Slagment as CO2 Resistant

System
 Presentation Outline
• Introduction
• Characteristics of Slagment
• Carbonation
• Sulfate Attack
• Slagment Slurry Designs
• Applications
• Case Histories
• The Way Forward
• The Summary
 Introduction
• BFS
– Glass-
Glass-like nonmetallic calcium
calcium--magnesium silicate-
silicate-
aluminosilicate
– Formed during iron manufacturing process
– When discharged from blast furnace, quickly
quenched with H2O to form granulated glass
– ground to a fineness close to Portland cement’s
cement’s
– consists of Silica (SiO2), Alumina (Al2O3), Magnesia
(MgO) and Calcia (CaO)
– More consistent than Portland cement
– Cheaper than Portland cement
Introduction
 Introduction
Typical Composition:
– CaO: 37.7%
– SiO2: 37%
– Al2O3: 8.4%
– MgO: 10.8%
– Fe2O3: 2.6%
– SO3: 0.1%
– Insolubles: 0.85%
 Introduction
Percent
Constituent 1949a. 1957a. 1968a. 1985a.
Mean Range Mean Range Mean Range Mean Range
Calcium Oxide (CaO) 41 34-48 41 31-47 39 32-44 39 34-43
Silicon Dioxide (SiO2) 36 31-45 36 31-44 36 32-40 36 27-38
Aluminum Oxide (Al2O3) 13 10-17 13 8-18 12 8-20 10 7-12
Magnesium Oxide (MgO) 7 1-15 7 2-16 11 2-19 12 7-15
Iron
0.5 0.1-1.0 0.5 0.2-0.9 0.4 0.2-0.9 0.5 0.2-1.6
(FeO or Fe2O3)
Manganese Oxide
0.8 0.1-1.4 0.8 0.2-2.3 0.5 0.2-2.0 0.44 0.15-0.76
(MnO)
Sulfur
1.5 0.9-2.3 1.6 0.7-2.3 1.4 0.6-2.3 1.4 1.0-1.9
(S)
a. Data source is the National Slag Association data: 1949 (22 sources); 1957 (29 sources); 1968 (30 sources) and 1985 (18
sources).
 Introduction
• BFS Blaine fineness is higher than
Portland cement’s
– ~ 400 – 500 m2/kg for BFS
– ~ 280 – 350 m2/kg for G cement
• Specific Gravity:
– BFS 2.9
– PC 3.2
 Introduction
• BFS blended with Cement to form
Slagment
• Typically Slagment blends:
– 60% : 40% (BFS : Cement)
– Ratios range from (20% : 80%) to (80% : 20%)
 Characteristics of Slagment
• Denser CSH microstructure
• Lower permeability
• Better fluid loss control
• Higher gas migration control
• Higher long
long--term strength/durability
• Lower early strength
• Lower heat of hydration
• Lower water demand
• Higher sulfate resistance
• Higher resistance to carbonation
• More consistent response with lignosulfonate
retarder (R
(R--15LS, R-
R-21LS)
 Characteristics of Slagment
OPC 75% OPC 50% OPC 25% OPC
(Ref.) 25% BFS 50% BFS 75% BFS
Water demand (%)* 26.25 25.25 25.00 26.50
Setting times (min.)
- initial 180 185 210 220
- final 230 255 270 295
Compressive strength (psi)
- at 2 days 3582 2872 1856 899
- at 7 days 5700 5250 4322 3437
- at 28 days 7629 7310 7469 6990
- at 56 days 7977 8224 8644 7847
- at 90 days 8586 8760 9355 8383
Pore size distribution at 28 days*
- total porosity (%) 14 14.4 13.6 13.9
- spec. pore surface (m2/g) 5.1 5.9 7 9.4
- average pore radius (nm) 49 41 30 19
* expressed in % of the OPC
Characteristics of Slagment
Characteristics of Slagment
 Carbonation
• CO2 dissolves in H2O to form carbonic
acid
• C3S and C2S in Portland cement react
with water to form CSH and Ca(OH)2
• Carbonic acid reacts with Ca(OH)2 to
form CaCO3
• Carbonic acid reacts with CSH to form
weak and porous silica gel
• Above reactions reduces pH
Carbonation
 Carbonation
• Casing exposed to hydrating cement
slurry rapidly forms a thin passivity layer
of oxide
• Passivation is state of steel which has
passivity layer of oxide protecting steel
from reaction with oxygen and water
• Reduction in pH destroys “passivation”
on casing
 Carbonation
• End Results:
– Deteriorating strengths of cement
– Higher cement permeability
– Gas migration likelihood increased
– Corroded and pitted casings
– Interzonal communication effected
– Burst or collapsed casings
 Carbonation
• Slagment helps reduce carbonation by:
– Forming denser CSH microstructure
– Reducing cement permeability
– Reducing the formation of Ca(OH)2
– Increasing silica content of cement
– Preventing reduction in pH
 Sulfate Attack
• Sulfates attack Ca(OH)2, CSH and calcium
aluminate hydrate
– Produces weak and expansive gypsum
– Causes disruptive expansion
– Destroys CSH
– Causes cracking
– Causes loss of cohesion
• Severity of Attack:
– <150 ppm Mild
– 150 – 1500 ppm Moderate
– 1500 – 10000 ppm Severe
– >10000 ppm Very Severe
 Sulfate Attack
• Slagment helps reduce sulfate attack by:
– Reducing formation of Ca(OH)2
– Reducing ingress of sulfates into cement
• Dense microstructure
• Low permeability
– Reducing the availability of C3A
• C3A reacts with gypsum to form ettringite,
resulting in disruptive expansion
– Increasing silica content of cement
• Improves strength
 Slagment Slurry Design
• Better strength development when
BFS used with:
– finer cement (Class C)
– High C3A content cement (Class A & C)
• For highest medium-
medium-term strength,
use 50:50 ratio
• For highest long
long--term strength, use
60 to 70% BFS content
 Slagment Slurry Design
• Replace 65% of cement with BFS
– Reduces resultant Ca(OH)2 formed
– BFS hydrates without forming Ca(OH)2
– BFS has ~ 35% silica (22.75% from total cementitious
material)
• Add another 12.25% to get 35% total silica

• Use Class A cement at 35%

• Add BA
BA--100LS to further improve gas
migration control
• Add FL
FL--45LS, FLFL--33LS, FL
FL--63L to
control fluid loss
 Applications
• CO2 presence
– Concentration of 10% - 30% moderate attack
– Concentration of > 30% strong attack
• H2S presence
– Concentration of > 150 ppm
• High temperature
– Geothermal wells
– Silica can be included in the form of BFS, instead of
silica flour
• Reduces permeability while combats strength retrogression
 The Summary
• Slagment is applicable for high CO2 &
H2S content and high temperature
wells
• Slagment has a lot of advantages over
normal cement
• BJ has good track records with
Slagment in APR – Malaysia,
Indonesia, Myanmar, New Zealand