Fly-Ash-Based Microbial Self-Healing Cement: A Sustainable Solution for Oil Well Integrity

Abstract

The cement sheath is critical for ensuring the long-term safety and operational efficiency of oil and gas wells. However, complex geological conditions and operational stresses during production can induce cement sheath deterioration and cracking, leading to reduced zonal isolation, diminished hydrocarbon recovery, and elevated operational expenditures. This study investigates the development of a novel microbial self-healing well cement slurry system, employing fly ash as microbial carriers and sustained-release microcapsules encapsulating calcium sources and nutrients. Systematic evaluations were conducted, encompassing microbial viability, cement slurry rheology, fluid loss control, anti-channeling capability, and the mechanical strength, permeability, and microstructural characteristics of set cement stones. Results demonstrated that fly ash outperformed blast furnace slag and nano-silica as a carrier, exhibiting superior microbial loading capacity and viability. Optimal performance was observed with additions of 3% microorganisms and 3% microcapsules to the cement slurry. Microscopic analysis further revealed effective calcium carbonate precipitation within and around micro-pores, indicating a self-healing mechanism. These findings highlight the significant potential of the proposed system to enhance cement sheath integrity through localized self-healing, offering valuable insights for the development of advanced, durable well-cementing materials tailored for challenging downhole environments.