Cement-Formation Debonding Due to Temperature Variation in Geothermal Wells: An Intensive Numerical Simulation Assessment

Geothermal wells are subjected to higher loads compared to conventional oil and gas wells due to the thermal cycles that occur during both production and non-production phases. These temperature variations can affect the cohesion of the cement within the formation and casing, creating micro-annuli channels that can ultimately compromise the integrity of the well. Therefore, this study employs an intensive finite element methodology to analyze the debonding criteria of casing–cement systems in geothermal wells by examining over 36 independent models. The wellbore cooling and heating processes were simulated using three cohesive zone models (CZM): Type I (tensile), Type II (shear), and mixed (Type I and II simultaneously). The analysis revealed that Type I debonding occurs first during cooling at a temperature of around 10 °C, while Type II is the primary failure mode during heating. Evaluations of interfacial bonding shear strength (IBSS) values indicated that the debonding of the cement would even occur at high IBSS values (3 and 4 MPa) at a differential temperature of 300 °C, while the other IBSS of 1 MPa withstands only 60 °C. However, achieving an IBSS of 4 MPa with current technology is highly unlikely. Therefore, geothermal well operation and construction must be modified to keep the differential temperature below the critical temperature at which the debonding of the cement initiates. The study also found that debonding during cooling happens at lower differential temperatures due to generally lower values for interfacial bonding tensile strength (IBTS), typically less than 1 MPa. The novelty of the study is that it provides new insights into how specific temperatures trigger different types of debonding, highlights that high IBSS values may not prevent debonding at high differential temperatures, and recommends operational adjustments to maintain temperatures below critical levels to enhance cement integrity. Additionally, this study reveals that debonding during cooling occurs at a lower differential temperature change due to the reduced value of the interfacial bonding tensile strength (IBTS).