WO2014035923A1 - Acid-soluble cement compositions comprising cement kiln dust and methods of use - Google Patents

Acid-soluble cement compositions comprising cement kiln dust and methods of use Download PDF

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Publication number
WO2014035923A1
WO2014035923A1 PCT/US2013/056719 US2013056719W WO2014035923A1 WO 2014035923 A1 WO2014035923 A1 WO 2014035923A1 US 2013056719 W US2013056719 W US 2013056719W WO 2014035923 A1 WO2014035923 A1 WO 2014035923A1
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WIPO (PCT)
Prior art keywords
acid
soluble
cement
composition
additive
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Application number
PCT/US2013/056719
Other languages
French (fr)
Inventor
James Robert Benkley
Darrell Chad Brenneis
Craig Wayne Roddy
Original Assignee
Halliburton Energy Services, Inc.
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Filing date
Publication date
Priority claimed from US13/595,493 external-priority patent/US8950486B2/en
Application filed by Halliburton Energy Services, Inc. filed Critical Halliburton Energy Services, Inc.
Priority to IN1221DEN2015 priority Critical patent/IN2015DN01221A/en
Priority to BR112015004026A priority patent/BR112015004026A2/en
Priority to MX2015002469A priority patent/MX2015002469A/en
Priority to CA 2881910 priority patent/CA2881910A1/en
Priority to AU2013309038A priority patent/AU2013309038B2/en
Priority to EP13833974.2A priority patent/EP2888335A4/en
Publication of WO2014035923A1 publication Critical patent/WO2014035923A1/en

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Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/0092Temporary binders, mortars or concrete, i.e. materials intended to be destroyed or removed after hardening, e.g. by acid dissolution
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions 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
    • C04B28/021Ash cements, e.g. fly ash cements ; Cements based on incineration residues, e.g. alkali-activated slags from waste incineration ; Kiln dust cements
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions 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
    • C04B28/04Portland cements
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/42Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
    • C09K8/46Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement
    • C09K8/467Compositions 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
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Definitions

  • the preseni invention relates to cementing operations and, more particularly, in certain embodiments, to acid-soluble cement compositions that comprise cement kiln dust ( ** CKD”) and associated methods of use.
  • cement compositions may be used in a variety of subterranean applications.
  • a pipe string e.g., easing, liners, expandable tubuiars, etc.
  • the process of cementing the pipe string in place is commonly referred to as "primary cementing/'
  • a cement composition may be pumped into an annuius between the walls of the well bore and the exterio surface of the pipe string disposed therein.
  • the cement composition may set in the annular space, thereby forming an annular sheath of hardened, substantially impermeable cement (i, ,, a cement sheath) that may support and position the pipe string in the well bore and may bond the exterior surface of the pipe string to the subterranean formation, Among other things, the cement sheath surrounding the pipe string functions to prevent the migration of fluids in the annuius, as well as protecting the pipe string from corrosion.
  • Cement compositions also may be used in remedial cementing methods, for example, to sea! cracks o holes in pipe strings or cement sheaths, to seal highly permeable formation zones or fractures, to place a cement plug, and th like. Cement compositions also may be used in surface applications, for example, construction cementing,
  • an acid-soluble cement composition may be desirable in applications where it is anticipated that the hardened cement will be removed in subsequent well bore operations.
  • One particular application includes use of an acid-soluble cement composition to plug permeable zones in a formation that may allow the undesired flow of • fluid into, or from, the well bore.
  • the permeable atones may result in the loss of circulation of fluids, such as a drilling fluid or a cement composition, in the well bore or an undesired influx of gas or water into the well bore.
  • the permeable zones include, for example, vugs, voids, fractures (natural, or otherwise produced) and the like.
  • Other applications for acid-soiuble cement compositions include, for example, the formation of annular plugs and isolation of gravel-packed well bore intervals. Examples of acid-soluble cement compositions include those comprising Sorei cements and Portland cements.
  • the present invention relates to cementing operations and, more particularly, in certain embodiments, to acid-soluble cement compositions that comprise CKD and associated methods of use,
  • An embodiment of the present invention provides a method of cementing comprising: providing an acid-soluble cement composition comprising a kiln dust and water; allowing the acid-soluble cement composition to set to form an acid-soiubie hardened mass; and contacting the acid-soluble hardened mass with an acid.
  • the method of cementing may comprise placing an acid-soluble cement composition in a subterranean formation.
  • the acid-soluble cement composition ma comprise cement kiln dust in an amount of 100% by weight of a total amount of eementitioos components in the acid-soluble cement composition and water.
  • the method further may comprise allowing the acid-sokible cement composition, to set to form an acid-soluble hardened mass.
  • the method further may comprise contacting the acid-soluble hardened mass with an acid.
  • Another embodiment of the present invention provides a method of cementing.
  • the method may comprise placing an acid-soluble cement composition in a subterranean formation.
  • the acid-soluble cement composition may comprise -cement, kiln dust and water, wherein the acid-soiubie cement composition is free of any acid-soluble tillers.
  • the method further may comprise allowing the acid-soluble cement composition to set to form an acid-sol uhle hardened mass.
  • the method further may comprise contacting the acid-soluble hardened mass with an acid.
  • the present invention relates to cementing operations and, more particularly, in certain embodiments, to acid-soluble cement compositions that comprise C D and associated methods of use.
  • One of the many potential advantages of embodiments of the present invention is that the inclusion of the CKD in the acid-soluble cement compositions should reduce the amount of, or potentially eliminate, a higher cost additive, such as Portland or Sorel cement, resulting in a more economical ceme.nl composition.
  • Another potential advantage of embodiments of the present invention is that reduction of the amount of Portland cement should reduce the carbon footprint of the acid-soluble cement compositions.
  • Embodiments of the aeicl-sokibie cement compositions of the present invention may comprise CKD.
  • Additional embodiments of the acid-soluble cement compositions may comprise a hydraulic cement; a component selected from the group consisting of CKD, a. natural pozzolan, and a combination thereof and water.
  • the hydraulic cement may comprise Sorel cement.
  • the cement compositions may further comprise an acid-soluble filler.
  • the cement compositions may comprise CKD and be tree of any acid-soluble fillers.
  • the cement compositions may further comprise a source of calcium ions (e.g., hydraied lime).
  • cement compositions of the present invention may also be included in embodiments of the cement compositions of the present invention as desired, including, but not limited to. .fly ash, slag cement, metakaolin, shale, zeolite, combinations thereof, and the like, Additionally, embodiments of the cement compositions of the present invention may be foamed and/or extended as desired by those of ordinary skill in the art.
  • the acid-soluble cement compositions of the present invention should have a density suitable .for a particular application as desired by those of ordinary skill in the art, with the benefit of this disclosure, in some embodiments, the cement compositions of the present invention may have a density in the range of from about 8 pounds per gallon ("ppg") to about 16 ppg. In other embodiments, the cement compositions ma be foamed to a density in the range of from about 8 ppg to about 1.3 ppg.
  • Embodiments of the acid-soluble cement compositions of the present invention may comprise 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/o sulfur, which set and harden by reaction with water.
  • Suitable hydraulic cements include, but are not limited to, Sore! cements. Portland cements, pozzolana cements, gypsum cements, high alumina content cements, slag cements, silica cements, and combinations thereof.
  • 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, G, and H cements according to American Petroleum institute, API Specification for Materials and Testing for Well Cements, API Specification 10, Fifth Ed, July 1 , 1990.
  • cements suitable for use in the present invention may be classified as AST Type I, 11, or ' 111.
  • acid-soluble fillers can be used with hydraulic cements ⁇ such as Portland cement) thai do harden into an acid-soluble mass.
  • the hydraulic cement generally may be included in the acid- soluble cement compositions in an amount sufficient to provide the desired compressive strength, density, and/or cost, lit accordance with embodiments, at least a portion of the hydraulic cement and potentially eve all of the hydraulic cement, may be replaced with Cf D and/or a natural pozzofan. In an embodiment, at a least a portion of the hydraulic cement i replaced with C D and/or a natural pozzolan. in some embodiments, the hydraulic cement may be present in the cement compositions of the present inventio in an amount in the range of 0% to about 99% b weight of cementitious components.
  • cementitious components refers to the concentration of the particular component by weight of total amount of cementitious components included in the cement composition
  • cementitious components include those components or combinations of components of the cement compositions that hydraulic-ally set, or otherwise harden, to develop compressive strength, including, for example. Sore! cement, Portland cement, CKD, fly ash, pumice, slag, lime, shale, and the like.
  • the cementitious components may comprise the hydraulic cement and any additional cementitious components that may be present in the acid-soluble cement composition.
  • the hydraulic cement may be present, in certain embodiments, in an.
  • the hydraulic cement may be present in an amount in the range of 0% to about 95% by weight of cementitious components, in another embodiment, the hydraulic cement may be present in an amount in the range of about 20% to about 95% by weight of cementitious components. In yet another embodiment, the hydraulic cement may be present in an amount in the range of about 50% to about 90% by weight of cementitious components.
  • An example of a suitable hydraulic cement comprises a Sorel cement
  • Sorel cements typically include magnesia-based cement systems formed from a mixture of magnesium oxide and magnesium chloride.
  • Sorel cement is intended to encompass any of a variety of metal oxides and soluble salts which together form a hydraulic cement, in the presence of water, the metal oxide and the soluble salt forming the Sorel cement should solidify into an acid-soluble mass.
  • Embodiments of the Sorel cements should rapidly develop a desirable compressive strength, in accordance with embodiments, at least a portion of the Sorel cement may be replaced with C D and/or a natural poacsolan. In an embodiment, at a least a portion of the soluble salt is replaced with CKD and/or a natural poxzolan.
  • the Sorel cement comprises a metal oxide.
  • the Sorel cement comprises an alkaline earth metal oxide, such as magnesium, oxide.
  • a suitable metal oxide is THERMATEI LT additive, available from Halliburton Energy Services, inc.
  • the metal oxide present in the Sorel cement should have an activity level sufficient to provide the desired reactivity. For example, the higher the activity level of the metal oxide, the fester the reaction of the metal oxide with the other components of the Sorel cement to -form the hardened mass.
  • the activity level of the metal oxide may vary based on a number of factors. For example, the particle size differential of the metal oxide particles may affect the activity level.
  • a smaller particle size differential may result in a higher activity level due, inter alia, to a greater surface area.
  • Another factor that may affect the activity level of the metal oxide is a sintering process.
  • metal oxide with varying activity levels may be provided.
  • Metal oxide that has not been treated by a sintering process may have a very high activity level, and thus it may be highly reactive in the Sorel cements.
  • a relatively more reactive metal oxide may be desired, such as where it may be desired to have a cement composition with a relatively short set time, for example, whet) desired to rapidly sea! off a permeable zone.
  • a relatively less reactive metal oxide may be desired, for example, where a delay may be desired between mixing the cement composition and the formation of a hardened mass.
  • the Sorel cement comprises an alkaline earth metal chloride, such as magnesium chloride.
  • an alkaline earth metal chloride such as magnesium chloride.
  • An example of a suitable magnesium chloride is C-TEK additive, available .from Halliburton Energy Services, Inc.
  • the Sore! cement comprises magnesium sulfate or ammonium mono or dibasic phosphate.
  • the Sore! cement may comprise the metal oxide and the soluble salt in a metal-oxide-to-soluble-salt ratio of about. 3: 1 to about 1 :3.
  • the metai-oxide-to-aoiuble-sait ratio may range from about 2:1 to about ⁇ :2.
  • the meial ⁇ oxide ⁇ io ⁇ soluble ⁇ saIt ratio may range from about 1.5:1 to about 1 : 1.5,
  • One of ordinary skill in the art will recognize the appropriate ratio of the metal oxide and soluble salt to include for a. particular application.
  • Embodiments of the acid-soluble cement compositions generally may comprise CKD, which is a material generated in the manufacture of cement CKD, as that term is used herein, 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 is a material generated in the manufacture of cement 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 is a material generated in the manufacture of cement CKD
  • CKD is a material generated in the manufacture of cement 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.
  • large quantities of CKD are collected in the production of cement that are commonly disposed of as waste. Disposal of
  • CKD generally may comprise a variety of oxides, such as SiOa, AI 2O3, FejOj, Ca.0, gO, SO3, a ⁇ O. and K?0.
  • oxides such as SiOa, AI 2O3, FejOj, Ca.0, gO, SO3, a ⁇ O. and K?0.
  • CKD Is used herein to mean cement kiln dust made as described above and equivalent forms of cement kiln, dust made in other ways,
  • the CKD generally may exhibit cementitious properties, in that it may set and harden in. the presence of water.
  • the CKD may be used, among other things, to replace higher cost cementitious components, such as Portland cement and/or Sore! cement, resulting in more economical cement compositions, in addition, substitution of the CKD for the Portland and/or Sorel. cement should result in a cement composition with a reduced carbon footprint.
  • the CKD may be included in the acid-soluble cement compositions in an amount sufficient to provide the desired compressive strength, density, cost reduction, and/or reduced carbon footprint.
  • the CK D may be present in the cement compositions of the present invention in an amount in the range of from about 1% to 100% by weight of cementitious components.
  • the CKD may be present in an amount of 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 05%, about 70%, about 75%, about 80%, about 90%, or about 95%.
  • the CKD may be present in an amount in the range of from about 5% to about 99% by weight of eementitious components. In another embodiment, the CKD may be present in an amount in the range of from about 5% to about 80% by weight of eementitious components, in yet another embodiment, the CKD may he present in an amount in the range of from about 50% to about 80% by weight of eementitious components.
  • One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of CKD to include lor a chosen application.
  • embodimen ts of the acid-soluble cement compositions may comprise lime kiln dust, which is a materia! that is generated during the manufacture of lime.
  • lime kiln dust typically refers to a partially calcined kiln feed which can be removed from the gas stream and collected, for example, in a dust collector during the manufacture of lime.
  • Lime kiln dust generally may comprise varying amounts of free Hme and free magnesium, lime stone, and/or doiomitic limestone and a variety of oxides, such as SK A1 2 0 5 , CaO, gO, SO,, Na?Q, and . A and other components, such as chlorides.
  • Embodiments of the acid-soluble cement compositions may further comprise a natural pozzoian.
  • Natural pozzolans are generally present on the Earth's surface and set and harden in the presence of hydrated lime and water.
  • Examples of natural pozxoSans include pumieite, diatomaceous earth, volcanic ash, opaline shale, tuff, and combinations thereof.
  • pumieite is a volcanic rock thai exhibits eementitious properties, in that it may set and harden in the presence of a source of calcium ions and water. Hydrated lime may be used in combination with the pumieite, for example, to provide sufficient calcium tons for the pumieite to set.
  • the natural pozzoian may be used, among other things, to replace higher cost eementitious components, such as Portland or Sorei cement, in embodiments of the sealant compositions, resulting in more economical sealant compositions.
  • substitution of the . natural pozzoian. for the Portland cement and/or Sore! cement should result in a cement composition with a reduced carbon footprint.
  • the natural pozzolan may be included in an amount sufficient to provide the desired compressive strength, density, cost reduction and/or reduced carbon footprint .for a particular application.
  • the natural po zo!an may be present in the acid-soluble cement compositions of the present invention in an amount in the range of from about 1 % to about 100% by weight of eementitious components.
  • the natural pozzolan may be present in an amount of 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%, or about 95%, hi one embodiment, the natural pozxolan may be present in an amount in the range of from about 5% to about 99% by weight of eementitious components, In another embodiment, the natural poxzolan may be present in an amount i the range of from about 5% to about 80% by weight of eementitious components, in yet another embodiment, the natural pozzolan may be present in an amount in the range of from about 10% to about 50% by weight of eementitious components, in yet another embodiment, the natural pozzolan may be present in an amount in the range of from about 25% to about 50% by weight of eementitious components.
  • the natural pozzolan may be present in an amount of from about 25% to about 50% by weight of eementitious components
  • the water that may be used in embodiments of the cement compositions may include, for 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, Generally, the water may be from any source, provided that the wafer does not contain an excess of compounds that may undesirably affect other components in the cement composition. In some embodimen ts, the water may be included in an amount sufficient to form a pumpabie slurry. In some embodiments, the water may be included in the cement compositions of the present invention in an amount in the range of about 40% to about 200% by weight of eementitious components.
  • the water may be included in an amount in the .range of about 40% to about 150% by weight of eementitious components.
  • an amount in the .range of about 40% to about 150% by weight of eementitious components One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of water to include for a chosen application,
  • Embodiments of the cement compositions may further comprise a source of calcium ions, such as lime.
  • the source of calcium ions may included hydrated lime.
  • the source of calcium ions may be included in embodiments of the cement compositions, for example to, form a hydraulic composition with other components of the cement compositions, such as the pumice, fly ash, slag, and/or shale.
  • the lime may be included in the cement compositions in an amount sufficient for a particular application, in some embodiments, the lime may be present in an amount in the range of from, about 1% to about 40% by weight of eementitious components.
  • the lime may be present in an amount of about 5%, about 10%, about 1.5%, about 20%, about 25%, about 30%, or about 35%, In one embodiment, the lime may be present, in an amount in the range of from about 5% to about 20% by weight of eementitious components.
  • the lime may be present, in an amount in the range of from about 5% to about 20% by weight of eementitious components.
  • compositions may further comprise an acid-soluble filler.
  • the acid-soluble filler may be used, for example, in compositions that comprise Portland cement with the acid-soluble filler providing an acid-solubie component so that the compositions can be dissolved and removed.
  • the acid-soluble filler is present in a cement composition comprising a Sore! cement.
  • suitable acid-soluble filler materials that are non-reactive with other components in the compositions, including without limitation dolomite, magnesium carbonate, calcium carbonate, and zinc carbonate.
  • the acid-soluble filler may be present in the acid-soluble cement composition in an amount of from about 0,1% to about 300% by weight of the eementitious component.
  • the acid-soluble filler is present in an amount of from about 50% to about 400% by weight of the eementitious component in an embodiment, the acid- soluble filler is present in an amount of from about 100% to about 300% b weight of the eementitious component, in.
  • the acid-soluble cement compositions may be free of the acid-soluble .filler in that the acid-solubie cement compositions comprises the acid-solubie filler in an amount of about 0% by weight of the eementitious component.
  • Embodiments of the acid-soluble cement compositions may further comprise fly ash,
  • fly ash A variety of fl ashes may be suitable, including fly ash classified as Class C and Class P fly ash according to American Petroleum institute, APS. Specification for Materials and Testing for Well Cements, API Specification 1 , Fifth Ed., July 1 , 1 90.
  • Class C fly ash comprises both silica and lime so thai, when mixed with water, it should set to form a hardened mass.
  • Class V fly ash generally does no contain sufficient lime, so an additional source of calcium ions is required for the Class F fly ash to form a hydraulic composition, hi some embodiments, lime may be mixed with Class F fl ash in an amount in the range of about 0.1% to about.
  • fly ash 25% by weight of t.be fly ash.
  • the lime may be hydrated lime.
  • Suitable examples of fly ash include, but are not limited to., POZMiX* ' A cement additive, commercially available -from Halliburton Energy Services, Inc., Duncan, Oklahoma.
  • the fly ash generally may be included in the acid-soluble cement compositions in an amount sufficient to provide the desired compressive strength, density, and/or cost.
  • the fly ash may be present in the cement compositions of the present invention in an amount in the range of about 5% to about 75% by weight of cemeniitious components.
  • the fly ash may be present in an amount in the range of about 1 % to about 60% by weight of eementitious components.
  • One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of the fly ash to include for a chosen application.
  • Embodiments of the acid-soluble cement, compositions may further comprise a slag cement.
  • a slag cement that may be suitable for use may comprise slag.
  • Slag generally does not contain sufficient basic materia!, so s!ag cement may further comprise a base to produce a hydraulic composition that may react with water to set to form a hardened mass.
  • suitable sources of bases include, but are not limited to, sodium hydroxide, sodium bicarbonate, sodium carbonate, lime, and combinations thereof.
  • the slag cement generally may be included in the acid-soluble cement composition in an amount sufficient to provide the desired compressive strength, density, and/or cost, in some embodiments, the slag cement may be present in the cement, compositions of the present invention in an amount in the range of about 0.1% to about 99% b weight of cemeniitious components, in some embodiments, the slag cement may be present in an amount in the range of about 5% to about 75% by weight of eementitious components.
  • One of ordinary skill in the art. with the benefit of this disclosure * will recognize the appropriate amount of the slag cement to include for a chosen, application.
  • Embodiments of the acid-soluble cement compositions may further comprise metakaolin.
  • metakaolin is a white pozxolan that may be prepared by heating kaolin clay, for example, to temperatures in the range of about 600 Q C to about 800°C.
  • the metakaolin may be present in the cement compositions of the present invention in an amount in the range of about 5% to about 95% by weight of eementitious components, in some embodiments, the metakaolin may be present in an amount in the range of about 10% to about 50% by weight of eementitious components.
  • Embodiments of the acid-soluble cement compositions may further comprise shale.
  • shale included in the cement compositions may react with excess lime to form a suitable, cementing material, for example, calcium silicate hydrate,
  • a variety of shales may be suitable, including those comprising silicon, aluminum, calcium, and/or magnesium.
  • An example of a suitable shale comprises vitri fied shale.
  • vitrified shale include, but are not limited to, PRESSUR-SEAL FINE LCM material and PRESSUR-SEAE COARSE LCM material, which are commercially available from ⁇ Energy Services, Inc., Houston, Texas.
  • the shale may have any particle size distribution as desired for a particular application. In certain embodiments, the shale may have a particle size distribution in the range of about 37 micrometers to about 4,750 micrometers.
  • the shale may be included in the acid-soluble cement compositions of the present invention in. an amount sufficient to provide the desired compressi e strength, density, and/or cost, hi some embodiments, the shale may be present in the cement compositions of the present invention in an amount in the range of about 5% to about 75% by weight of cementitious components, hi some embodiments, the shale may be present in an amount in the range of about 10% to about. 35% by weight of cementitious components.
  • the appropriate amount of the shale to include for a chosen application.
  • Embodiments of the acid-soluble cement compositions ma further comprise zeolite.
  • Zeolites generally are porous a imino-silicate minerals that may be either a natural or synthetic material. Synthetic zeolites are based on the same type of structural cell as natural zeolites, and may comprise alununosi!icate hydrates. As used herein, the term "zeolite” refers to ail natural and synthetic forms of zeolite. Examples of suitable zeolites are described in more detail in U.S. Patent No. 7,445,669, An example of a suitable source of zeolite is available from the C2C Zeolite Corporation o Calgary, Canada.
  • the zeolite may be present in the cement compositions of the present, invention in an amount in the range of about 5% to about 65% by weight of cementitious components. In certain embodiments, the zeolite may be present in an amount in the range of about 10% to about 40% by weight of cementitious components.
  • One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of the zeolite to include for a chosen application.
  • Embodiments of the acid-soluble cement compositions may further comprise a set-retarding additive.
  • set-retarding additive refers to an additive thai retards the setting of the acid-soluble cement compositions of the present invention.
  • suitable set-retarding additives include,, bui are not limited to, ammonium, alkali metals,, alkaline earth metals, metal salts of su!fba!ky Sated lignins, organic acids (e.g., Irydroxyearhoxy acids), copolymers that comprise acrylic acid or maleic acid, and combinations thereof.
  • a suitable sulfoalkylaied Hgnin comprises a sulfomethylated 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 b reference. Suitable set-retarding additives are commercially available from Halliburton Energy Services, Inc. under the trademarks HR*-4, HR* ' -5, IIR*-?, HR*-12, H . ⁇ 15, HR*- 25, fiR ⁇ -601 , SCRTM- 100, and SCRTM-50(> retarders.
  • the set- retarding additive may be included in the cement compositions of the present in vention in an amount sufficient to provide the desired set retardation, in some embodiments, the set- retarding additive may be present in the cement compositions of the present invention an amount in the range of about 0.1% to about 5% by weigh t of cementitious componen ts.
  • the set- retarding additive may be present in the cement compositions of the present invention an amount in the range of about 0.1% to about 5% by weigh t of cementitious componen ts.
  • additives may be added to the acid-soluble cement 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, rneeiianical-property-enhancing additives, lost-circulation materials, filtration-control additives, dispersants, fluid- ioss-control additives, defoaming agents, foaming agents, oil-swellable particles, water-swe.llab.le particles, thixotropie additi ves, and combinations thereof.
  • additi ves include crystalline silica, amorphous silica, fumed silica, salts, fibers, hydratable clays, microspheres, rice husk ash, elastomers, elastomerie particles, resins, latex, combinations thereof, 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 fo a particular application and desired result.
  • the components of the acid-soluble cement compositions may be combined i any order desired to form an acid-soluble cement composition that can be placed into a subterranean formation.
  • the component of the acid-soluble cement compositions may be combined using any mixing device compatible with the composition, including a bulk mixer, for example, in some embodiments, a dry blend may first be formed by dry blending dry components comprising, for example, C .D and/or hydraulic cement. The dry blend may then be combined with water to .form the acid-soluble cement composition.
  • Other suitable techniques may be used for preparation of the aeid-soluble cement compositions as will be appreciated by those of ordinary skill in the art in accordance with embodiments of the present invention.
  • the acid-soluble cement compositions of the present invention may be used in subterranean operations in accordance with embodiments of the present invention.
  • the cement composition may be used to seal off one or more subterranean zones from a well bore; to plug a void or crack in a conduit disposed in the well bore; t plug a void or crack in a cement sheath disposed in the well bore; to plug an opening between the cement sheath and the conduit; to prevent the loss of fluid from the well bore into loss circulation zones such as a void, vug, or fracture; to form an annular plug; to isolate a gravel packed interval of the well bore; or combinaiions thereof.
  • the acid-soluble cement composition may be used to form an acid-soluble barrier (e.g., a plug, a seal, etc.) in a subterranean formation.
  • an acid-soluble barrier e.g., a plug, a seal, etc.
  • the acid-soluble cement composition may be introduced into a well-bore annufus and allowed to set to form an acld-solub!e cement sheath,
  • An example of a method of the present invention comprises placing an acid- soluble cement composition in & subterranean formation, and allowing the acid-soluble cement composition to set in the formation
  • the phrase "placing an acid-soluble cement composition in the subterranean formation” encompasses placement of the eement composition in the well bore and/or placement of the cement composition in rock surrounding the well bore with the well bore penetrating the subterranean formation, among others.
  • the cement composition should form an acid-soluble hardened mas In the subterranean formation.
  • the acid-soluble hardened mass can be left in the subterranean formation permanently or can be removed.
  • Removal of the hardened mass may be desired so that the subterranean formation can be utilized in subsequent hydrocarbon production in accordance with embodiments of the present invention.
  • removal of the hardened mass includes contacting the hardened mass with an aqueous acid composition to at least partially dissolve the hardened mass.
  • the hardened mass may be completed removed, in other embodiments, the hardened mass may be partially removed.
  • the aqueous acid composition may contact the hardened mass to form through openings in the hardened mass to place the subterranean formation in communication with the interior of a pipe string, for example.
  • the aqueous acid composition may include, for example, from about 7.5% to about 28% hydrochloric acid by weight of the composition.
  • the aqueous acid composition includes hydrochloric acid in an amount of about 15% by weight.
  • Another example of a method of the -present invention comprises placing an acid-soluble cement composition in a well-bore annufus (e.g., an atmu!us between a pipe string disposed in a well bore and a wall of the well bore); and allowing the acid soluble cement composition to set.
  • the acid-soluble cement composition may set in the well-bore annulus to form an acid-soluble cement sheath.
  • removal of the hardened mass includes contacting the hardened mass with an aqueous acid composition to at least partially dissolve the hardened mass.
  • the aqueous acid composition may contact the hardened mass to form through openings in the hardened mass to place the subterranean formation in communication with the interior of a pipe string, for example.
  • the aqueous acid composition may be placed into the well bore and allowed to contact the hardened mass through one or more openings in the pipe string.
  • a series of acid-soluble cement compositions was prepared at room temperature and subjected to crush strength and solubility testing. Each of the samples contained sufficient water to provide the density provided in the table below and. comprised various quantities of Class H Portland cement, Holcim CKD, and/or calcium carbonate, as indicated in the table below.
  • Crush Strength ' Testing For the crush strength testing, each sample was poured into a 2-inch cube, allowed to cure in a water bath at 150*F for 48 hours (Samples I - 5) or 72 hours (Samples 6-10), and then crushed. The crush strengths were determined using a Tinius Olson tester in accordance with API Specification 10.
  • Example 3 thus indicates that acid-soluble cement compositions containing from 25% to 100% CKD by weight, from 0% to 75% Portland cement by weight, and from 100% to 300% calcium carbonate by weight may have properties suitable for use in acid- soluble operations.
  • the samples were prepared at room temperature with thickening time tests conducted at I40*F on a portion of each composition in accordance with API Specification 10.
  • the crush strength of Sample 12 was determined by pouring the sample into a 2-inch cube, allowing it to cure in a water bath at 160°F for 72 hours, and then crushing the cured cube.
  • the crush strength was determined using a Tinius Olson tester in accordance with API Speci fication 10. The results of the thickening time and force resistance tests are provided in the table below.
  • Example 2 thus indicates that acid-soluble cement com-positiom containing from 25% to 50% CK.D by weight, from 50% to 75% Portland cement by weight, and 100% calcium carbonate by weight may have properties suitable for use in acid-soluble operations.
  • An additional acid-soluble cement composition was prepared to determine force resistance properties of compositions comprising pumicite.
  • T he composition contained sufficient water to provide the density provided in the table be!ow and comprised Class Portland cement, 200-mesh pumicite, calcium carbonate, a set-retarding additive (HR* «5 retartfer), and hydrated lime, as indicated in the table below.
  • HR* set-retarding additive
  • hydrated lime as indicated in the table below.
  • the composition was poured into a 2-inch cube and cured at 180°F for 24 hours. The acid solubility of the composition was then determined by submerging the cured cube in a 15% by weight hydrochloric acid solution in accordance with the procedure described above in Example 1.
  • the composition was poured into a 2-inch cube, allowed to cure in a water bath for 24 hours at 1 BO'T, and then crushed.
  • the 24-hour crush strength was determined using a Tinius Olson tester in accordance with API Specification 10. The results of the tests are set forth in. the table below. In the following table, percent by weight is based on the weight of the cement and the C D in the samples.
  • Example 3 thus indicates that acid-soluble cement corn-positions containing Portland cement, puniicite, and calcium carbonate may have properties suitable for use in acid-soluble operations.
  • compositions comprising Sore! cement (e.g. f a mixture of magnesium chloride and magnesium oxide), C- .0, and/or pumicite.
  • Sore! cement e.g. f a mixture of magnesium chloride and magnesium oxide
  • C- .0 a mixture of magnesium chloride and magnesium oxide
  • pumicite e.g. f a mixture of magnesium chloride and magnesium oxide
  • Each of the samples contained water, magnesium chloride (C-TEK), magnesium oxide (TH ERM ⁇ . ' 1 LT additive), Ho!cim CKD* - 200-mesh pumicite, and/or hydrated lime, as indicated in the table below.
  • the crush strength of the compositions was determined b pouring each composition into a 2-inch cube, allowing the cube to cure in -a water bath at 140°F for either 24 or 48 hours, and then crushing the cured cube,
  • the crush strengths were determined using a Tinius Olson tester in accordance with API Specification 10. The results of the tests are set. forth in the table below.
  • Example 4 thus indicates that acid-soluble cement compositions containing
  • Example 5 thus indicates that acid-soluble cement compositions having a lightweight and containing Sorel cement and cement kiln dust may have properties suitable for use in acid-soluble operations.
  • Example thus indicates that acid-soiuble cement compositions containing
  • cement and cement kiln dost may have properties suitable for use in acid-soiuble operations.
  • An additional, acid-soluble cement composition was prepared at room. temperature and subjected to crush strength and solubility testing. This sample was prepared to test the Solubility of an acid-soluble cement composition comprising CKD and tree of any acid-soiuble fillers.
  • the sample comprised Holcim CKD (25% bwob), Texas Lehigh Class H Portland cement (.25% bwob), fly ash (POZM.IX* A cement additive, 25% bwob), bentoiiite (2,5% bwob), a set-retarding additive (HR 'fc -800 retarder, 0,4% bwob), a fluid-loss- control additive (HALAD ' *-447.
  • bwob 0.25% bwob
  • a free-wate.r-control additive WG-17 EXP tree- water control agent, 0,2% bwob
  • fresh water 6.2 gal/sk
  • % bwob indicates the percent of the component by weight of a cement blend comprising the CKD, Portland cement, and fly ash.
  • gal/sk indicates gallon per 89.5- pound sack of the cement blend. The sample had a density of 14 pounds per gallon.
  • Crush Strength Testing For the crush strength testing, a portion of the sample was poured into a 2-inch cube and allowed to cure in a water bath at 140°F for 7 days. Alter curing, the sample cubes were placed in an 80°F water bath tor at least 30 minutes and then crushed. The crush strengths were determined using a Tinius Olson tester in accordance with API Specification 10. The determined crush strength was 2,200 psi.
  • Solubilit Testing For the solubility testing, a portion of the sample was poured into a 2-inch cube and allowed to cure in a water bath at !40 Q F for 48 hours. After curing, the sample cubes were placed in an 80°F water bath for at least 30 minutes and then weighed to determine an initial weight. Each sample cube was then submerged in 2,000 milliliters of a 15% by weight hydrochloric acid solution in a 3,000 milliliter beaker at ambient conditions. The sample cube was supported in the acid solution above a magnetic
  • Example 7 thus indicates that acid-soluble cement compositions containing
  • additional acid-soluble filler may have solubility properties suitable for use in acid-soluble operations.
  • An additional acid-soiubie cement composition was prepared at room temperature and subjected to crush strength and solubility testing. This sample was prepared to further test the solubility of an acid-soluble cement composition comprising CKD and free of any acid-soluble fillers.
  • the sample comprised Bolemi CKD (100% bwob), calcium chloride (3% bwob). and fresh water (6,67 gal/sk).
  • the abbreviation "% bwob” indicates the percent of the component by weight of a cement blend consisting of the CKD. ' The sample had a density of 13 pounds per gallon.
  • Crush Strength Testing For the crush strength testing, a portion of the sample was poured, into a 2-inch x. 4-inch cylinder and allowed to cure n a water bath at 17 ⁇ F for 24 hours. After curing, the sample cubes were placed In an 80°F water bath for at least. 30 minutes and then crushed. The crush strengths were determined using a Tinius Olson tester in accordance with API Specification 10. The determined crush strength was 345 psi.
  • Solubility Testing For the solubility testing, a portion of the sample was poured into a 2-inch x 4-inch cylinder and allowed to cure in a water bath at ! 40°F for 24 hours. After curing, the sample cylinders were placed in an 80°F water bath for at least 30 minutes and then weighed to determine an initial weight. Each sample cylinder was then submerged in 2.000 milliliters of a 7,5% by weight hydrochloric acid solution at 140 3 ⁇ 4 F in a 3,000 milliliter beaker. The sample cylinder was supported in the acid solution above a magnetic stir bar. The magnetic stir bar was rotated to create a slight vortex on the surface of die acid solution..
  • Example 8 thus indicates that acid-soluble cement compositions containing CKD and free of an additional acid-soluble filler may have solubility properties suitable lor use in aesd-soJubSe operations,
  • compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of * or “consist of the various components and steps.
  • indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of Che element that it introduces.
  • ranges from any Sower Strait 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 oilier 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 falling within the range are specifically disclosed. In particular, every range of values (of the form, "from about a to about b," or. equivalent! ' -, "from approximately a to b.

Abstract

The present invention relates to acid-soluble cement compositions that comprise cement kiln dust ("CKD") and associated methods of use. An embodiment provides a method of cementing comprising: providing an acid-soluble cement composition comprising a kiln dust and water; allowing the acid-soluble cement composition to set to form an acid-soluble hardened mass; and contacting the acid-soluble hardened mass with an acid.

Description

ACID-SOLUBLE CEMENT COMPOSITIONS COMPRISING CEMENT KILN
OUST AND METHODS OF USE,
BACKGROUND
[0001] The preseni invention relates to cementing operations and, more particularly, in certain embodiments, to acid-soluble cement compositions that comprise cement kiln dust (**CKD") and associated methods of use.
[0002] Cement compositions may be used in a variety of subterranean applications. For example, in subterranean well construction, a pipe string (e.g., easing, liners, expandable tubuiars, etc.) may be run into a well bore and cemented in place. The process of cementing the pipe string in place is commonly referred to as "primary cementing/' In a typical primary cementing method, a cement composition may be pumped into an annuius between the walls of the well bore and the exterio surface of the pipe string disposed therein. The cement composition may set in the annular space, thereby forming an annular sheath of hardened, substantially impermeable cement (i, ,, a cement sheath) that may support and position the pipe string in the well bore and may bond the exterior surface of the pipe string to the subterranean formation, Among other things, the cement sheath surrounding the pipe string functions to prevent the migration of fluids in the annuius, as well as protecting the pipe string from corrosion. Cement compositions also may be used in remedial cementing methods, for example, to sea! cracks o holes in pipe strings or cement sheaths, to seal highly permeable formation zones or fractures, to place a cement plug, and th like. Cement compositions also may be used in surface applications, for example, construction cementing,
[0003] In some applications, it may be desirable for the cement composition to be acid soluble. For instance, an acid-soluble cement composition may be desirable in applications where it is anticipated that the hardened cement will be removed in subsequent well bore operations. One particular application includes use of an acid-soluble cement composition to plug permeable zones in a formation that may allow the undesired flow of fluid into, or from, the well bore. For example, the permeable atones may result in the loss of circulation of fluids, such as a drilling fluid or a cement composition, in the well bore or an undesired influx of gas or water into the well bore. The permeable zones include, for example, vugs, voids, fractures (natural, or otherwise produced) and the like. Other applications for acid-soiuble cement compositions include, for example, the formation of annular plugs and isolation of gravel-packed well bore intervals. Examples of acid-soluble cement compositions include those comprising Sorei cements and Portland cements. SUMMARY
[0004] The present invention relates to cementing operations and, more particularly, in certain embodiments, to acid-soluble cement compositions that comprise CKD and associated methods of use,
[0005] An embodiment of the present invention prov ides a method of cementing comprising: providing an acid-soluble cement composition comprising a kiln dust and water; allowing the acid-soluble cement composition to set to form an acid-soiubie hardened mass; and contacting the acid-soluble hardened mass with an acid.
£0006] Another embodiment of the present invention provides a method cementing. The method of cementing may comprise placing an acid-soluble cement composition in a subterranean formation. The acid-soluble cement composition ma comprise cement kiln dust in an amount of 100% by weight of a total amount of eementitioos components in the acid-soluble cement composition and water. The method further may comprise allowing the acid-sokible cement composition, to set to form an acid-soluble hardened mass. The method further may comprise contacting the acid-soluble hardened mass with an acid.
[0007] Another embodiment of the present invention provides a method of cementing. The method may comprise placing an acid-soluble cement composition in a subterranean formation. The acid-soluble cement composition may comprise -cement, kiln dust and water,, wherein the acid-soiubie cement composition is free of any acid-soluble tillers. The method further may comprise allowing the acid-soluble cement composition to set to form an acid-sol uhle hardened mass. The method further may comprise contacting the acid-soluble hardened mass with an acid.
[0008] The features and advantages, of the present: in vention wil l be readily apparent to those skilled in the art. While numerous changes may be made by those skilled in the art, such changes are within the spirit of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0009] The present invention relates to cementing operations and, more particularly, in certain embodiments, to acid-soluble cement compositions that comprise C D and associated methods of use. There may be several potential advantages to the methods and compositions of the present invention, only some of which may be alluded to herein. One of the many potential advantages of embodiments of the present invention is that the inclusion of the CKD in the acid-soluble cement compositions should reduce the amount of, or potentially eliminate, a higher cost additive, such as Portland or Sorel cement, resulting in a more economical ceme.nl composition. Another potential advantage of embodiments of the present invention is that reduction of the amount of Portland cement should reduce the carbon footprint of the acid-soluble cement compositions.
[0010] Embodiments of the aeicl-sokibie cement compositions of the present invention may comprise CKD. Additional embodiments of the acid-soluble cement compositions may comprise a hydraulic cement; a component selected from the group consisting of CKD, a. natural pozzolan, and a combination thereof and water. In an embodiment, the hydraulic cement ma comprise Sorel cement. In another embodiment, the cement compositions may further comprise an acid-soluble filler. in additional, embodiments, the cement compositions may comprise CKD and be tree of any acid-soluble fillers. In yet another embodiment, the cement compositions may further comprise a source of calcium ions (e.g., hydraied lime).. Other optional additives may also be included in embodiments of the cement compositions of the present invention as desired, including, but not limited to. .fly ash, slag cement, metakaolin, shale, zeolite, combinations thereof, and the like, Additionally, embodiments of the cement compositions of the present invention may be foamed and/or extended as desired by those of ordinary skill in the art.
[00 i 1] The acid-soluble cement compositions of the present invention should have a density suitable .for a particular application as desired by those of ordinary skill in the art, with the benefit of this disclosure, in some embodiments, the cement compositions of the present invention may have a density in the range of from about 8 pounds per gallon ("ppg") to about 16 ppg. In other embodiments, the cement compositions ma be foamed to a density in the range of from about 8 ppg to about 1.3 ppg.
[0012] Embodiments of the acid-soluble cement compositions of the present invention ma comprise 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/o sulfur, which set and harden by reaction with water. Suitable hydraulic cements include, but are not limited to, Sore! cements. Portland cements, pozzolana cements, gypsum cements, high alumina content cements, slag cements, silica cements, and combinations thereof. In certain embodiments, the hydraulic cement may comprise a Portland cement. In some embodiments, the Portland cements that are suited for use in the present invention are classified as Classes A, C, G, and H cements according to American Petroleum institute, API Specification for Materials and Testing for Well Cements, API Specification 10, Fifth Ed, July 1 , 1990. in addition, in some embodiments, cements suitable for use in the present invention may be classified as AST Type I, 11, or '111. As will be discussed in more detail below, acid-soluble fillers can be used with hydraulic cements {such as Portland cement) thai do harden into an acid-soluble mass.
[0013] Where present, the hydraulic cement generally may be included in the acid- soluble cement compositions in an amount sufficient to provide the desired compressive strength, density, and/or cost, lit accordance with embodiments, at least a portion of the hydraulic cement and potentially eve all of the hydraulic cement, may be replaced with Cf D and/or a natural pozzofan. In an embodiment, at a least a portion of the hydraulic cement i replaced with C D and/or a natural pozzolan. in some embodiments, the hydraulic cement may be present in the cement compositions of the present inventio in an amount in the range of 0% to about 99% b weight of cementitious components. As used herein, the term "by weight of cementitious components" refers to the concentration of the particular component by weight of total amount of cementitious components included in the cement composition, Cementitious components include those components or combinations of components of the cement compositions that hydraulic-ally set, or otherwise harden, to develop compressive strength, including, for example. Sore! cement, Portland cement, CKD, fly ash, pumice, slag, lime, shale, and the like. For example, the cementitious components may comprise the hydraulic cement and any additional cementitious components that may be present in the acid-soluble cement composition. The hydraulic cement may be present, in certain embodiments, in an. amount of 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%, or about 95%, in an embodiment, the hydraulic cement may be present in an amount in the range of 0% to about 95% by weight of cementitious components, in another embodiment, the hydraulic cement may be present in an amount in the range of about 20% to about 95% by weight of cementitious components. In yet another embodiment, the hydraulic cement may be present in an amount in the range of about 50% to about 90% by weight of cementitious components. One of ordinary skill in the an, with the benefit of this disclosure, will recognize the appropriate amount of the hydraulic cement to include for a chosen application,
[0014] An example of a suitable hydraulic cement comprises a Sorel cement Sorel cements typically include magnesia-based cement systems formed from a mixture of magnesium oxide and magnesium chloride. However, as used herein, the term "Sorel cement" is intended to encompass any of a variety of metal oxides and soluble salts which together form a hydraulic cement, in the presence of water, the metal oxide and the soluble salt forming the Sorel cement should solidify into an acid-soluble mass. Embodiments of the Sorel cements should rapidly develop a desirable compressive strength, in accordance with embodiments, at least a portion of the Sorel cement may be replaced with C D and/or a natural poacsolan. In an embodiment, at a least a portion of the soluble salt is replaced with CKD and/or a natural poxzolan.
[0015] In an embodiment, the Sorel cement comprises a metal oxide. 'In one particular embodiment, the Sorel cement comprises an alkaline earth metal oxide, such as magnesium, oxide. A suitable metal oxide is THERMATEI LT additive, available from Halliburton Energy Services, inc. The metal oxide present in the Sorel cement should have an activity level sufficient to provide the desired reactivity. For example, the higher the activity level of the metal oxide, the fester the reaction of the metal oxide with the other components of the Sorel cement to -form the hardened mass. The activity level of the metal oxide may vary based on a number of factors. For example, the particle size differential of the metal oxide particles may affect the activity level. A smaller particle size differential may result in a higher activity level due, inter alia, to a greater surface area. Another factor that may affect the activity level of the metal oxide is a sintering process. By varying the heat applied during, and time of. the sintering process, metal oxide with varying activity levels may be provided. Metal oxide that has not been treated by a sintering process may have a very high activity level, and thus it may be highly reactive in the Sorel cements. In an embodiment, a relatively more reactive metal oxide may be desired, such as where it may be desired to have a cement composition with a relatively short set time, for example, whet) desired to rapidly sea! off a permeable zone. In an alternative embodiment, a relatively less reactive metal oxide may be desired, for example, where a delay may be desired between mixing the cement composition and the formation of a hardened mass.
[0016] A wide variety of soluble salts are suitable for use in the Sorel cement, including metal chlorides. .In one embodiment, the Sorel cement comprises an alkaline earth metal chloride, such as magnesium chloride. An example of a suitable magnesium chloride is C-TEK additive, available .from Halliburton Energy Services, Inc. I an alternative embodiment, the Sore! cement comprises magnesium sulfate or ammonium mono or dibasic phosphate.
[0017] In an embodiment, the Sore! cement may comprise the metal oxide and the soluble salt in a metal-oxide-to-soluble-salt ratio of about. 3: 1 to about 1 :3. in another embodiment, the metai-oxide-to-aoiuble-sait ratio may range from about 2:1 to about \ :2. In yet another embodiment, the meial~oxide~io~soluble~saIt ratio may range from about 1.5:1 to about 1 : 1.5, One of ordinary skill in the art will recognize the appropriate ratio of the metal oxide and soluble salt to include for a. particular application.
[001.8] Embodiments of the acid-soluble cement compositions generally may comprise CKD, which is a material generated in the manufacture of cement CKD, as that term is used herein, 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. Usually, large quantities of CKD are collected in the production of cement that are commonly disposed of as waste. Disposal of the CKD as waste 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 SiOa, AI 2O3, FejOj, Ca.0, gO, SO3, a^O. and K?0. The term "CKD" Is used herein to mean cement kiln dust made as described above and equivalent forms of cement kiln, dust made in other ways,
f00l9| The CKD generally may exhibit cementitious properties, in that it may set and harden in. the presence of water. In accordance with embodiments of the present invention, the CKD may be used, among other things, to replace higher cost cementitious components,, such as Portland cement and/or Sore! cement, resulting in more economical cement compositions, in addition, substitution of the CKD for the Portland and/or Sorel. cement should result in a cement composition with a reduced carbon footprint.
[0020] The CKD may be included in the acid-soluble cement compositions in an amount sufficient to provide the desired compressive strength, density, cost reduction, and/or reduced carbon footprint. In some embodiments, the CK D may be present in the cement compositions of the present invention in an amount in the range of from about 1% to 100% by weight of cementitious components. For example, the CKD may be present in an amount of 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 05%, about 70%, about 75%, about 80%, about 90%, or about 95%. hi one embodiment;, the CKD may be present in an amount in the range of from about 5% to about 99% by weight of eementitious components. In another embodiment, the CKD may be present in an amount in the range of from about 5% to about 80% by weight of eementitious components, in yet another embodiment, the CKD may he present in an amount in the range of from about 50% to about 80% by weight of eementitious components. One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of CKD to include lor a chosen application.
[0021 ] While the preceding description describes CKD, the present invention is broad enough to encompass the use of other part ially calcined kiln feeds that may be present in embodiments of the cement compositions of the present invention in an amount in a range of form about 1 % to about i 0% by weight of eementitious components. For example, embodimen ts of the acid-soluble cement compositions may comprise lime kiln dust, which is a materia! that is generated during the manufacture of lime. The term "lime kiln dust" typically refers to a partially calcined kiln feed which can be removed from the gas stream and collected, for example, in a dust collector during the manufacture of lime. The chemical analysis of lime kiln dust from various Hme manufactures varies depending on a number of factors, including the particular limestone or doloniiiic limestone feed, the type of kiln, the mode of operation of the kiln, the efficiencies of the lime production operation, and the associated dust collection systems. Lime kiln dust generally may comprise varying amounts of free Hme and free magnesium, lime stone, and/or doiomitic limestone and a variety of oxides, such as SK A1205, CaO, gO, SO,, Na?Q, and .A and other components, such as chlorides.
[0022] Embodiments of the acid-soluble cement compositions may further comprise a natural pozzoian. Natural pozzolans are generally present on the Earth's surface and set and harden in the presence of hydrated lime and water. Examples of natural pozxoSans include pumieite, diatomaceous earth, volcanic ash, opaline shale, tuff, and combinations thereof. Generally, pumieite is a volcanic rock thai exhibits eementitious properties, in that it may set and harden in the presence of a source of calcium ions and water. Hydrated lime may be used in combination with the pumieite, for example, to provide sufficient calcium tons for the pumieite to set. The natural pozzoian may be used, among other things, to replace higher cost eementitious components, such as Portland or Sorei cement, in embodiments of the sealant compositions, resulting in more economical sealant compositions. In addition, substitution of the . natural pozzoian. for the Portland cement and/or Sore! cement should result in a cement composition with a reduced carbon footprint. [0023 ] Where present, the natural pozzolan may be included in an amount sufficient to provide the desired compressive strength, density, cost reduction and/or reduced carbon footprint .for a particular application. In some embodiments, the natural po zo!an may be present in the acid-soluble cement compositions of the present invention in an amount in the range of from about 1 % to about 100% by weight of eementitious components. For example, the natural pozzolan may be present in an amount of 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%, or about 95%, hi one embodiment, the natural pozxolan may be present in an amount in the range of from about 5% to about 99% by weight of eementitious components, In another embodiment, the natural poxzolan may be present in an amount i the range of from about 5% to about 80% by weight of eementitious components, in yet another embodiment, the natural pozzolan may be present in an amount in the range of from about 10% to about 50% by weight of eementitious components, in yet another embodiment, the natural pozzolan may be present in an amount in the range of from about 25% to about 50% by weight of eementitious components. One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of the natural pozzolan to include for a chosen application.
[0024] The water that may be used in embodiments of the cement compositions may Include, for 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, Generally, the water may be from any source, provided that the wafer does not contain an excess of compounds that may undesirably affect other components in the cement composition. In some embodimen ts, the water may be included in an amount sufficient to form a pumpabie slurry. In some embodiments, the water may be included in the cement compositions of the present invention in an amount in the range of about 40% to about 200% by weight of eementitious components. In some embodiments, the water may be included in an amount in the .range of about 40% to about 150% by weight of eementitious components. One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of water to include for a chosen application,
[00251 Embodiments of the cement compositions may further comprise a source of calcium ions, such as lime. In certain embodiments, the source of calcium ions may includ hydrated lime. The source of calcium ions may be included in embodiments of the cement compositions, for example to, form a hydraulic composition with other components of the cement compositions, such as the pumice, fly ash, slag, and/or shale. Where present, the lime may be included in the cement compositions in an amount sufficient for a particular application, in some embodiments, the lime may be present in an amount in the range of from, about 1% to about 40% by weight of eementitious components. For example, the lime may be present in an amount of about 5%, about 10%, about 1.5%, about 20%, about 25%, about 30%, or about 35%, In one embodiment, the lime may be present, in an amount in the range of from about 5% to about 20% by weight of eementitious components. One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of the lime to include for a chosen application.
[0026] Embodiments of the acid-soluble cement, compositions may further comprise an acid-soluble filler. The acid-soluble filler may be used, for example, in compositions that comprise Portland cement with the acid-soluble filler providing an acid-solubie component so that the compositions can be dissolved and removed. In an embodiment, the acid-soluble filler is present in a cement composition comprising a Sore! cement. Examples of suitable acid-soluble filler materials that are non-reactive with other components in the compositions, including without limitation dolomite, magnesium carbonate, calcium carbonate, and zinc carbonate. Where used, the acid-soluble filler may be present in the acid-soluble cement composition in an amount of from about 0,1% to about 300% by weight of the eementitious component. In an embodiment, the acid-soluble filler is present in an amount of from about 50% to about 400% by weight of the eementitious component in an embodiment, the acid- soluble filler is present in an amount of from about 100% to about 300% b weight of the eementitious component, in. alternative embodiments, the acid-soluble cement compositions may be free of the acid-soluble .filler in that the acid-solubie cement compositions comprises the acid-solubie filler in an amount of about 0% by weight of the eementitious component. One of ordinary skill in the ait, with the benefit of this disclosure, will recognize the appropriate amount of the acid-soluble filler to include for a chosen appl ication,
[0027] Embodiments of the acid-soluble cement compositions ma further comprise fly ash, A variety of fl ashes may be suitable, including fly ash classified as Class C and Class P fly ash according to American Petroleum institute, APS. Specification for Materials and Testing for Well Cements, API Specification 1 , Fifth Ed., July 1 , 1 90. Class C fly ash. comprises both silica and lime so thai, when mixed with water, it should set to form a hardened mass. Class V fly ash generally does no contain sufficient lime, so an additional source of calcium ions is required for the Class F fly ash to form a hydraulic composition, hi some embodiments, lime may be mixed with Class F fl ash in an amount in the range of about 0.1% to about. 25% by weight of t.be fly ash. In some instances, the lime may be hydrated lime. Suitable examples of fly ash include, but are not limited to., POZMiX*' A cement additive, commercially available -from Halliburton Energy Services, Inc., Duncan, Oklahoma.
[0028] Where present, the fly ash generally may be included in the acid-soluble cement compositions in an amount sufficient to provide the desired compressive strength, density, and/or cost. In some embodiments, the fly ash may be present in the cement compositions of the present invention in an amount in the range of about 5% to about 75% by weight of cemeniitious components. In some embodiments, the fly ash may be present in an amount in the range of about 1 % to about 60% by weight of eementitious components. One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of the fly ash to include for a chosen application.
[0029] Embodiments of the acid-soluble cement, compositions ma further comprise a slag cement. In some embodiments, a slag cement that may be suitable for use may comprise slag. Slag generally does not contain sufficient basic materia!, so s!ag cement may further comprise a base to produce a hydraulic composition that may react with water to set to form a hardened mass. Examples of suitable sources of bases include, but are not limited to, sodium hydroxide, sodium bicarbonate, sodium carbonate, lime, and combinations thereof.
[0030] Where present, the slag cement generally may be included in the acid-soluble cement composition in an amount sufficient to provide the desired compressive strength, density, and/or cost, in some embodiments, the slag cement may be present in the cement, compositions of the present invention in an amount in the range of about 0.1% to about 99% b weight of cemeniitious components, in some embodiments, the slag cement may be present in an amount in the range of about 5% to about 75% by weight of eementitious components. One of ordinary skill in the art. with the benefit of this disclosure* will recognize the appropriate amount of the slag cement to include for a chosen, application.
[0031 ] Embodiments of the acid-soluble cement compositions may further comprise metakaolin. Generally, metakaolin is a white pozxolan that may be prepared by heating kaolin clay, for example, to temperatures in the range of about 600QC to about 800°C. in some embodiments, the metakaolin may be present in the cement compositions of the present invention in an amount in the range of about 5% to about 95% by weight of eementitious components, in some embodiments, the metakaolin may be present in an amount in the range of about 10% to about 50% by weight of eementitious components. One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount oft.be metakaolin to include for a chosen application. [0032] Embodiments of the acid-soluble cement compositions may further comprise shale. Among other things, shale included in the cement compositions may react with excess lime to form a suitable, cementing material, for example, calcium silicate hydrate, A variety of shales may be suitable, including those comprising silicon, aluminum, calcium, and/or magnesium. An example of a suitable shale comprises vitri fied shale. Suitable examples of vitrified shale include, but are not limited to, PRESSUR-SEAL FINE LCM material and PRESSUR-SEAE COARSE LCM material, which are commercially available from ΪΧΙ Energy Services, Inc., Houston, Texas. Generally, the shale may have any particle size distribution as desired for a particular application. In certain embodiments, the shale may have a particle size distribution in the range of about 37 micrometers to about 4,750 micrometers.
[0033] Where present, the shale may be included in the acid-soluble cement compositions of the present invention in. an amount sufficient to provide the desired compressi e strength, density, and/or cost, hi some embodiments, the shale may be present in the cement compositions of the present invention in an amount in the range of about 5% to about 75% by weight of cementitious components, hi some embodiments, the shale may be present in an amount in the range of about 10% to about. 35% by weight of cementitious components. One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of the shale to include for a chosen application.
[0034] Embodiments of the acid-soluble cement compositions ma further comprise zeolite. Zeolites generally are porous a imino-silicate minerals that may be either a natural or synthetic material. Synthetic zeolites are based on the same type of structural cell as natural zeolites, and may comprise alununosi!icate hydrates. As used herein, the term "zeolite" refers to ail natural and synthetic forms of zeolite. Examples of suitable zeolites are described in more detail in U.S. Patent No. 7,445,669, An example of a suitable source of zeolite is available from the C2C Zeolite Corporation o Calgary, Canada. In some embodiments, the zeolite may be present in the cement compositions of the present, invention in an amount in the range of about 5% to about 65% by weight of cementitious components. In certain embodiments, the zeolite may be present in an amount in the range of about 10% to about 40% by weight of cementitious components. One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of the zeolite to include for a chosen application.
[0035] Embodiments of the acid-soluble cement compositions may further comprise a set-retarding additive. As used herein, the term "set-retarding additive" refers to an additive thai retards the setting of the acid-soluble cement compositions of the present invention. Examples of suitable set-retarding additives include,, bui are not limited to, ammonium, alkali metals,, alkaline earth metals, metal salts of su!fba!ky Sated lignins, organic acids (e.g., Irydroxyearhoxy acids), copolymers that comprise acrylic acid or maleic acid, and combinations thereof. One example of a suitable sulfoalkylaied Hgnin comprises a sulfomethylated 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 b reference. Suitable set-retarding additives are commercially available from Halliburton Energy Services, Inc. under the trademarks HR*-4, HR*'-5, IIR*-?, HR*-12, H .^15, HR*- 25, fiR^-601 , SCR™- 100, and SCR™-50(> retarders. Generally, where used, the set- retarding additive ma be included in the cement compositions of the present in vention in an amount sufficient to provide the desired set retardation, in some embodiments, the set- retarding additive may be present in the cement compositions of the present invention an amount in the range of about 0.1% to about 5% by weigh t of cementitious componen ts. One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of the set-retarding additive to include for a chosen application.
[0036] Optionally, other additional additives may be added to the acid-soluble cement compositions of the present invention as deemed appropriate by one skilled in the art, with the benefit of this disclosure. Examples of such additives include, but are not limited to, strength-retrogression additives, set accelerators, weighting agents, lightweight additives, gas-generating additives, rneeiianical-property-enhancing additives, lost-circulation materials, filtration-control additives, dispersants, fluid- ioss-control additives, defoaming agents, foaming agents, oil-swellable particles, water-swe.llab.le particles, thixotropie additi ves, and combinations thereof. Specific examples of these, and other, additi ves include crystalline silica, amorphous silica, fumed silica, salts, fibers, hydratable clays, microspheres, rice husk ash, elastomers, elastomerie particles, resins, latex, combinations thereof, 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 fo a particular application and desired result.
[0037] 'The components of the acid-soluble cement compositions may be combined i any order desired to form an acid-soluble cement composition that can be placed into a subterranean formation. in addition, the component of the acid-soluble cement compositions may be combined using any mixing device compatible with the composition, including a bulk mixer, for example, in some embodiments, a dry blend may first be formed by dry blending dry components comprising, for example, C .D and/or hydraulic cement. The dry blend may then be combined with water to .form the acid-soluble cement composition. Other suitable techniques may be used for preparation of the aeid-soluble cement compositions as will be appreciated by those of ordinary skill in the art in accordance with embodiments of the present invention.
[0038] As will be appreciated by those of ordinary skill in the art. the acid-soluble cement compositions of the present invention may be used in subterranean operations in accordance with embodiments of the present invention. Without limitation, the cement composition may be used to seal off one or more subterranean zones from a well bore; to plug a void or crack in a conduit disposed in the well bore; t plug a void or crack in a cement sheath disposed in the well bore; to plug an opening between the cement sheath and the conduit; to prevent the loss of fluid from the well bore into loss circulation zones such as a void, vug, or fracture; to form an annular plug; to isolate a gravel packed interval of the well bore; or combinaiions thereof. In an embodiment, the acid-soluble cement composition may be used to form an acid-soluble barrier (e.g., a plug, a seal, etc.) in a subterranean formation. For example, the acid-soluble cement composition may be introduced into a well-bore annufus and allowed to set to form an acld-solub!e cement sheath,
[0039] An example of a method of the present invention comprises placing an acid- soluble cement composition in & subterranean formation, and allowing the acid-soluble cement composition to set in the formation, it is intended to be understood that the phrase "placing an acid-soluble cement composition in the subterranean formation" encompasses placement of the eement composition in the well bore and/or placement of the cement composition in rock surrounding the well bore with the well bore penetrating the subterranean formation, among others. The cement composition should form an acid-soluble hardened mas In the subterranean formation. The acid-soluble hardened mass can be left in the subterranean formation permanently or can be removed. Removal of the hardened mass may be desired so that the subterranean formation can be utilized in subsequent hydrocarbon production in accordance with embodiments of the present invention. In an embodiment, removal of the hardened mass includes contacting the hardened mass with an aqueous acid composition to at least partially dissolve the hardened mass. in some embodiments, the hardened mass may be completed removed, in other embodiments, the hardened mass may be partially removed. For example, the aqueous acid composition may contact the hardened mass to form through openings in the hardened mass to place the subterranean formation in communication with the interior of a pipe string, for example. The aqueous acid composition may include, for example, from about 7.5% to about 28% hydrochloric acid by weight of the composition. In an embodiment, the aqueous acid composition includes hydrochloric acid in an amount of about 15% by weight. [0040] Another example of a method of the -present invention comprises placing an acid-soluble cement composition in a well-bore annufus (e.g., an atmu!us between a pipe string disposed in a well bore and a wall of the well bore); and allowing the acid soluble cement composition to set. For example, the acid-soluble cement composition may set in the well-bore annulus to form an acid-soluble cement sheath. The acid-soluble cement sheath can be left in the subterranean formation permanently or can be removed- Removal of the hardened mass may be desired so that the subterranean formation can be utilized in subsequent hydrocarbon production in accordance with embodiments of the present invention, in an embodiment, removal of the hardened mass includes contacting the hardened mass with an aqueous acid composition to at least partially dissolve the hardened mass. For example, the aqueous acid composition may contact the hardened mass to form through openings in the hardened mass to place the subterranean formation in communication with the interior of a pipe string, for example. In some embodiment, the aqueous acid composition may be placed into the well bore and allowed to contact the hardened mass through one or more openings in the pipe string.
[00 Ϊ ] To facilitate a better understanding of the present invention, the following examples of certain aspects of some embodiments are given. In no way should the following examples be read to limit, or define, the scope of the invention.
EXAMPLE 1
[0042] A series of acid-soluble cement compositions was prepared at room temperature and subjected to crush strength and solubility testing. Each of the samples contained sufficient water to provide the density provided in the table below and. comprised various quantities of Class H Portland cement, Holcim CKD, and/or calcium carbonate, as indicated in the table below.
[0043] Solubilit Testing: For the solubility testing, each sample was poured into a 2-inch cube and allowed to cure in a water bath at 150°F for either 48 hours (Samples 1-5) or 72 hour (Samples 6-1 ). After curing, the sample cubes are placed in an 80CF water bath for at least 30 minutes and then weighed to determine an initial weight. Each sample cube was then submerged in 2,000 milliliters of a 15% by weight hydrochloric acid solution in a 3,00 milliliter beaker. The sample cube was supported in the acid solution above a magnetic stir bar. The magnetic stir bar was rotated to create a sltsht vortex on the surface of the acid solution. After 30 minutes, the sample cube was removed from the acid solution, and weighed to determine a final weight. The acid solubility of each composition was calculated by the following formula: Acid Solubility ~ (initial Weight - Final Weight) Initial Weight x 100
[0044] Crush Strength 'Testing: For the crush strength testing, each sample was poured into a 2-inch cube, allowed to cure in a water bath at 150*F for 48 hours (Samples I - 5) or 72 hours (Samples 6-10), and then crushed. The crush strengths were determined using a Tinius Olson tester in accordance with API Specification 10.
[0045] The results of the tests are set forth in the table below. lit the following table, percent by weight is based on the weight of the cement and the CKD in the samples.
TABLE 1
Crush Strength Tests:
Cement, CKD, and CaCOh
Figure imgf000016_0001
[0046] Example 3 thus indicates that acid-soluble cement compositions containing from 25% to 100% CKD by weight, from 0% to 75% Portland cement by weight, and from 100% to 300% calcium carbonate by weight may have properties suitable for use in acid- soluble operations.
EXAMPLE 2
[0047] An additional series of acid-soluble cement compositions was prepared and subjected to thickening time, force resistance, and rheologiea.1 tests. Each of the samples contained sufficient water to provide the density provided in the table below and comprised various quantities of Class H Portland cement, Holcim CKD, calcium carbonate, a dispersam (CFR "-3 cement, friction reducer), and/or a set-retarding additive, a indicated in the table below, in. the following tables, percent by weight is based on the weight of the cement and the CKD in the samples.
[0048] The samples were prepared at room temperature with thickening time tests conducted at I40*F on a portion of each composition in accordance with API Specification 10. The crush strength of Sample 12 was determined by pouring the sample into a 2-inch cube, allowing it to cure in a water bath at 160°F for 72 hours, and then crushing the cured cube. The crush strength was determined using a Tinius Olson tester in accordance with API Speci fication 10. The results of the thickening time and force resistance tests are provided in the table below.
TABLE 2
Thickening Time Tests:
Cement, CKD, and CaCG3
Figure imgf000017_0001
[0049] For the rheologieal tests, additional portions of the acid-soluble' cement compositions were conditioned in an atmospheric consistometer to the test temperature. After conditioning, the rheology of the compositions was determined using a Fann Mode! 35 viscometer at the temperature indicated in the table below using a bob nd sleeve and spring #1 in accordance with the procedure set forth in API Specification 10. The results of the rheologieal tests are set forth in the table below, in the following table, percent by weight is based on the weight of the cement and the CKD In the samples. TABLE 3
Rhco!ogicai Tests:
Figure imgf000018_0001
[0050] Example 2 thus indicates that acid-soluble cement com-positiom containing from 25% to 50% CK.D by weight, from 50% to 75% Portland cement by weight, and 100% calcium carbonate by weight may have properties suitable for use in acid-soluble operations.
EXAMPLE 3
[0051] An additional acid-soluble cement composition was prepared to determine force resistance properties of compositions comprising pumicite. T he composition contained sufficient water to provide the density provided in the table be!ow and comprised Class Portland cement, 200-mesh pumicite, calcium carbonate, a set-retarding additive (HR*«5 retartfer), and hydrated lime, as indicated in the table below. For the acid solubility testing, the composition was poured into a 2-inch cube and cured at 180°F for 24 hours. The acid solubility of the composition was then determined by submerging the cured cube in a 15% by weight hydrochloric acid solution in accordance with the procedure described above in Example 1. For the crush strength testing, the composition was poured into a 2-inch cube, allowed to cure in a water bath for 24 hours at 1 BO'T, and then crushed. The 24-hour crush strength was determined using a Tinius Olson tester in accordance with API Specification 10. The results of the tests are set forth in. the table below. In the following table, percent by weight is based on the weight of the cement and the C D in the samples.
TABLE 4
Crush Strength Tests: Cement, Ptimieite, and CaCOj
Figure imgf000020_0001
[0052] Example 3 thus indicates that acid-soluble cement corn-positions containing Portland cement, puniicite, and calcium carbonate may have properties suitable for use in acid-soluble operations.
EXAMPLE 4
[0053] An additional serie of acid-soluble cement compositions was prepared at room iemperatore to determine force resistance properties of compositions comprising Sore! cement (e.g.f a mixture of magnesium chloride and magnesium oxide), C- .0, and/or pumicite. Each of the samples contained water, magnesium chloride (C-TEK), magnesium oxide (TH ERM ΑΤΕΚ.' 1 LT additive), Ho!cim CKD* - 200-mesh pumicite, and/or hydrated lime, as indicated in the table below. The crush strength of the compositions was determined b pouring each composition into a 2-inch cube, allowing the cube to cure in -a water bath at 140°F for either 24 or 48 hours, and then crushing the cured cube, The crush strengths were determined using a Tinius Olson tester in accordance with API Specification 10. The results of the tests are set. forth in the table below.
TABLE 5
Crush t SSttrreennggtthh * T'. ests:
Sore! Cement, CKD, and/or Pumicite
Figure imgf000021_0001
[0054] Example 4 thus indicates that acid-soluble cement compositions containing
Sore! cement, cement kiln dust, .and/or pumicite may have propertie -suitable tor use i acid- soluble operations. EXAMPLE 5
[0055] An additional series of acid-soluble cement compositions was prepared at room temperature to determine force resistance properties of. lightweight compositions comprising Sorel cement (e.g., a mixture of magnesium chloride and magnesium oxide) and CKD. Each, of the samples contained water, magnesium chloride (C-TB additive), magnesium oxide (THERMATEK'*' LT additive), Holcim CKD, a set-retarding additive (R- TE . inhibitor), and glass bubbles (HGS 2000 glass bobbies}, as indicated in the tabic below, he crush strength of the compositions was determined by pouring each composition into a 2- inch cube, allowing the cube to cure in a water bath at I40°F for 24 hours, and then crushing the cured cube. The crash strengths were determined using a Tinkts Olson tester in accordance with API Specification 10. The results of the tests are set forth in the table below.
TABLE 6
Crush Strength Tests:
Sorel Cement and CKD
Figure imgf000022_0001
[0056] Example 5 thus indicates that acid-soluble cement compositions having a lightweight and containing Sorel cement and cement kiln dust may have properties suitable for use in acid-soluble operations.
EXAMPLE 6
[0057] An additional series of acid-soluble cement compositions was prepared at room, temperature and subjected to thickening time tests at 140°F in accordance with API Specification 10. Each of the samples contained water, magnesium chloride (C-TEK additive), magnesium oxide (THERM ATEK"' LT additive), Holcim CKD, and a retarder (R- TEK. inhibitor) as indicated in the table below. The results of the tests are set forth in the table below.
2 i TABLE 7
Thickening Time Tests:
Sorei Cement and€'$£ϊ>
Figure imgf000023_0001
[0058] Example thus indicates that acid-soiuble cement compositions containing
Sore! cement and cement kiln dost may have properties suitable for use in acid-soiuble operations.
EXAMPLE 7
[0059] An additional, acid-soluble cement composition was prepared at room. temperature and subjected to crush strength and solubility testing. This sample was prepared to test the Solubility of an acid-soluble cement composition comprising CKD and tree of any acid-soiuble fillers. The sample comprised Holcim CKD (25% bwob), Texas Lehigh Class H Portland cement (.25% bwob), fly ash (POZM.IX* A cement additive, 25% bwob), bentoiiite (2,5% bwob), a set-retarding additive (HR'fc-800 retarder, 0,4% bwob), a fluid-loss- control additive (HALAD'*-447. 0.25% bwob), a free-wate.r-control additive (WG-17 EXP tree- water control agent, 0,2% bwob), and fresh water ( 6.2 gal/sk). The abbreviation "% bwob" indicates the percent of the component by weight of a cement blend comprising the CKD, Portland cement, and fly ash. The abbreviation "gal/sk" indicates gallon per 89.5- pound sack of the cement blend. The sample had a density of 14 pounds per gallon.
[0060] Crush Strength Testing: For the crush strength testing, a portion of the sample was poured into a 2-inch cube and allowed to cure in a water bath at 140°F for 7 days. Alter curing, the sample cubes were placed in an 80°F water bath tor at least 30 minutes and then crushed. The crush strengths were determined using a Tinius Olson tester in accordance with API Specification 10. The determined crush strength was 2,200 psi.
[0061 ] Solubilit Testing: For the solubility testing, a portion of the sample was poured into a 2-inch cube and allowed to cure in a water bath at !40QF for 48 hours. After curing, the sample cubes were placed in an 80°F water bath for at least 30 minutes and then weighed to determine an initial weight. Each sample cube was then submerged in 2,000 milliliters of a 15% by weight hydrochloric acid solution in a 3,000 milliliter beaker at ambient conditions. The sample cube was supported in the acid solution above a magnetic
77 stir bar. The magnetic stir bar was rotated to create a slight vortex on the surface of the acid solution. At specified intervals, the sample cube was removed from the acid solution and weighed to determine an interval weight. Weight loss of the cube was determined by subtracting the interval weight from the initial weight. The sample cube was then returned to the acid solution. The acid solubility of each composition was calculated by the following formula;
Acid Solubility - Weight Loss / initial Weight χ ! 00
After 2 hours, the testing was completed. The results of the solubility testing are set forth in the table below.
TABLE 8
Acid-Solubility Tests:
25% C D, 50% Cement, and 25% Fly Ash in 15% HCL
Figure imgf000024_0001
[0062] The solubility testing was repeated using a 7.5% by weight hydrochloric acid solution. The results of this test are set forth below.
TABLE 9
Acid-SoluMlity Tests:
25% CKD, 50% Cement, and 25% Fly Ash in 7,5% HCL
Figure imgf000025_0001
[0063] Example 7 thus indicates that acid-soluble cement compositions containing
CKD and free of an. additional acid-soluble filler may have solubility properties suitable for use in acid-soluble operations.
EXAMPLE 8
[0064] An additional acid-soiubie cement composition was prepared at room temperature and subjected to crush strength and solubility testing. This sample was prepared to further test the solubility of an acid-soluble cement composition comprising CKD and free of any acid-soluble fillers. The sample comprised Bolemi CKD (100% bwob), calcium chloride (3% bwob). and fresh water (6,67 gal/sk). The abbreviation "% bwob" indicates the percent of the component by weight of a cement blend consisting of the CKD. 'The sample had a density of 13 pounds per gallon.
[0065] Crush Strength Testing: For the crush strength testing, a portion of the sample was poured, into a 2-inch x. 4-inch cylinder and allowed to cure n a water bath at 17{ F for 24 hours. After curing, the sample cubes were placed In an 80°F water bath for at least. 30 minutes and then crushed. The crush strengths were determined using a Tinius Olson tester in accordance with API Specification 10. The determined crush strength was 345 psi.
[0066] Solubility Testing: For the solubility testing, a portion of the sample was poured into a 2-inch x 4-inch cylinder and allowed to cure in a water bath at ! 40°F for 24 hours. After curing, the sample cylinders were placed in an 80°F water bath for at least 30 minutes and then weighed to determine an initial weight. Each sample cylinder was then submerged in 2.000 milliliters of a 7,5% by weight hydrochloric acid solution at 140¾F in a 3,000 milliliter beaker. The sample cylinder was supported in the acid solution above a magnetic stir bar. The magnetic stir bar was rotated to create a slight vortex on the surface of die acid solution.. The sample cylinder was observed, and the time for complete dissolution of the sample cylinder was recorded, if not completely dissolved, the sample cylinder was removed from the acid solution after 2 hours and weighed to determine a final weight. The acid solubility was. then was calculated by the following formula:
Acid Solubility » (Initial Weight - Final Weight) / initial Weight x 100
The solubility testing was repeated using a 7.5% by weight hydrochloric acid solution and a 15% by weight hydrochloric acid solution. The results of the solubility testing are set forth in the table below.
TABLE 10
Acid-Solubility Tests: 100% CK
Figure imgf000026_0001
[0067] Example 8 thus indicates that acid-soluble cement compositions containing CKD and free of an additional acid-soluble filler may have solubility properties suitable lor use in aesd-soJubSe operations,
[0068] It should be understood that the compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps, the compositions and methods can also "consist essentially of* or "consist of the various components and steps. Moreover, the indefinite articles "a" or "an," as used in the claims, are defined herein to mean one or more than one of Che element that it introduces.
0069] For the sake of brevity, only certain ranges ar explicitly disclosed herein. However, ranges from any Sower Strait 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 oilier 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. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, "from about a to about b," or. equivalent!)'-, "from approximately a to b.,! or, equivalent!)', "from approximately a-b") disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value ma serve as its own lower or upper limit combined with any other point or individual value or any other lo wer or upper limit, to recite a range not explicitly recited.
[0070] Therefore, the present invention is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present invention, may be modified and practiced hi different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, the invention covers all combinations of all those embodiments. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present invention. If there is any conflict in the usages of a word or term in this specification and one or raore paters.t(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

Claims

What is claimed is:
1 . A method of cementing comprising;
providing an acid-soluble cement, composition comprisin a kiln dust and water;
allowing the acid-soluble cement composition, to set to form an acid-soluble hardened mass; and
contacting the acid-soluble hardened mass with an acid.
2. A method according to claim I wherein the acid-soluble cement, composition has a density of about 8 pounds per gallon to about 1 pounds per gallon.
3. A method according to claim .1 or claim 2 wherein the acid-soluble cement composition further comprises a. hydraulic cement selected from the group consisting of a Portland cement, a pozzolana cement, a gypsum cement, a high alumina content cement, a slag cement, a silica cement, and any combination thereof.
4. A method according to any preceding claim wherein the kiln dust comprises cement kiln dust,
5. A method according to any preceding claim wherein the kiln dust comprises lime kiln dust.
6. A method according to any preceding claim, wherein the kiln dust is present in an amount in a range of from about 1% to 100% by weight of a total amount of cementitious components present in the acid-soluble cement composition.
7. A method according to an one of claims 1 , 2 or 4-6 wherein the kiln dust is present in an amount of about 100% by weight o f a total amount of cementitious components present in the acid-soluble cement composition.
8. A method according to any one of claims .1 , 2 or 4-7 wherein the acid-soluble cement composition, is tree of any additional cementitious components other than the kiln dust.
9. A method according to any preceding claim wherein the acid-soluble cement composition is free of an acid soluble filler.
10. A method according to any preceding claim wherein the acid-soluble cement composition is free of an acid-soluble filler selected from the group consisting of dolomite, magnesium carbonate, calcium carbonate, zinc carbonate, and any combination thereof.
1 1. A method according to any one of claims 1-6, 9, or .10 wherein the acid- soluble cement composition further comprises an additive selected from the group consisting of a. fly ash. a slag cement, metakaolin, shale, zeolite, crystalline silica, amorphous silica. filmed silica, salt, fiber, h draiable clay, microsphere, rice husk ash, an elastomer, an elastomerie particle, a resin, a latex, and any combination thereof,
12, A method according to any preceding claim wherein the acid-soluble cement composition further comprises an additive selected from the group consisting of a set- retarding additive, a strength-retrogression additive, a set accelerator, a weighting agent a lightweight additive, a gas-generating addilive, a mechanical-property-enhancing additive, a lost-circulation material, a filtration-control additive, a dispersant, a fluid- loss-control additive, a defoaming agent, a foaming agent, an oi!-swe!iable particle, a water-swellable panicle, a thixotropic additive, and any combination thereof,
13, A method according to any preceding claim wherein contacting the aeici- soluble hardened mass with an acid comprises contacting the acid-soluble hardened mass with an aqueous acid composition, wherein the aqueous acid composition comprises hydrochloric acid present in the aqueous acid composition in an amount of about 7,5% to about 28% by weight of the aqueous acid composition.
14, A method according to any preceding claim further comprising; placing the acid-soluble cement composition into a subterranean formation.
15. A method according to claim 14 wherein the acid-soluble cement composition is allowed to set in a well-bore annulus in the subterranean formation, wherein the acid contacts the acid-soluble hardened mass through one or more openings in a pipe string disposed in the subterranean formation.
16. A method of cementing comprising;
placing an acid-soluble cement composition in a subterranean formation, the acid-soluble cement composition comprising:
cement kiln dust in an amount of 100% b weight of a total amount of cementitious components in the acid-soluble cement composition; and
water;
allowing the acid-soluble cement composition to set to form an acid-soluble hardened mass; and
contacting the acid-soluble hardened mass with an acid.
1 7. A method .according to claim 16 wherein the acid-soluble cement composition is free of an acid-soluble filler.
18. A method according to claim 16 or claim. 1 7 wherein the acid-soluble cement composition is free of an acid-soluble filler selected from the group consisting of dolomite, magnesium carbonate, calcium carbonate, zinc carbonate, and any combination thereof.
19. A method according to any one of claims 16- 18 wherein the acid-soluble cement composition further comprises an additive selected from the group consisting of a set-retarding additive, a strength-retrogression additive, a set accelerator, a weighting agent a lightweight additive, a gas-generating additive, a mechanica!-property-enhaneing additive, a lost-circulation material, a filtration-control additive, a dispersant, a fluid-loss-control additive, a defoaming agent, a foaming agent, an oil-swellablc particle, a vvaier-swellable particle, a tfoixotropic additive, and any combination thereof.
20. A method according to any one of claims 16-19 wherein contacting the aeid- soluhle hardened mass with an acid comprises contacting the acid-soluble hardened mass with an aqueous acid composition, wherein the aqueous acid composition comprises hydrochloric acid present in the aqueous acid composition in an amount of about 7.5% to about 28% by weight of the aqueous acid composition.
21. A method according to any one of claims 16-20 wherein the placing the acid- soluble composition comprises placing the acid-soluble composition in a well-bore annul us between a pipe string di sposed in the subterranean formation and a wall of a well. bore.
22. A method according to any one of claims 16-21 wherein the acid-soluble cement composition is allowed to set in a. well-bore annulus in the subterranean formation, wherein the acid contacts the acid-soluble hardened mass through one or more openings in a pipe string disposed in the subterranean formation,
23. A method of cementing comprising:
placing an acid-soluble cement composition in a subterranean formation, the acid-soluble cement composition, comprising cement kiin dust and water, wherein the acid- soluble cement composition is free of any acid-soluble fillers;
allowing the acid-soluble cement composition to set to form an acid-soluble hardened mass; and
contacting the acid-soluble hardened mass with an acid.
24. A method according to claim 23 wherein the acid-soluble cement composition further comprises a hydraulic cement selected from the group consisting of a Portland cement, a pozzolana cement, a gypsum cement, a high alumin content cement, a slag cement, a silica cement, and any combination thereof,
25. A method according to claim 23 or claim 24 wherein the cement kiln. dust, is present in an amount in a range of from about 1 % to 1.00% by weight, of a total amount of eemeniitious components present in the acid-soluble cement composition,
26, A method according to any one of claims 23-25 wherein the cement kilo dust is present in an amount of about 100% by weight of a total amount of cementitious components present in the ackl-soluble cement composition.
27. A method according to any one of claims 23-26 wherein the acid-soluble cement composition is free of any additional cementitious components other than the cement kiln dust.
28. A method according to an one of claims 23-25 wherein the acid-soluble cement composition farther comprises an additive selected from the group consisting of a fly ash, a slag cement, metakaolin, shale, zeolite, crystalline silica, amorphous silica, famed silica, salt, fiber, hydratable clay, microsphere, rice husk ash, an elastomer, an eiastomeric particle, a resin, a latex, and any combination thereof,
29, A method according to any one of claims 23-28 wherein the -acid-soluble cement composition further comprises an additive selected front the group consisting of a set-retarding additive, a strength-retrogression additive, a set accelerator, a weighting agent, a lightweight additive, a gas-generating additive, a mechanical-property-enhaneing additive, a lost-circulation material, a. filtration-control additive, a dispersanL a fluid-loss-eontrol addiisve, a defoaming agent, a foaming agent, an oil-sweliabie particle, a. water-swel Sable particle, a thixotropic additive, and any combination thereof
30. A method according to any one of claims 23-29 wherein contacting the acid- soluble hardened mass with an acid comprises contacting the acid-soluble hardened mass with an aqueous acid composition, wherein the aqueous acid composition comprises hydrochloric acid present in. the aqueous acid composition in an amount of about 7.5% to about 28% by weight of the aqueous acid composition.
31 , A method according to any one of claims 23-30 wherein the acid-soluble cement composition is allowed to set In a well-bore annulus in the subterranean formation, wherein the acid contacts the acid-soluble hardened mass through one or more openings in a pipe strin disposed in the subterranean formation.
PCT/US2013/056719 2012-08-27 2013-08-27 Acid-soluble cement compositions comprising cement kiln dust and methods of use WO2014035923A1 (en)

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