Natural Pozzolanic material and its application in oil

Natural Pozzolanic material and its application in oil well cementing

7-2-2018

Dionysios Kotinis

1

2Imerys Group/ Metallurgy Division

Imerys Group key figures 2016

€4.2 bnRevenue*

17,500Employees

10Technology Centers

€582 mCurrent operating income*

270Operating sites

#1 or #2On most of our markets

14.0%Operating margin*

+50Countries

* 2016 financial data

+ 90 New products in 2016


Imerys offers high value-added functional solutions…

Beneficiated mineral resources (clay, bentonite, diatomite, feldspar, kaolin, mica, moler, wollastonite, etc.)

Formulations (ceramic bodies, continuous casting fluxes for steel, monolithic refractories, etc.)

Synthetic minerals (synthetic graphite, zirconia, etc.)

Developed from high quality assets:

Unique portfolio of mineral resources

Wide range of exclusive technologies and processes

Materials science expertise

Know how and customers’ applications knowledge

The world leader in mineral-based specialties for industry, Imerys delivers high value-added, functional solutions to a

great number of sectors, from processing industries to consumer goods and building products.

The Group draws on its knowledge of applications, scientific expertise and technological know-how to offer solutions

beneficiating its mineral resources, produce synthetic minerals and develop formulations. Imerys thus contributes

essential properties to customers’ products and performance, such as refractoriness, hardness, conductivity, opacity,

durability, purity, lightness, filtration, absorption and repellency. Imerys meets ambitious criteria for responsible

development, regarding social, environmental or corporate governance.


Imerys businesses are leaders in most of their markets

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& Specialties

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& Performance Additives

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Metallurgy Division


Imerys Metallurgy business units

BPI- Bentonite & Perlite Intermediates MA- Metalcasting & Absorbents SCF- Steel Casting Fluxes

Bentonite and Perlite ore and primary

processing Milled and blended bentonite for metal

casting and additional applications

Multi-mineral solutions for steel casting

applications

Iron ore pellets

Oil and gas drilling

Pet litter

Civil engineering

Plasters & Mortars

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Lightweight Pet litter

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solutions

Absorbents Pet litter

Moulding sand binder

Pet litter Civil engineering

Bauxite ore and primary processing

Alumina

Metallurgy Division operates a portfolio of businesses centred around 4 minerals and 1 process enabler and sharing the following

characteristics:

Regional if not global market leadership (not less than #2 when present)

World-class reserves (cost-base & quality) and operations

Mature markets (iron casting, steel, construction, paper)


Imerys Metallurgy global footprint

% of revenue by geographic destination in 2016

Bentonite and Perlite Intermediates (BPI)

Metalcasting & Absorbents (MA)

Steel Casting Fluxes (SCF)

Metallurgy locations by business unit

Revenues 2016 excl. Damolin acquired 1/2017

North America

South America

Asia Pacific

Europe & Middle-East

33%

1%

57%

9%

Confidential Innovation – Metallurgy

Oil Well Cementing (OWC)

OWC is the operation in which a cement slurry is purred through the

inside of the casing, displacing the drilling mud and out into the

annulus to set within 24 hours between the casing and the formation

Cement is used to hold the casing in place and to prevent fluid

migration between subsurface formations

Cement slurry ingredients:

Cement: Specific API cement types are used in oil well cementing

Water

Extenders – either pozzolanic additives or other lightweight additives that

are used to decrease slurry density

Weighing agents – inorganic additives (hematite, barite, etc.) that are used

to increase slurry density

Retarders and accelerators – chemicals or salts that control cement setting

times

Anti-segregating agents – bentonite or other gelling additives

Other chemical additives – fluid loss controllers, dispersants, lost-

circulation agents, etc.

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Oilfield Materials in Cementing

Oilwell cements: 1) Support vertical and radial loads to the casing2) Isolate porous formations3) Seal subsurface fluid streams,4) Protect the casing from corrosion5) Form stability and improve pipe cementlight-weight blends; pozzolanic content; rapid hardening

Additives for Cementing

• Accelerators and salts

• Extenders and density-reducing additives OR Density-

increasing agents

• Silica to reduce or prevent high-temperature strength

retrogression

• Dispersants, Retarders

• Bond improving and expanding agents

• Fluid loss additives

• Antigas migration agents, Antifoam and defoaming agents

• Additives and mixtures to reduce or prevent lost circulation

• Free water control and solid suspending agents

Planning Drilling Cementing Casing -

Completion Stimulation ProductionAbandonme

nt

Photo from BBC


Cement performance in Oil Wells

Cement is used in oilfield applications to provide structural support for the well casing and to prevent migration of fluids

and gas between formations where it could escape to the surface or contaminate surface water. The cement is poured

into the well through the casing and, upon reaching the bottom, is forced out under pressure and up between the

wellbore and the casing, where it is allowed to harden.

Oilwell cement specifications are set forth by the American Petroleum Institute, which designates cement Classes A

through H. Oilwell cement is produced from portland cement but is specifically formulated to seal oil and gas wells

under a variety of conditions, including wide ranges of depth, temperature, and pressure.

Oilfield cement can encounter temperatures ranging from below zero to over 300 degrees Celsius and bottom hole

pressures of more than 2,000 kilograms per square centimeter. Therefore, the cement slurry must be carefully

designed so that it will form a permanent seal under such severe conditions. This cement must also remain fluid for up

to four hours in order to be effective. A variety of cement additives are available, including set accelerators and

retarders, foam control agents, fluid loss controllers, friction reducers, and weighting agents.

Oilfield cements can be used in more specialized applications, such as sealing fractures and channels in oil

formations, in addition to drilling and completion activities. These fractures can cause problems by opening up

channels between injection wells and production wells, causing a drop in pressure and restricted oil flow. In such

applications, cements compete primarily with polymers, which are often used in similar fashion. In addition, cement is

used to plug orphaned and abandoned wells. Plugging of oil and gas wells prevents environmental damage from leaks

and other materials from flowing into the wellbore. Well closure also eliminates safety issues posed by open wells.


Cement extenders in Oil Well Cementing

Types: Most cement extenders used are pozzolanic materials and glass bubbles

Specific Gravity: Cement extenders have specific gravity lower than that of the cement produce lightweight slurries

Consistency: Extended cement slurry has similar consistency to a cement slurry

Water demand: Most extenders also have a high water demand that effectively gives a higher yield and lighter slurry.

Compressive strength: In case of pozzolanic materials they also tend to improve compressive strength over time.

Durability: Pozzolanic materials reduce permeability and minimize attack from formation waters. They can also reduce

the effect of sulfate attack, chloride attack and water absorption

Common pozzolanic materials used in OWC:

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Pozzolan Advantages Disadvantages

Fly Ash Low cost Variations in quality and quantity.

Low water demand

Diatomaceous Earth High water demand Poor pozzolanic activity, Effect on

viscosity

Calcined DE High water demand. Good pozzolanic activity High cost

Silica Fume High water demand. Very good pozzolanic activity Effect on viscosity – stickiness

Metakaolin Very good pozzolanic activity High cost

Cenospheres Very light Variations in quality and quantity

Glass hollow spheres Very light Very high cost ++

Coal residue

can

dramatically

effect slurry

viscosity


Application description: Lightweight cement slurries – use of extenders

Cement slurry need to be carefully designed

in order to move through a narrow window

of densities as to be correctly placed into

the wellbore and not cause fractures

Typically, the cement slurry needs to be

heavier than the mud in order to displace it

but also light enough to not create

hydrostatic pressures higher than the

fracture pressure of the wellbore

In many cementing jobs, especially in

offshore operations in the Golf of Mexico, the

wells exhibit low fracture pressure due to

gas pressure in one of the annuli

Normal weight cement slurries typically

weigh around 15.0 ppg – lower than that the

slurries are called lightweight and higher,

heavyweight

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Mud density

Cement density

A sufficient density reduction could be achieved by increasing the amount of water in the slurry but this leads

to weak formulations that would eventually collapse

For this reason, cementing engineers use materials that are lighter than cement but still contribute to the

strength development of the cement slurry – cement extenders


Oil Well Cementing – Imerys Offerings

ExtenderStrength Retrogression Reduces

Pozzolans -Strength Enhancers

Lightweight Additives

Lost Circulation Controllers

Bentonite

Carbonates

Diatomite

Metakaolin

Mica

Perlite

Silica Flour

Imercrete

Part of the process of preparing a well for further drilling, production or abandonment, cementing a well is the

procedure of developing and pumping cement into place in a wellbore.

Imerys portfolio for oilwell cement additives includes:


ImerCrete

A new, lightweight, natural, super pozzolanic additive of

volcanic glass origin

Effectively reduces the density of oil well cement having a

density of 2,3 kg/m3

Can replace cement in high percentages resulting to a final

mix of high compressive strength

Improves workability, pumpability and durability of your oil

well cement

Has consistent quality and availability

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Imercrete is a cement extender for oil well cementing (OWC) with good pozzolanic activity, that

is lightweight, has high yield and steady supply and quality


ImerCrete™ CSE

A pozzolanic additive that yields a STRONGER cement at a

FASTER rate, while maintaining a LIGHTER density .

IMPROVED EFFICIENCY Obtain higher compressive strength at same

density

Achieve 90% compressive strength in 12 hours

HIGHER STRENGTH ACTIVITY INDEX Maintain compressive strength at a lower

density

50:50

ImerCrete®CSE

50:25:25

Fly Ash +

ImerCrete®CSE

50:50

Fly Ash

Compressive strength of cement slurry with 13.8 ppg

density

ppg : pounds per gallon

(lighter slurries need more weaker and are typically weaker)

Imerys Minerals Arabia LLC

The company finished in July 2017 the construction of a state of the art plant in Rabigh

Industrial City to produce, market and sell a natural pozzolan material aiming to reach

ultimate production of 76,000 MT/year on maturity stage.

Imerys Minerals Arabia is a joint venture company between

the Imerys (70%) and the Saudi company Eastern

Trading & Cont. Co. (30%).

Micrasil

ISO 9001:2015, ISO 14001:2015, OHSAS 18001:2007

Imerys Minerals Arabia : Rabigh Plant

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Challenging climatic conditions due to desert climate Temperature varies by 20 to 25 degrees

Aggressive soil environment (high chlorine content) due to desert conditions

High strength-High performance concrete required in demanding projects (skyscrapers, airports) dictated by the growth strategy and the need to exploit small areas Concrete with compression strength above 100 Mpa

Minimum service life above 100 years!

Use of SCM is critical success factor

Concrete Market needs in Supplementary Cementitious Materials (SCM)

19

07/02/2018Micrasil BP Update 2016

3

What is MICRASIL ?

High activity natural pozzolan for use in high performance concrete

concrete additive that has the same or better performance than the

current offerings in terms of strength and durability

A product based on a natural amorphous aluminosilicate (SiO2+Al2O3

min 85% by mass) milled to a powderous form in order to enhance its

pozzolanic activity (98% of its mass below 45 μm)

Easily dissolvable in high PH like in hydrated cement mixes (e.g.

concrete, fiber cement, cement mortars, cement grouts or slurries)

Usage

Addition in both structural and non-structural Portland cement based

concrete mixtures, to increase strength and/or durability.

Production of high performance concrete, in respect of both high

strength and enhanced durability.

Micrasil & the pozzolanic activity chart

21

®

Micrasil

Key features and technical benefits of Micrasil

22

®

Consistent chemistry, thus consistent performance

Low water demand: (when compared with SF and GGBS)

Comparatively same or better mechanical properties at all ages

Low chloride permeability (improved durability)

Insignificant change in drying shrinkage

Low heat of hydration

Reduced cost by reduction of plasticizer dosage

Compatible with all types of cement, admixtures

and other pozzolanic materials

Locally produced

Light color makes it easy to use it in a coloured

or architectural concrete and mortars

Micrasil

Standards describing the use of Micrasil in cement and concrete

23

®

ASTM C 618: Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for

Use as a Mineral Admixture in Portland Cement Concrete.

BS EN 197-1: Cement – Part 1: Composition, specifications and conformity criteria for

common cements.

ACI 232 – 1R: Guide for use of Raw or Processed Natural Pozzolans in Concrete.

AASHTO M 295: Standard Specification for Coal Fly Ash and Raw or Calcined Natural

Pozzolan for Use as Mineral Admixture in

Portland Cement Concrete.

European Technical Approval according to

EN 206 – 1 by DiBT (Germany).

Micrasil


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Thank you

Documents

Natural Pozzolanic material and its application in oil