Optimizing Red Mud/Class G Cement Mixture for Lightweight Cement Slurries

ABSTRACT: This study explores the viability of incorporating red mud, an aluminum manufacturing byproduct, into oil well cement production, aiming to enhance sustainability in the oil and gas industry. This comprehensive study employed an array of experimental procedures, constructing cement slurries that combined Saudi Class G cement with red mud in an 85/15 proportion. The intent behind this mixture was to evaluate whether red mud could serve as a sustainable alternative raw material in cement production without compromising quality. To elaborate further, the study's analytical depth involved adjusting the proportions of viscosifiers and fluid loss additives to fine-tune the slurry's characteristics, targeting an optimal balance of viscosity and fluid retention. The goal was to produce a cement slurry with a density of 13.5 pounds per gallon (ppg), which classifies it as a lightweight slurry, often advantageous for shallow casings cementing and cementing across fragile formations. In-depth evaluations were performed to analyze critical aspects of the slurry, namely its rheological behavior, free water content, and thickening time. Initial findings pointed out that when only Class G cement and red mud were used, the resulting material properties did not meet industry expectations. However, upon the strategic addition of viscosifiers and fluid loss additives to the slurry formula, a marked improvement in slurry performance was observed, meeting the stringent standards for oil well cements. These enhancements are significant as they demonstrate the potential role of red mud in creating more eco-friendly cementing solutions that do not sacrifice quality or performance. The research thus puts forward red mud as a credible, sustainable component in oil and gas sector. 1. INTRODUCTION The rising levels of carbon dioxide (CO2), a significant contributor to the Earth's greenhouse effect, are causing widespread concern due to their role in exacerbating global warming and the resulting shifts in climate patterns (Markewitz et al., 2012). This troubling trend has highlighted the urgent need for effective CO2 management strategies to address the growing environmental impact. Consequently, the international community is increasingly focusing on how to best dispose of this potent greenhouse gas (Ahmed Ali et al., 2020; Lal, 2004; Patrinos & Bradley, 2009; Weiss, 2021). The oil and gas industry stands at a crossroads, compelled by environmental concerns and economic imperatives to seek innovative solutions that balance sustainability with operational efficiency (Chernova et al., 2021; Jafarinejad, 2017; Skea, 1992). Cement plays a critical role in oil well construction, providing structural integrity and zonal isolation. However, conventional cement production methods rely heavily on finite natural resources, often resulting in significant environmental impact (Al-Dadi et al., 2014; Chen et al., 2010; Habert, 2014; Mohamad et al., 2022). In this context, the exploration of alternative raw materials becomes imperative to mitigate environmental degradation and enhance resource efficiency (Ali et al., 2023; Fakher et al., 2023; Mahmoud & Elkatatny, 2020).