MIT/UMI CIMENTAGE ET LES FUITES DE GAZ: «BOTTOM-UP» CONCEPTS SCIENTIFIQUES / VERROUS ENVIRONNEMENTAUX. Franz-Josef Ulm and Roland Pellenq

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1 1 Gaz et Huiles de Schistes et leur Exploitation: Concepts Fondamentaux et Verrous Technologiques February 14, 2014 CIMENTAGE ET LES FUITES DE GAZ: «BOTTOM-UP» CONCEPTS SCIENTIFIQUES / VERROUS ENVIRONNEMENTAUX MIT/UMI Franz-Josef Ulm and Roland Pellenq (with: MJ. Qomi; M. Bauchy, M. Abuhaikal; K. Krakowiak, C. Hoover; S. Moeini)

2 CEMENTING ~ 160,000 km/year* 2 * In 2007

3 La Problematique Gaz de Schiste 3 2.Cement Liner Casing Debonding, Microannuli creation 4.Long Term durability and Fatigue 1.Fracturing of the Cement Liner due to Thermal Shock 3.Loss of Sealing Properties due to material aging What is the Probability of Failure of Cement Liner? How to improve it? Picture Credits: Schlumberger

4 PROBABILITY DENSITY La Problematique 4 Probability of Failure Some Values Home (30yr): p=10-5 Bridge (75yr): p=10-8 Leakage in Nuclear Plant: p=10-6 /yr LOAD Probability of Failure STRENGTH Shale Gas Leakage: (Marcellus, 2010)*: p~2/100 /yr How much is still a matter of debate 1.9% (Cornell, 2011) to % (UT Austin, PNAS, 2013)

5 MULTISCALE MODELING * Masoero et al., PRL 2012; CSHub@MIT <10 nm 1nm 100nm >100nm clinker Hyd. Prod. Courtesy of Dr. Hegoi Manzano (2011) Atomic scale I.G. Richardson, Cem. Concr. Res., (2004) Meso-scale C-S-H growth, morphology and mechanical properties Micro-scale

6 OUTLINE 6 La Problematique Molecular Scale: Glass Physics Concepts for Calcium-Silica-Hydrates Meso-Scale: Colloidal Physics Macro-Scale: Microporomechanics Conclusions

7 7 MOLECULAR SCALE

8 MOLECULAR RIGIDITY THEORY Rigidity theory * M. Bauchy, R. Pellenq; CSHub@MIT Flexible (floppy) N c < N dof Isostatic N c = N dof Stressed-rigid N c > N dof Application to molecular networks : Bond-Stretching Constraint Bond-Bending Constraint Flexible : Number of constraint per atom n c < 3 (DOF per atom) Stressed-Rigid : n c > 3 Isostatic criterion : n c = 3 Think about Corning Gorilla Glass on your I-Phone

9 Redesigning Cement Hydrates Botton-Up 9 * M. Bauchy, MJ. Qomi, R. Pellenq; CSHub@MIT (E) (G) TERNARY RIGIDITY MAP OF CALCIUM-SILICA-HYDRATES

10 Today 2013 Molecular Fracture Resistance 10 Importing Glass Physics Concepts E.g., Design of Corning s Gorilla Glass (on your I- phone) We employ same molecular design principles for cement. Potential: 20% higher fracture resistance from molecular design. Source: Bauchy, Javad et al. (CSHub@MIT, 2013)

11 11 MESO SCALE

12 COLLOIDAL PHYSICS 12 Setting = Transition from Liquid to Solid ensuring Sealing There is a link between Processing and Microtexture Development Source: Grossier, Masoero, Yip, Pellenq, Van Vliet & Ulm, 2012

13 Mesoscale Simulation Approach 13 * Masoero et al., PRL 2012; CSHub@MIT

14 14 Strength & Stiffness due to Jamming of Colloidal System * Masoero et al., PRL 2012; CSHub@MIT Nanoindentation Results Vandamme & Ulm, PNAS (2009) Packing Density, η

15 15 Tension/Shrinkage due to Jamming of Colloidal System Jamming Provides Strength and Stiffness * Masoero et al., PRL 2012; CSHub@MIT Entails Inter-Particle Tension, thus Shrinkage

16 16 CAN THIS INTER-PARTICLE TENSION-SHRINKAGE BE MEASURED?

17 17 DESIGN PRINCIPLE Test design by Muhannad Abuhaikal/MIT With the support of Schlumberger/Cambridge MA

18 Colloidal Shrinkage Eigenstress* 18 * Ulm et al. (2014) SHRINKAGE UNDER SATURATED CONDITIONS COLLOIDAL EIGENSTRESS UNDER SATURATED CONDITIONS TIME/h

19 19 MACRO SCALE: DOES IT MATTER?

20 Micro-Chemo-Poro-Mechanics 20 Upscaling of meso-scale information to continuum scale * Ulm et al. (2014) Level III Level II Eigenstress Level I

21 Casing-Cement, Cement-Rock, Engineering Borehole Fracture Model 21 * Ulm et al. (2014) Cement Liner p F r σ θθ + p

22 Model Predictions: Pressure + Stress 22 Stress and pressure normalized by formation pressure (p F = 40 MPa)

23 RISK OF FRACTURE Predictions 23 RISK OF DEBONDING INTERFACE TOUGHNESS Interface Toughness from Pull-off Curves (Courtesy Schlumberger)

24 RISK OF FRACTURE Predictions 2 24 RADIAL CRACKING * Moeini & Ulm (2013) Robustness = Fracture Resistance (material) Fracture Potential (load) > 1

25 25 Fracture EARLY AGES Ange-Therese Akono, Pedro Reis, Christian Hoover, FJ. Ulm

26 STRESS INTENSITY / TOUGHNESS Shift of Paradigm: Fracture Design ROBUSTNESS = FRACTURE TOUGHNESS (ξ) STRESS INTENSITY (Σ θθ + p) > 1 Fracture Toughness affected by: - Mix Design, - Curing Conditions, - Al, Si, Doping Principle of Fracture Design HYDRATION DEGREE Stress Intensity affected by: - Formation Pressure, Permeability - Colloidal Shrinkage, Mix Design,

27 GORILLA GLASS CEMENTS To bore-well scale. 27 TEMPERATURE / DEPTH DEPTH FRACTURE RESISTANCE Gas Shale Window Bottom-Up: from atoms to bore hole temperature and pressure conditions for gas shale (T~ C) Potential: x % higher and STABLE fracture resistance = x% lower leaching risk. Source: Krakowiak et al, 2012

28 Why does it matter? 28 CT Scan of cement sheath Before and after thermal cycling (Ph.D. Ali Abawi, 2013 NTNU Trondheim, Norway)

29 29 In Sum; Cementing for gas shale apps = Enabling technology needs Sciences SHIFT OF PARADIGM THROUGH SCIENCE (GLASS & COLLOIDAL PHYSICS) & ENGINEERING (MECHANICS, MATERIALS SCIENCES) ENVIRONMENTAL FOOTPRINT e.g. GAS LEACHING