Metakaolin is a supplementary
cementitious material produced through
the calcination of kaolinitic rocks. The scarcity of high-grade and
commercial quantities of kaolinitic-based rocks makes metakaolin expensive.
The objective of this study is to evaluate the feasibility of the
kaolinitic shale obtained from the mud-rich Qusaiba Member of Saudi
Arabia as a source of metakaolin. The rock was dried, ground, and
passed through a 75 μm sieve to obtain a fine powder. The powder
was calcined at 1202, 1292, 1382, 1472, and 1562 °F for 1 h.
The optimum calcination temperature required to convert the material
into metakaolin was found to be 1562 °F using X-ray diffraction,
Fourier transform infrared spectroscopy, and thermogravimetry analysis
techniques. The analytical techniques indicated that the kaolinitic
shale is of high grade and less ordered, which would make it an excellent
source of a highly reactive metakaolin. Cement systems designed at
12.5 ppg (1.50 g/cm
3
) with the metakaolin produced from
the Qusaiba kaolinitic shale as 30% cement replacement exhibits mechanical
properties that would be ideal for downhole oil-wellbore applications.