Smart Expandable Polymer Cement Additive to Improve Zonal Isolation

One of the critical issues that might happen in some oil and gas wells is the failure of the cement sheaths and its debonding from the casing string. Cement shrinkage during setting is regarded as one of the main causes behind formation of microannulus cracks. In this paper, a new class of polymer-based expandable additives is presented in the form of fibers to address shrinkage and debonding issues in the subsurface. The proposed fiber additives are made from shape memory polymers. These fibers expand upon exposure to temperatures above certain limits; which is selected to be below the temperature of the cementing zone. In this situation, the expansion occurs before the cement setting but after its placement. If the expansion occurs after cement setting, it may lead to microfractures. As a result of the controlled expansion of the cement paste, the creation of channels and fluid migration can be minimized while maintaining the mechanical properties required for cement integrity. Considering the inert property of the proposed additive, the cement water ratio and its chemical properties do not change. The cement expansion, fluid loss, gel strength, compressive strength, and tensile strength of the samples containing these fibers are examined by destructive and nondestructive methods and presented here. The proposed class of expandable additives can help the operators reach sustainable well integrity by improving the bonding between the cement and casing.