EP2855393A1 - Settable compositions comprising cement kiln dust and rice husk ash and methods of use - Google Patents
Settable compositions comprising cement kiln dust and rice husk ash and methods of useInfo
- Publication number
- EP2855393A1 EP2855393A1 EP13726993.2A EP13726993A EP2855393A1 EP 2855393 A1 EP2855393 A1 EP 2855393A1 EP 13726993 A EP13726993 A EP 13726993A EP 2855393 A1 EP2855393 A1 EP 2855393A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- additive
- composition
- rice husk
- amount
- range
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 239000000203 mixture Substances 0.000 title claims abstract description 133
- 235000007164 Oryza sativa Nutrition 0.000 title claims abstract description 68
- 235000009566 rice Nutrition 0.000 title claims abstract description 68
- 239000010903 husk Substances 0.000 title claims abstract description 67
- 239000004568 cement Substances 0.000 title claims abstract description 61
- 238000000034 method Methods 0.000 title claims abstract description 46
- 239000000428 dust Substances 0.000 title claims abstract description 27
- 240000007594 Oryza sativa Species 0.000 title 1
- 241000209094 Oryza Species 0.000 claims abstract description 67
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 31
- 230000015572 biosynthetic process Effects 0.000 claims abstract description 22
- 239000002956 ash Substances 0.000 claims description 61
- 239000000654 additive Substances 0.000 claims description 49
- 230000000996 additive effect Effects 0.000 claims description 35
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 18
- 239000011396 hydraulic cement Substances 0.000 claims description 16
- 239000011398 Portland cement Substances 0.000 claims description 14
- 239000002245 particle Substances 0.000 claims description 13
- 239000002893 slag Substances 0.000 claims description 11
- 239000010881 fly ash Substances 0.000 claims description 10
- 230000000979 retarding effect Effects 0.000 claims description 10
- -1 shale Substances 0.000 claims description 10
- 230000001066 destructive effect Effects 0.000 claims description 8
- 239000003795 chemical substances by application Substances 0.000 claims description 7
- 239000002270 dispersing agent Substances 0.000 claims description 7
- 235000008733 Citrus aurantifolia Nutrition 0.000 claims description 6
- 235000011941 Tilia x europaea Nutrition 0.000 claims description 6
- 229910021536 Zeolite Inorganic materials 0.000 claims description 6
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims description 6
- 239000004571 lime Substances 0.000 claims description 6
- 230000000246 remedial effect Effects 0.000 claims description 6
- 150000003839 salts Chemical class 0.000 claims description 6
- 239000010457 zeolite Substances 0.000 claims description 6
- 239000004816 latex Substances 0.000 claims description 5
- 229920000126 latex Polymers 0.000 claims description 5
- 239000000463 material Substances 0.000 claims description 5
- 229910002026 crystalline silica Inorganic materials 0.000 claims description 4
- 229920001971 elastomer Polymers 0.000 claims description 4
- 239000000806 elastomer Substances 0.000 claims description 4
- 230000002708 enhancing effect Effects 0.000 claims description 4
- 239000000835 fiber Substances 0.000 claims description 4
- 239000004088 foaming agent Substances 0.000 claims description 4
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 4
- 239000004005 microsphere Substances 0.000 claims description 4
- 239000011347 resin Substances 0.000 claims description 4
- 229920005989 resin Polymers 0.000 claims description 4
- 235000012239 silicon dioxide Nutrition 0.000 claims description 4
- 229910021485 fumed silica Inorganic materials 0.000 claims description 3
- 239000008262 pumice Substances 0.000 claims description 3
- 239000000377 silicon dioxide Substances 0.000 claims description 3
- 230000009974 thixotropic effect Effects 0.000 claims description 2
- 239000004927 clay Substances 0.000 claims 3
- 240000007673 Origanum vulgare Species 0.000 claims 2
- 208000005156 Dehydration Diseases 0.000 claims 1
- 239000002518 antifoaming agent Substances 0.000 claims 1
- 238000005755 formation reaction Methods 0.000 description 16
- 230000008901 benefit Effects 0.000 description 14
- 238000012360 testing method Methods 0.000 description 12
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 7
- 229910052799 carbon Inorganic materials 0.000 description 5
- 239000002699 waste material Substances 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 239000010451 perlite Substances 0.000 description 3
- 235000019362 perlite Nutrition 0.000 description 3
- 239000002253 acid Substances 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- CDBYLPFSWZWCQE-UHFFFAOYSA-L sodium carbonate Substances [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 2
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical class [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 241001508691 Martes zibellina Species 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- UIIMBOGNXHQVGW-DEQYMQKBSA-M Sodium bicarbonate-14C Chemical compound [Na+].O[14C]([O-])=O UIIMBOGNXHQVGW-DEQYMQKBSA-M 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 239000008186 active pharmaceutical agent Substances 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 150000001340 alkali metals Chemical class 0.000 description 1
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 1
- 150000001342 alkaline earth metals Chemical class 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 239000012267 brine Substances 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 235000013339 cereals Nutrition 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 239000002361 compost Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000009837 dry grinding Methods 0.000 description 1
- 238000005367 electrostatic precipitation Methods 0.000 description 1
- 239000003623 enhancer Substances 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000003546 flue gas Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- 239000013505 freshwater Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 239000010440 gypsum Substances 0.000 description 1
- 229910052602 gypsum Inorganic materials 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 229920005610 lignin Polymers 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Chemical class 0.000 description 1
- 230000005012 migration Effects 0.000 description 1
- 238000013508 migration Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 150000007524 organic acids Chemical class 0.000 description 1
- 235000005985 organic acids Nutrition 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000013535 sea water Substances 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- 235000017550 sodium carbonate Nutrition 0.000 description 1
- 235000011121 sodium hydroxide Nutrition 0.000 description 1
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B18/04—Waste materials; Refuse
- C04B18/06—Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
- C04B18/10—Burned or pyrolised refuse
- C04B18/101—Burned rice husks or other burned vegetable material
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B18/04—Waste materials; Refuse
- C04B18/16—Waste materials; Refuse from building or ceramic industry
- C04B18/162—Cement kiln dust; Lime kiln dust
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/04—Portland cements
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B30/00—Compositions for artificial stone, not containing binders
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/42—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
- C09K8/46—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement
- C09K8/467—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement containing additives for specific purposes
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Definitions
- the present " invention relates to cementing operations and, more particularly; in certain embodiments, to methods and compositions that comprise cement kiln dust f'CKD' and rice husk ash.
- sellable compositions are commonly utilized.
- the term "sellable composition * ' refers to a composition(s) that hydraulica!ly sets or otherwise develops compressive strength
- Sellable compositions may be used in primary cementing operations whereby pipe strings, such, as casing and liners, are cemented in well bores.
- a setiabie composition may be pumped into an aonuius between a subterranean formation and the pipe string disposed in the subterranean formation.
- the setiabie composition should set in the annulus, thereby forming an annular sheath of hardened cement ⁇ e.g., a cement sheath) that should support and positio the pipe siring in the well bore and bond the exterior surface of the pipe string to the wails of the well bore.
- Sellable compositions also may be used in remedial cementing methods, such as the placement of cement plugs, and in squeeze cementing tor sealing voids in a pipe string, cement sheath, gravel pack, formation, and the like.
- Setiabie compositions used heretofore commonly comprise Portland cement.
- Portland cement generally is a major component of the cost for the sellable compositions.
- other components may be included in. the setiabie composition in addition to, or in place of, the Portland cement.
- Such components may include fly ash, slag cement, shale, metakaolm, micro-fine cement, and the like.
- Fly ash refers to the residue from the combustion of powdered or ground coal, wherein the fly ash carried by the flue gases may be recovered, for example, by electrostatic precipitation.
- Slag refers to a granulated, blast furnace by-product formed in. the production of east iron and generally comprises the oxidized impurities found in iron ore.
- Slag cement generally comprises slag and a base, for example, such as sodium hydroxide, sodium bicarbonate, sodium carbonate, or lime, to produce a sellable composition that, when combined with water, may set to .form a hardened mass.
- the present invention relates to cementing operations and, more particularly, in certain embodiments,, to methods and compositions that comprise C D and rice husk ash.
- An embodiment provides a method of cementing comprising: placing a settabie composition into a subterranean formation, the settabie composition comprising cement kiln dust, rice husk ash, and water; and allowing the settabie composition to set,
- Another embodiment provides a method of cementing comprising; placing a settabie composition into a subterranean formation, the settabie composition comprising cement kiln dust, rice husk ash, Portland cement, and water; and allowing the settabie compost tion to set.
- Another embodiment provides a method of cementing comprising: placing a settabie composition into a subterranean formation, the settabi composition comprising: cement kiln dust, rice husk ash, and water, wherein the cement kiln dust is present in an amount in a range of from about 50% to about 80% by weight of the cement kiln dust and the riee husk ash, wherein the rice husk ash is present in an amount in a range of from about 20% to about 50% by weight of the cement kiln dust and the rice husk ash, wherein the water is present in an amount in a range of from about 40% to about 200% by weight of the cement kiln dust and the riee husk ash, wherein the settabie coniposiiioii is essentially free of Portland cement; and allowing the settabie composition to set.
- Another embodiment provides a settabie composition
- a settabie composition comprising: cement kiln dust; riee husk ash; and water,
- the present invention relates to cementing operations and, more particularly, in certain embodiments, to methods and compositions thai comprise CKD and rice husk ash.
- methods and compositions thai comprise CKD and rice husk ash.
- One of the many potential advantages of embodiments of the present invention is that inclusion of rice husk ash in sellable compositions comprising C D may improve the mechanical properties of the CRD- containing settable compositions.
- inclusion of rice husk ash may provide increased compressive strength for settable compositions comprising CKD
- Another potential advantage of embodiments of the present invention is that the CKD and/o rice husk ash may be used to reduce the cost of the settable compositions.
- Embodiments of the settable compositions of the present invention may comprise CKD, rice husk ash, and water.
- Other optional additives may also be included in embodiments of the settable compositions as desired, including, but not limited to, unexpanded periite, pumkite, fly ash, slag cement, metakaolin, shale, zeolite, combinations thereof, and the like.
- Embodiments of the settable compositions may also be foamed and/or extended as desired by those of ordinary skill in the art.
- the settable compositions of the present invention should have a density suitable for a particular application as desired by those of ordinary ski!! in the art, with the benefit of this disclosure.
- the settable compositions may have a density in the range of from about 8 pounds per gallon pg") to about 16 ppg. In other embodiments, the settable compositions may be foamed to a densit in the range of from about 8 ppg to about 13 ppg,
- Embodiments of the settable compositions generally may comprise CKD.
- CKD refers to a partially calcined kiln feed which is removed from the gas stream and collected, for example, in a dust collector during the manufacture of cement.
- CKD a partially calcined kiln feed which is removed from the gas stream and collected, for example, in a dust collector during the manufacture of cement.
- large quantities of CKD are collected in the production of cement that re commonly disposed of as waste. Disposal of the waste C .D can add undesirable costs to the manufacture of the cement, as well as the environmental concerns associated with its disposal.
- the chemical analysis of CKD from various cement manufactures varies depending on a number of factors, including the particular kiln feed, the efficiencies of the cement production operation, and the associated dust collection systems.
- CKD generally may comprise a variety of oxides, such as SK3 ⁇ 4, Aivi3 ⁇ 4, Fe 2 C3 ⁇ 4, CaO, gO, S0 3 , a 2 0, and ⁇ , ⁇ .
- the C D generally may exhibit eemenlitious properties, in that it may set and harden in the presence of water.
- the CKD ma be used, among other things, to replace higher cost cemeiitiiious components, such as Portland cement, resulting in more economical settable compositions, in addition, substitution of the CKD for the Portland cement can result in a settable compositio with a reduced carbon footprint.
- the CKD may be included in the settable compositions in an amount sufficient to provide the desired compressive strength, density cost reduction, and/or reduced carbon footprint.
- the CKD may be present in the settable compositions of the present i vention in an. amount in the range of from about 0.1 % to about 99% by weight of cementitioiis components.
- cementitious components include those components or combinations of components of the settable compositions thai hydrau!ically set, or otherwise harden, to develop compressive strength, including, for example, CKD, rice husk ash, unexpended perlite, fly ash, purnicite, slag, lime, shale, and the like.
- the CKD may be present, in certain, embodiments, in an amount ranging between any of and/or includin any of about 0.1%, about i %, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 90%, about 95%, or about 99%. in.
- the CKD may be present in the settable composition in an amount, in the range of from about 5% to about 95% by weight of cementitioiis components, in another embodiment, the CKD may be present in an amount in the range of from about 50 to about 95% by weight of eemeniitious components., in yet another embodiment, the CKD may be present in an amount in the range of from about 50% to about 80% by weight of eemeniitious components.
- One of ordinary skill in the art wit the benefit of this disclosure,. will recognize the appropriate amount of CKD to include for a chosen application.
- Embodiments of the settable compositions generally may comprise rice husk ash.
- rice husk refers to the hard protective coverings of grains of rice that are separated from the rice during production.
- Rice husks are also commonly referred to as rice hulls or rice shells. Large quantitie of rice husks are typically generated during the production of ri ce that are usually disposed of as waste. However, disposal of the rice husks in landfills can be problematic as space in landfills may be limited.
- the rice husks typically contains a substantially amount of silica and when burned ield an ash. referred to herein as "rice husk ash,” which is rich In amorphous silica.
- the ash obtained from combustion of the rice husks may be further processed by dry grinding the ash to a powder form.
- Addition of the rice husk, ash to sellable compositions comprising C D has been shown to provide increases in compressive strength.
- the rice husk ash may be included in CKD-containing settable compositions to increase the compressive strength thereof.
- inclusion of the rice husk ash in a settable compositions comprising CKD may increase the compressive strength in an amount greater than or equal to about 10% in one embodiment, greater than or equal to about 25% in another embodiment, greater than or equal to about 50% in another embodiment, and greater than or equal to about 75% in yet another embodiment, as compared to the same settable composition that does not contain the .latex strength enhancer.
- “compressive strength” is measured at a specified time after the composition has been mixed and the composition is maintained under specified temperature and pressure conditions. For example, compressi ve strength can be measured at a time in the range of about 24 to about 48 hours after the composition is mixed and the composition is maintained at a temperature of 160°P and atmospheric pressure.
- Compressive strength can be measured by either a destructive method or non-destructive method.
- the destructive method physically, tests the strength of settable composition samples at various points in time by crushing the samples in a compression-testing machine.
- the compressive strength is calculated from the failure load divided by the cross-sectional area resisting the load and is reported in units of pound-force per square inch (psi)
- Non-destructive methods typically may employ an Ultrasonic Cement .Analyzer (“OCA”), available from Fann Instrument Company, Houston, TX.
- OCA Ultrasonic Cement .Analyzer
- the rice husk ash may be present in the settable compositions of the present invention in an amount in the range of from about 0.1% to about 99% by weight of cementitioos components.
- the rice husk ash may be present, in certain embodiments, in m amount ranging between any of and/or including any of about 0.1 %, about 1%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%. about 90%, about 95%, or about 99%.
- the rice husk ash may be present in the settable compositions in an amount in the range of from about 5% to about 95% by weight of cementitioos components, in another embodiment, the rice husk; ash ma be present i an amount in the range of from about 5% to about 50% by weight of cementitious components. In yet another embodiment, the rice husk, ash may be present in an amount in the range of from about 20% to about 50% by weight of cementitious components.
- One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of rice husk ash to include for a chosen application.
- the water that may be used in embodiments of the sellable compositions includes, tor example, freshwater, saltwater (e.g., water containing one or more salts dissolved therein), brine (e.g., saturated, saltwater produced from subterranean formations), seawater, or combinations thereof.
- the water may be from any source, provided that the water does not contain an excess of compounds that may undesirably affect other components in the settable composition, in some embodiments, the water may be included in an amount sufficient to form a punipable slurry.
- the water . may be included in the settable composiiions of the present invention in an amount in the range of about 40% to about 200% by weight of cementitious components, in some embodiments, the water may be included in an amount in the range of about 40% to about 150% by weight of cementittous components.
- the appropriate amount of water to include for a chosen, application.. will recognize the appropriate amount of water to include for a chosen, application..
- the settable compositions may further comprise a hydraulic cement
- a hydraulic cement A variety of hydraulic cements may be utilized in accordance with the present invention, including, but not limited to, those comprising calcium, aluminum, silicon, oxygen, iron, and/or sulfur, which set and harden by reaction with water.
- Suitable hydraulic cements include, but are not limited to, Portland cements, pozzolana cements, gypsum cements, high alumina content cements, silica cements, and an combination thereof, in certain embodiments, the hydraulic cement may comprise a Portland cement
- the Portland cements that are suited for use in the present invention are classified as Classes A, C, fi, and G cements according to American Petroleum Institute, . ⁇ / 1 Specification for Materials a/id Testing for Weil Cements, API Specification 10, Fifth Ed., July 1, 1990.
- cements suitable for use in the present invention may include cements classified as ASTM Type 1, 11, or lit.
- embodiments of the settable compositions of the present invention may comprise hydraulic cement in an amount of 0% to about 75%.
- the hydraulic cement may be present, in certain embodiments, in an amount ranging between any of and/or including any of about 1%, about 5%, about 10%, about 15%, about 20%, about 24%, about 25%, about 30%, about 35%, about 40%, about 50%, about 55%, about 60%, about 65%, about 70%, or about 75%.
- the hydraulic cement may be present in an amount in the range of from about 0% to about 20%. . In another embodiment, the hydraulic cement may be present in an amount in the range of from about 0% to about 10%. to yet another embodiment, the sellable compositions may be essentially free of hydraulic cement As used herein, the term "essentially free"' means that hydraulic cement is not present or. to the extent, that, trace amounts of hydraulic cement may be present, is present in an amount less than about 1% b weight of cementitious components. In certain embodiments, the sellable composition may contain hydraulic cement in. an amount less than about 0.1 % by weight of cementitious components and, alternatively, less than about 0.01 % b weight of cementitious components. By way of example, the sellable composition, in certain embodiments, may be free of hydraulic cement, to that the sellable composition contains no hydraulic cement,
- Embodiments of the sellable compositions further may comprise a set retarding additive.
- set retarding additive refers to an additive that retards the setting of the sellable compositions of the present invention.
- suitable set retarding additives include, but are not limited to, ammonium, alkali metals, alkaline earth metals, metal salts of suifoaikyialed lign ns, organic acids (e.g., hydroxycarbox acids), copolymers that comprise acrylic acid or nialeic acid, and combinations thereof.
- a suitable solf alkylated ligniu comprises a sulfomeihy ' la ted lignin.
- Suitable set retarding additives are disclosed in more detail in United States Patent No. Re. 31, 190 » the entire disclosure of which is incorporated herein by reference. Suitable set retarding additives are commercially available from Halliburton Energy Services, Inc. under the trademarks HR* 4, S IR* 5, HR 3 ⁇ 4 7, HR* 12, HR*15, i ! ' 3 ⁇ 45, HR* ' 601, SCR.' * 100, and SCRTM 500 retarders. Generally, where used, the set retarding additive may be included in the sellable compositions of the present invention in an.
- the set retarding additive may be present in the sellable compositions of the present invention an amount in the range of about 0.1% to about 5% by weight of cementitious components.
- the set retarding additive may be present in the sellable compositions of the present invention an amount in the range of about 0.1% to about 5% by weight of cementitious components.
- additives may be added to the sellable compositions of the present invention as deemed appropriate by one skilled in the art, with the benefit of this disclosure.
- additives include, but are not limited to, strength-retrogression additives, set accelerators, weighting agents, lightweight additives, gas-generating additives, mechanical property enhancing additives, lost-circulation materials, filtration-control additives, dispersants, f d- loss-control additives, defbaming agents, foaming agents, oi!-swe!lable particles, water-swei Sable particles, thixotropic additives, and combinations thereof.
- additives include unexpended perlite, punu te, fly ash, slag cement, ' metakaolin, shale, zeolite, crystalline silica, amorphous silica, fumed silica, salts, fibers, hydraiabie clays, microspheres, elastomers, elastomeric particles, resins, latex, combinations ⁇ hereof, and the like.
- a person having ordinary skill in the art, with the benefit of this disclosure, will readily be able to determine the type and amount of additive useful for a particular application and desired result
- the CKD and the rice husk ash may be combined to form a cementitious component
- additional components may also be included in the cementitious component as filler or for other purposes as will be apparent to one of ordinary skill in the art with the benefit of this disclosure.
- the cementitious component further may comprise unexpanded perlite, pumicite, fly ash, slag cement metakaolin, shale, zeolite, or combinations thereof.
- the cementitious component may be placed in a bag or other suitable container for storage and/or delivery to a well site, in an embodiment, the cementitious component may then be combined with water to create a settable composition.
- the components of the settable compositions may be combined in any order as will be appreciated by those of ordinary skill i the art.
- the CKD and rice husk ash may be combined with water to create a settable composition.
- one or more additional components as described above, for example, may also be included in the settable composition.
- the components of the settable composition may be combined using any mixing device compatible with the composition as known to one of ordinary skill in the art, for example a bulk mixer.
- embodiments of the settable compositions may be used in a variety of subterranean applications, including primary and remedial cementing.
- Embodiments of the settable compositions may be introduced into a subterranean formation and allowed to set therein.
- the settable composition may be placed into a space between a subterranean formation and a conduit located in the subterranean formation.
- introducing the settable composition into a subterranean formation includes introduction into an portion of the subterranean formation, including, without limitation, into a well bore drilled into the subterranean formation, into a near well bore region, surrounding the well bore, or into both.
- a settable composition may be introduced into a space outside a conduit (e.g., pipe strings, liners) located in the subterranean formation.
- the conduit may be located in a well bore drilled into the subterranean formation,.
- the settable composition may be allowed to set to form an annular sheath of hardened cement in. the space outside conduit.
- the set settable composition may form a barrier, preventing the migration of fluids in the well bore.
- the set settable composition also .may, for example, support the conduit in the well bore.
- a settable composition may be used, for example, in squeeze-cementing operations or in the placement of cement plugs.
- the settable composition may be placed in a well bore to plug a void or crack in the formation, in a gravel pack, in the conduit, in the cement sheath, and/or a microannulus between the cement sheath and the conduit
- sample settable compositions were prepared and tested to analyse the force resistance properties of settable compositions that comprise CKD and rice husk; ash.
- the sample compositions were allowed to cure in a water bath at I 6(f ' f for 24 hours at ambient pressure.
- crush strengths destructive compressive strengths
- the results of the crush strength tests are set forth in the table below.
- Test Nos. 1 - 10 Ten different tests were conducted, designated Test Nos. 1 - 10, using the indicated amounts of water, CKD, rice husk, ash, hydraied lime, and cement dispersant. The amounts of these components are indicated in the table be!ow with percent by weight ("% by wt") indicating the percent of the component by weight of the cement and rice husk ash. The amount of rice husk ash was varied in an amount ranging from 0% to 50% by weight. Tests 1 and 5 were comparative tests that did not include any rice husk ash. The dispersant used, was CFR-3TM cement friction reducer, from Halliburton Energy Services, Inc., Duncan, Oklahoma.
- the CKD used was supplied by Boieem (US) Inc., from Ada, Oklahoma.
- the rice husk ash used was supplied by Rice!and Foods, inc., Stuttgart,, Arkansas, and had particles ranging from, about 1 micron to about 10 microns.
- compositions and methods arc described in terms of “comprising,” “containing “ or “including” various components or steps, the composition ' s and methods can also “consist essentially of or “consist of the various components and steps,
- ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited.
- any numerical range with a lower limit and an upper limit is disclosed, any number and any included range felling within the range is specifically disclosed. In particular, every range of values (of the form, "from about a.
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- Environmental & Geological Engineering (AREA)
- Inorganic Chemistry (AREA)
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- General Life Sciences & Earth Sciences (AREA)
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Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/479,476 US8327939B2 (en) | 2005-09-09 | 2012-05-24 | Settable compositions comprising cement kiln dust and rice husk ash and methods of use |
PCT/US2013/042311 WO2013177336A1 (en) | 2012-05-24 | 2013-05-22 | Settable compositions comprising cement kiln dust and rice husk ash and methods of use |
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EP2855393A1 true EP2855393A1 (en) | 2015-04-08 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP13726993.2A Withdrawn EP2855393A1 (en) | 2012-05-24 | 2013-05-22 | Settable compositions comprising cement kiln dust and rice husk ash and methods of use |
Country Status (8)
Country | Link |
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EP (1) | EP2855393A1 (en) |
AR (1) | AR091136A1 (en) |
AU (1) | AU2013266319B2 (en) |
CA (1) | CA2861662C (en) |
MX (1) | MX2014010133A (en) |
MY (1) | MY170676A (en) |
NO (1) | NO20140725A1 (en) |
WO (1) | WO2013177336A1 (en) |
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CA3159156A1 (en) * | 2019-11-20 | 2021-05-27 | Suversol International, LLC | Product and method for improving cement performance |
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US8307899B2 (en) * | 2005-09-09 | 2012-11-13 | Halliburton Energy Services, Inc. | Methods of plugging and abandoning a well using compositions comprising cement kiln dust and pumicite |
US8522873B2 (en) * | 2005-09-09 | 2013-09-03 | Halliburton Energy Services, Inc. | Spacer fluids containing cement kiln dust and methods of use |
US7789150B2 (en) * | 2005-09-09 | 2010-09-07 | Halliburton Energy Services Inc. | Latex compositions comprising pozzolan and/or cement kiln dust and methods of use |
-
2013
- 2013-05-22 EP EP13726993.2A patent/EP2855393A1/en not_active Withdrawn
- 2013-05-22 AU AU2013266319A patent/AU2013266319B2/en active Active
- 2013-05-22 MY MYPI2014003234A patent/MY170676A/en unknown
- 2013-05-22 CA CA2861662A patent/CA2861662C/en not_active Expired - Fee Related
- 2013-05-22 MX MX2014010133A patent/MX2014010133A/en unknown
- 2013-05-22 WO PCT/US2013/042311 patent/WO2013177336A1/en active Application Filing
- 2013-05-23 AR ARP130101793 patent/AR091136A1/en unknown
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2014
- 2014-06-10 NO NO20140725A patent/NO20140725A1/en unknown
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See references of WO2013177336A1 * |
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MY170676A (en) | 2019-08-26 |
AR091136A1 (en) | 2015-01-14 |
MX2014010133A (en) | 2014-09-08 |
NO20140725A1 (en) | 2015-02-23 |
CA2861662C (en) | 2018-01-02 |
AU2013266319A1 (en) | 2014-06-19 |
AU2013266319B2 (en) | 2015-07-23 |
WO2013177336A1 (en) | 2013-11-28 |
CA2861662A1 (en) | 2013-11-28 |
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