This research work designed a novel mud-cake solidification method to improve the zonal isolation of oil and gas wells. The calculation methodology of mud-cake compressive strength was proposed. The optimal formula of activator and solid precursors, the proper activating time and the best activator concentration were determined by the compressive strength test. The effects of solid precursors on the properties of drilling fluid were evaluated. Test results show that the respective percentage of bentonite, metakaolin, slag and activator is 1 : 1 : 0.3 : 0.8, as well as the optimum ratio of Na ₂ SiO ₃ /NaOH is 40 : 1. The optimum concentration of activator is 0.21 and the activating time should be more than 10 min. The solid precursors did not show any bad influence on the rheological property of drilling fluids. Even though the compressive strength decreased when the solid precursors blended with barite, the strength values can still achieve 8 MPa. The reaction of metakaolin and activator formed cross-link structure in the mud-cake matrix, which enhanced the connection of the loose bentonite particles, lead to the significant enhancement of shear bonding strength and hydraulic bonding strength. This mud-cake solidification method provides a new approach to improve the quality of zonal isolation.

This study explored the potential of ultrafine kaolin as a geopolymer raw material, focusing on the reactivity of calcined kaolin products and its influencing factors. Through a series of analytical techniques, including thickening experiments, particle size analysis, SEM, XRD, and FT-IR, the effects of calcination temperature, time, and Si-Al ratio were evaluated. The results indicated that calcination temperature significantly impacts reactivity, with optimal conditions found between 600 °C and 800 °C, yielding metakaolin with thickening times of 12 to 43 min. Temperatures above 900 °C led to the formation of low-reactivity phases like mullite. The Si-Al ratio also influenced thickening time, with durations varying from 97 min at 0.85 to 43 min at 0.9 and increasing to 157 min at 0.95. Calcination time had the smallest effect, with thickening times ranging from 10 to 25 min over 4 to 8 h. Additionally, calcination altered particle size, initially expanding due to thermal expansion and later shrinking due to lattice distortion above 700 °C. By adjusting these parameters, the reactivity of calcined kaolin could be tailored to suit specific needs. This research provides a theoretical foundation for metakaolin’s application in construction materials and offers novel insights into geopolymer preparation.

During the process of well cementing in deep water, the cement slurry experiences a wide range of temperature variation from low temperature at seabed to high temperature in downhole. The elevated temperature affects the rheology of cement slurry. The change of rheology of cement slurry could influence the safety of cementing operation. The aim of this paper is to develop a new kind of hydrophobically associating water-soluble polymer (NHAWP) as an additive to prepare a constant rheology oil well cement slurry, which can be used at temperature range from 4°C to 90°C. The acrylamide, 2-acrylamide-2-methylpropionic acid and stearyl methylacrylate were applied to synthesize the NHAWP by the inverse microemulsion polymerization. Test results indicate that the critical association temperature of NHAWP is 45°C. The critical association temperature is independent of NHAWP concentration, salt concentration and alkalinity of solution. When the temperature is below 45°C, NHAWP shows little influence on the viscosity of solution. When the temperature is above 45°C, the NHAWP forms spatial network structure by intermolecular hydrophobic association and thus increases the viscosity of solution significantly. The NHAWP also displays good thermal stability and excellent salt and alkali resistance properties. In addition, the NHAWP shows nearly no negative influence on the basic properties of cement slurry, which indicates that the NHAWP can be used as a constant rheology agent to prepare a cement slurry with constant rheology in the temperature range of 4°C to 90°C.