Using Red Mud to Achieve Sustainable Well Cement with Balanced Performance and Eco-Friendliness

Abstract This study investigates the feasibility of incorporating red mud, a byproduct of aluminum manufacturing, into oil well cement production to promote sustainability in the oil and gas industry. The research involved creating cement slurries by mixing Saudi Class G cement with red mud in an 85/15 ratio. The primary objective was to assess whether red mud could be used as a sustainable alternative raw material in cement production without compromising quality. To achieve this, the study involved fine-tuning the slurry's properties by adjusting the proportions of viscosifiers and fluid loss additives, aiming to balance viscosity and fluid retention effectively. The target was to produce a lightweight cement slurry with a density of 13.5 pounds per gallon (ppg), suitable for shallow casing cementing and fragile formations. Comprehensive evaluations were conducted to assess the slurry's rheological behavior, free water content, and thickening time. Initial results indicated that the properties of the slurry, when composed solely of Class G cement and red mud, did not meet industry standards. However, the strategic addition of viscosifiers and fluid loss additives led to a significant improvement in performance, aligning with the rigorous requirements for oil well cements. These findings highlight the potential of red mud as a sustainable component in cementing solutions for the oil and gas industry, offering an eco-friendly alternative without sacrificing quality or performance. This research positions red mud as a viable, sustainable material for the sector.