Voxel-Based Oil Well Cement Modeling for CO2 and H2 Damage Prediction
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Solution Overview
Problem
Cement failure in oil wells due to chemical reactions with CO2 or H2 leads to changes in mechanical properties, causing leakage and increased wellbore repair costs, necessitating improved methods to link chemical reactions to mechanical properties for better cement integration in hydrogen or carbon capture and storage wells.
Innovation Solution
A method involving digital rock physics (DRP) and numerical simulations using digital twins to predict chemo-mechanical changes in cement by characterizing samples, performing micro-CT scans, and exposing them to CO2 and H2, with AI/ML for enhanced speed and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cement is exposed to CO2 or H2 for chemical reactions, then the pore system changes leading to modified mechanical properties, but this causes cement failure and leakage in oil wells
Solution Approach 1:
The patent performs micro-CT scanning and digital twin creation before cement exposure to CO2/H2, establishing a baseline digital model that predicts future chemo-mechanical changes. This preliminary digital characterization allows virtual experimentation without physical damage to the cement sample.
Solution Approach 2:
The patent creates a digital twin copy of the cement sample that replicates its microstructure, composition, and mechanical properties. This digital copy can be exposed to CO2/H2 chemically while the physical sample remains intact, allowing repeated virtual testing without degrading the original cement.
2Measurement precision
If traditional methods are used to study cement properties, then experimental data can be obtained, but the link between chemical reactions and mechanical properties is not sufficiently established
Solution Approach 1:
The patent segments the cement analysis into multiple scales: bulk properties (composition, porosity), microstructure (pore network, crystal orientation), and mechanical properties (strength, stiffness). Each scale is characterized separately using specialized techniques, then integrated through the digital twin framework to establish relationships across scales.
Solution Approach 2:
The patent transitions from traditional single-scale experimental measurement to a multi-dimensional digital representation. The digital twin adds virtual dimensions that allow independent manipulation of chemical composition, microstructure, and mechanical properties, enabling systematic exploration of their relationships without physical constraints.
3Manufacturing precision
If detailed microstructural characterization is performed, then accurate chemo-mechanical predictions can be made, but the process time and computational resources increase
Solution Approach 1:
The patent performs all micro-CT scanning, digital twin creation, and baseline mechanical characterization before the cement exposure experiment. This preliminary digital modeling allows rapid virtual testing during and after exposure, eliminating the need for repeated physical measurement and significantly reducing total characterization time.
Solution Approach 2:
The digital twin serves as a reusable virtual copy that can be queried multiple times with different parameters and conditions without additional physical measurement time. Once created, the digital model can simulate chemo-mechanical behavior under various CO2/H2 exposure scenarios instantly, avoiding repeated time-consuming physical experiments.
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
Provides detailed insights into the link between chemical and mechanical properties of cement, enabling predictive modeling of chemo-mechanical changes, thus improving cement durability and reducing leakage risks in oil wells.
Implementation Method 1
performing a micro-CT scan of the cement sample to generate 2D micro-CT data
Implementation Method 2
Chemical reactions with CO2 or H2 can change the pore system leading to changes in the mechanical properties of cement
Data Source
AI summary
A chemo-mechanical change prediction system includes a characterization module operable to receive characterization information of a cement sample, a digital twin builder operable to receive 2D micro-CT data of a cement sample, the digital twin builder including an aggregator configured construct a 3D digital twin of the cement sample from the 2D micro-CT data and the characterization information. a DRP (digital rock physics) module operable to apply image-based computational techniques to the digital twin to segment various image components thereof into separate label fields for quantitative analysis, and an analyzer configured to determine chemo-mechanical changes in the cement sample due to exposure to carbon dioxide (CO2) and/or hydrogen (H2).