data Source
AI summary
Corrosion-resistant refractory binder compositions may include high alumina cement, high-alumina refractory aluminosilicate material, and phosphorous material. Examples of high-alumina refractory aluminosilicate material include crushed firebrick, firebrick grog, refractory mortar, fire clay, mullite, fused mullite, and combinations thereof. The binder composition may be mixed with sufficient amount of fluid such as water to form a slurry and introduced into a wellbore penetrating a subterranean formation, where it may be allowed to set at a point downhole. Such compositions, once set, may exhibit enhanced corrosion and heat resistance. Such compositions, once set, may additionally be cured. Curing may take place at higher temperatures and/or pressures, and may furthermore increase temperature resistance and/or strength of the set binder composition. In addition, the inclusion of high-alumina refractory aluminosilicate material may provide for enhanced consistency in such binder compositions formulated from different batches of high-alumina refractory aluminosilicate material.