A Review of Key Challenges and Evaluation of Well Integrity in CO2 Storage: Insights from Texas Potential CCS Fields

Increasing concern over climate change has made Carbon Capture and Storage (CCS) an important tool. Operators use deep geologic reservoirs as a form of favorable geological storage for long-term CO2 sequestration. However, the success of CCS hinges on the integrity of wells penetrating these formations, particularly legacy wells, which often exhibit significant uncertainties regarding cement tops in the annular space between the casing and formation, especially around or below the primary seal. Misalignment of cement plugs with the primary seal increases the risk of CO2 migrating beyond the seal, potentially creating pathways for fluid flow into upper formations, including underground sources of drinking water (USDW). These wells may not be leaking but might fail to meet the legal requirements of some federal and state agencies such as the Environmental Protection Agency (EPA), Railroad Commission of Texas (RRC), California CalGEM, and Pennsylvania DEP. This review evaluates the impact of CO2 exposure on cement and casing integrity including the fluid transport mechanisms, fracture behaviors, and operational stresses such as cyclic loading. Findings revealed that slow fluid circulation and confining pressure, primarily from overburden stress, promote self-sealing through mineral precipitation and elastic crack closure, enhancing well integrity. Sustained casing pressure can be a good indicator of well integrity status. While full-physics models provide accurate leakage prediction, surrogate models offer faster results as risk assessment tools. Comprehensive data collection on wellbore conditions, cement and casing properties, and environmental factors is essential to enhance predictive models, refine risk assessments, and develop effective remediation strategies for the long-term success of CCS projects.