WO2015017564A1 - Compositions comprenant des poussières de four et de la wollastonite et leurs procédés d'utilisation dans des formations souterraines - Google Patents

Compositions comprenant des poussières de four et de la wollastonite et leurs procédés d'utilisation dans des formations souterraines Download PDF

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Publication number
WO2015017564A1
WO2015017564A1 PCT/US2014/048935 US2014048935W WO2015017564A1 WO 2015017564 A1 WO2015017564 A1 WO 2015017564A1 US 2014048935 W US2014048935 W US 2014048935W WO 2015017564 A1 WO2015017564 A1 WO 2015017564A1
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WIPO (PCT)
Prior art keywords
settable composition
kiln dust
settable
amount
wollastonite
Prior art date
Application number
PCT/US2014/048935
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English (en)
Inventor
Jiten Chatterji
Darrell Chad Brenneis
Baya Adams
Craig Wayne Roddy
Original Assignee
Halliburton Energy Services, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US13/955,516 external-priority patent/US9150773B2/en
Application filed by Halliburton Energy Services, Inc. filed Critical Halliburton Energy Services, Inc.
Priority to CA2914252A priority Critical patent/CA2914252C/fr
Priority to MX2016000189A priority patent/MX2016000189A/es
Priority to AU2014296231A priority patent/AU2014296231B2/en
Priority to RU2016100193A priority patent/RU2640621C2/ru
Priority to GB1520970.3A priority patent/GB2529960B/en
Publication of WO2015017564A1 publication Critical patent/WO2015017564A1/fr
Priority to NO20160020A priority patent/NO20160020A1/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/021—Ash cements, e.g. fly ash cements ; Cements based on incineration residues, e.g. alkali-activated slags from waste incineration ; Kiln dust cements
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B33/00—Sealing or packing boreholes or wells
    • E21B33/10—Sealing or packing boreholes or wells in the borehole
    • E21B33/13—Methods or devices for cementing, for plugging holes, crevices or the like
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
    • C04B14/043—Alkaline-earth metal silicates, e.g. wollastonite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/0481—Other specific industrial waste materials not provided for elsewhere in C04B18/00
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/06—Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
    • C04B18/08—Flue dust, i.e. fly ash
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/16—Waste materials; Refuse from building or ceramic industry
    • C04B18/162—Cement kiln dust; Lime kiln dust
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/04—Portland cements
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/42—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/42—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
    • C09K8/46—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement
    • C09K8/467—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement containing additives for specific purposes
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • well treatments include a wide variety of methods that may be performed in oil, gas, geothermal and/or water wells, such as drilling, completion and workover methods.
  • the drilling, completion and workover methods may include, but are not limited to, drilling, fracturing, acidizing, logging, cementing, gravel packing, perforating and conformance methods.
  • Many of these well treatments are designed to enhance and/or facilitate the recovery of desirable fluids from a subterranean well.
  • settable compositions are commonly utilized.
  • the term "settable composition” refers to a composition(s) that hydraulically sets or otherwise develops compressive strength.
  • Settable compositions may be used in primary cementing operations whereby pipe strings, such as casing and liners, are cemented in well bores.
  • a settable composition may be pumped into an annulus between a subterranean formation and the pipe string disposed in the subterranean formation.
  • the settable composition should set in the annulus, thereby forming an annular sheath of hardened cement (e.g., a cement sheath) that should support and position the pipe string in the well bore and bond the exterior surface of the pipe string to the walls of the well bore.
  • Settable compositions also may be used in remedial cementing methods, such as the placement of cement plugs, and in squeeze cementing for sealing voids in a pipe string, cement sheath, gravel pack, formation, and the like.
  • Settable compositions may also be used in surface applications, for example, construction cementing.
  • Settable compositions for use in subterranean formations may further include Portland cement.
  • Portland cement generally is a major component of the cost for the settable compositions.
  • Other components may be included in the settable composition in addition to, or in place of, the Portland cement.
  • Such components may include fly ash, slag, shale, zeolite, metakaolin, pumice, perlite, lime, silica, rice-hull ash, micro-fine cement, lime kiln dust, and the like.
  • FIG. 1 illustrates a system for preparation and delivery of a settable composition to a well bore in accordance with certain embodiments.
  • FIG. 2A illustrates surface equipment that may be used in placement of a settable composition in a well bore in accordance with certain embodiments.
  • FIG. 2B illustrates placement of a settable composition into a well bore annulus in accordance with certain embodiments.
  • Embodiments relate to cementing operations and, more particularly, in certain embodiments, to settable compositions that comprise kiln dust and wollastonite and methods of use in subterranean formations.
  • the settable compositions may comprise kiln dust, wollastonite, and water.
  • the inclusion of the wollastonite in embodiments of the settable compositions may increase the strength of the resultant set composition.
  • the kiln dust, wollastonite, or a combination thereof may be used to reduce the amount of a higher cost component, such as Portland cement, resulting in a more economical settable composition.
  • Yet another potential advantage of some embodiments is that reduction of the amount of Portland cement can reduce the carbon footprint of the cementing operation.
  • Embodiments of the settable compositions may comprise kiln dust.
  • Kiln dust refers to a solid material generated as a by-product of the heating of certain materials in kilns.
  • the term "kiln dust" as used herein is intended to include kiln dust made as described herein and equivalent forms of kiln dust.
  • Kiln dust typically exhibits cementitious properties in that can set and harden in the presence of water. Examples of suitable kiln dusts include cement kiln dust, lime kiln dust, and combinations thereof.
  • Cement kiln dust may be generated as a by-product of cement production that is removed from the gas stream and collected, for example, in a dust collector.
  • cement kiln dust usually may comprise a variety of oxides, such as S1O2, AI2O3, Fe203, CaO, MgO, SO3, Na20, and K2O.
  • lime kiln dust which may be generated as a by-product of the calcination of lime.
  • the chemical analysis of lime kiln dust from various lime manufacturers varies depending on a number of factors, including the particular limestone or dolomitic 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 lime and free magnesium, lime stone, and/or dolomitic limestone and a variety of oxides, such as Si ( 3 ⁇ 4, AI2O3, Fe203, CaO, MgO, SO3, Na 2 0, and K2O, and other components, such as chlorides.
  • the kiln dust may be included in the settable compositions in an amount sufficient to provide, for example, the desired compressive strength, among other properties.
  • the kiln dust may be present in the settable compositions in an amount in the range of from about 1% to about 99% by weight of cementitious components ("% bwoc").
  • cementitious components refers to the components, or a combination thereof, of the settable compositions that hydraulically set, or otherwise harden, to develop compressive strength, including, for example, kiln dust, Portland cement, fly ash, natural pozzolans (e.g., pumice), slag, vitrified shale, metakaolin, rice husk ash, and the like.
  • the cementitious components in some embodiments may be present in the settable composition in an amount of from about 25% to about 75% by weight of the settable composition.
  • the kiln dust may be present in an amount, for example, ranging between any of and/or including any 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%, or about 90% bwoc.
  • the kiln dust may be present in the settable compositions in an amount in the range of from about 5% to 90% bwoc, from about 20% to about 50%, or from about 20% to about 30% bwoc.
  • One of ordinary skill in the art, with the benefit of this disclosure, should recognize the appropriate amount of the kiln dust to include for a chosen application.
  • the settable compositions may comprise wollastonite.
  • Wollastonite is generally a calcium inosilicate mineral used in industrial applications, such as ceramics, friction products, metal making, paint filler, and plastics. Wollastonite may be mined in a number of different locations throughout the world and then processed for use in industrial applications. Wollastonite may be considered a cementitious component as can set and harden in the presence of silica, lime and water.
  • the wollastonite used in some embodiments may have a mean particle size in a range of from about 1 micron to about 200 microns, and, alternatively, from about 5 microns to about 100 microns.
  • the wollastonite may be included in embodiments of the settable compositions in an amount suitable for a particular application. In some embodiments, the wollastonite may be present in the settable compositions in an amount in a range of from about 1% to about 75% bwoc. In particular embodiments, the wollastonite may be present in an amount ranging between any of and/or including any of 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%, or about 75% bwoc.
  • wollastonite may be present in the settable compositions in an amount in the range of from about 5% to 50% bwoc or from about 20% to about 30% bwoc.
  • amount of the wollastonite should recognize the amount of the wollastonite to include for a chosen application.
  • the water used in embodiments of the settable 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 any combination thereof.
  • the water may be from any source, provided, for example, that it does not contain an excess of compounds that may undesirably affect other components in the settable composition.
  • the water may be included in an amount sufficient to form a pumpable slurry.
  • the water may be included in the settable compositions in an amount in a range of from about 40% to about 200% bwoc. In some embodiments, the water may be included in an amount in a range of from about 40% to about 150% bwoc.
  • the settable compositions may further comprise a Portland cement, including, but not limited to, those classified as Class 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.
  • Portland cements suitable for use in some embodiments may be classified as ASTM Type 1, II, or III.
  • ASTM Type 1, II, or III the Portland cement generally may be included in the settable compositions in an amount sufficient to provide the desired compressive strength, density, and/or cost.
  • the Portland cement may be present in the settable compositions in an amount in the range of from about 1% to about 75% bwoc.
  • the hydraulic cement may be present in an amount ranging between any of and/or including any of about 1 %, about 5%, about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, or about 75% bwoc.
  • small- particle size cement refers to a cement having a particle size (or d50) no larger than about 5 microns, for example, in a range of about 1 micron to about 5 microns.
  • these optional additives individually may be included in the settable compositions in an amount in a range of from about 0.1% to about 90% bwoc.
  • one or more of the optional additives may be individually be included in an amount ranging between any of and/or including any 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 85%, or about 90% bwoc.
  • One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of the optional to include for a chosen application.
  • additives suitable for use in cementing operations may also be added to embodiments of the settable compositions as desired for a particular application.
  • additives include, but are not limited to, dispersants, strength-retrogression additives, set accelerators, set retarders, weighting agents, lightweight additives, gas-generating additives, mechanical property enhancing additives, lost-circulation materials, fluid loss control additives, foaming agents, defoaming agents, oil-swellable particles, water-swellable particles, thixotropic additives, and any combination thereof.
  • additives include crystalline silica, fumed silica, silicates, salts, fibers, hydratable clays, microspheres, diatomaceous earth, elastomers, elastomeric particles, resins, latex, any combination thereof, and the like.
  • Dispersants may be included in embodiments of the settable compositions. Where present, the dispersant should act, among other things, to control the rheology of the settable composition. While a variety of dispersants known to those skilled in the art may be used in some embodiments, examples of suitable dispersants include naphthalene sulfonic acid condensate with formaldehyde; acetone, formaldehyde, and sulfite condensate; melamine sulfonate condensed with formaldehyde; any combination thereof.
  • Strength-retrogression additives may be included in embodiments of the settable composition to, for example, prevent the retrogression of strength after the settable composition has been allowed to develop compressive strength when the settable composition is exposed to high temperatures. These additives may allow the settable compositions to form as intended, preventing cracks and premature failure of the cementitious composition.
  • suitable strength-retrogression additives may include, but are not limited to, amorphous silica, coarse grain crystalline silica, fine grain crystalline silica, or a combination thereof.
  • Set accelerators may be included in embodiments of the settable compositions to, for example, increase the rate of setting reactions. Control of setting time may allow for the ability to adjust to well bore conditions or customize set times for individual jobs. Examples of suitable set accelerators may include, but are not limited to, aluminum sulfate, alums, calcium chloride, calcium sulfate, gypsum-hemihydrate, sodium aluminate, sodium carbonate, sodium chloride, sodium silicate, sodium sulfate, ferric chloride, or a combination thereof.
  • Set retarders may be included in embodiments of the settable compositions to, for example, increase the thickening time of the settable compositions.
  • suitable set retarders include, but are not limited to, ammonium, alkali metals, alkaline earth metals, borax, metal salts of calcium lignosulfonate, carboxymethyl hydroxyethyl cellulose, sulfoalkylated lignins, hydroxycarboxy acids, copolymers of 2-acrylamido-2-methylpropane sulfonic acid salt and acrylic acid or maleic acid, saturated salt, or a combination thereof.
  • a suitable sulfoalkylated lignin comprises a sulfomethylated lignin.
  • Weighting agents may be included in embodiments of the settable compositions to, for example, increase the density of the settable compositions.
  • suitable weighting agents include, but not limited to, ground barium sulfate, barite, hematite, calcium carbonate, siderite, llmenite, manganese oxide, sand, salt, or a combination thereof.
  • Lightweight additives may be included in embodiments of the settable compositions to, for example, decrease the density of the settable compositions.
  • suitable lightweight additives include, but are not limited to, bentonite, coal, diatomaceous earth, expanded perlite, fly ash, gilsonite, hollow microspheres, low-density elastic beads, nitrogen, pozzolan-bentonite, sodium silicate, combinations thereof, or other lightweight additives known in the art.
  • Gas-generating additives may be included in embodiments of the settable compositions to release gas at a predetermined time, which may be beneficial to prevent gas migration from the formation through the settable composition before it hardens.
  • the generated gas may combine with or inhibit the permeation of the settable composition by formation gas.
  • suitable gas-generating additives include, but are not limited to, metal particles (e.g., aluminum powder) that react with an alkaline solution to generate a gas.
  • Mechanical-property-enhancing additives may be included in embodiments of the settable compositions to, for example, ensure adequate compressive strength and long-term structural integrity. These properties can be affected by the strains, stresses, temperature, pressure, and impact effects from a subterranean environment.
  • mechanical- property-enhancing additives include, but are not limited to, carbon fibers, glass fibers, metal fibers, mineral fibers, silica fibers, polymeric elastomers, and latexes.
  • Lost-circulation materials may be included in embodiments of the settable compositions to, for example, help prevent the loss of fluid circulation into the subterranean formation.
  • lost-circulation materials include but are not limited to, cedar bark, shredded cane stalks, mineral fiber, mica flakes, cellophane, calcium carbonate, ground rubber, polymeric materials, pieces of plastic, grounded marble, wood, nut hulls, formica, corncobs, and cotton hulls.
  • Fluid-loss-control additives may be included in embodiments of the settable compositions to, for example, decrease the volume of fluid that is lost to the subterranean formation.
  • Properties of the settable compositions may be significantly influenced by their water content. The loss of fluid can subject the settable compositions to degradation or complete failure of design properties.
  • suitable fluid-loss-control additives include, but not limited to, certain polymers, such as hydroxyethyl cellulose, carboxymethylhydroxyethyl cellulose, copolymers of 2-acrylamido-2-methylpropanesulfonic acid and acrylamide orN,N-dimethylacrylamide, and graft copolymers comprising a backbone of lignin or lignite and pendant groups comprising at least one member selected from the group consisting of 2-acrylamido-2-methylpropanesulfonic acid, acrylonitrile, and N,N- dimethylacrylamide.
  • certain polymers such as hydroxyethyl cellulose, carboxymethylhydroxyethyl cellulose, copolymers of 2-acrylamido-2-methylpropanesulfonic acid and acrylamide orN,N-dimethylacrylamide
  • graft copolymers comprising a backbone of lignin or lignite and pendant groups comprising at least one member selected from the group consisting of 2-acrylamido
  • Foaming agents may be included in embodiments of the settable compositions to, for example, facilitate foaming and/or stabilize the resultant foam formed therewith.
  • suitable foaming additives include, but are not limited to: mixtures of an ammonium salt of an alkyl ether sulfate, a cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water; mixtures of an ammonium salt of an alkyl ether sulfate surfactant, a cocoamidopropyl hydroxysultaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water; hydrolyzed keratin; mixtures of an ethoxylated alcohol ether sulfate surfactant, an alkyl or alkene amidopropyl betaine surfactant, and an alky] or alkene dimethylamine oxide surfactant; aqueous solutions of an
  • Defoaming additives may be included in embodiments of the settable compositions to, for example, reduce tendency for the settable composition to foam during mixing and pumping of the settable compositions.
  • suitable defoaming additives include, but are not limited to, polyol silicone compounds. Suitable defoaming additives are available from Halliburton Energy Services, Inc., under the product name D-AIRTM defoamers.
  • Thixotropic additives may be included in embodiments of the settable compositions to, for example, provide a settable composition that can be pumpable as a thin or low viscosity fluid, but when allowed to remain quiescent attains a relatively high viscosity.
  • thixotropic additives may be used to help control free water, create rapid gelation as the slurry sets, combat lost circulation, prevent "fallback" in annular column, and minimize gas migration.
  • thixotropic additives include, but are not limited to, gypsum, water soluble carboxyalkyl, hydroxyalkyl, mixed carboxyalkyl hydroxyalkyl either of cellulose, polyvalent metal salts, zirconium oxychloride with hydroxyethyl cellulose, or a combination thereof.
  • the settable compositions generally should have a density suitable for a particular application.
  • the settable composition may have a density of about 4 pounds per gallon ("lb/gal") to about 20 lb/gal.
  • the settable compositions may have a density of from about 8 lb/gal to about 17 lb/gal.
  • Embodiments of the settable compositions may be foamed or unfoamed or may comprise other means to reduce their densities, such as hollow microspheres, low-density elastic beads, or other density-reducing additives known in the art.
  • the settable compositions may be foamed with one or more foaming additives and a gas.
  • the components of the settable composition may be combined in any order desired to form a settable composition that can be placed into a subterranean formation.
  • the components of the settable compositions may be combined using any mixing device compatible with the composition, including a bulk mixer, recirculating tub, or jet mixer, for example.
  • the settable compositions may be prepared by combining the dry components with water.
  • Other additives may be combined with the water before it is added to the dry components.
  • the solid components may be dry blended prior to their combination with the water.
  • a dry blend may be prepared that comprises the wollastonite, kiln dust, and optional additive, such as the Portland cement, among others.
  • Other suitable techniques may be used for preparation of the settable compositions as will be appreciated by those of ordinary skill in the art in accordance with certain embodiments.
  • the settable compositions may develop a desirable compressive strength in the well bore annulus for subterranean cementing operations.
  • Compressive strength is generally the capacity of a material or structure to withstand axially directed pushing forces.
  • the compressive strength may be measured at a specified time after the settable composition has been positioned and the settable composition is maintained under specified temperature and pressure conditions.
  • Compressive strength can be measured by either a destructive method or non-destructive method. The destructive method physically tests the strength of set compositions at various points in time by crushing the samples in a compression-testing machine.
  • the compressive strength is calculated from the failure load divided by the cross-sectional area resisting the load and is reported in units of pound-force per square inch (psi).
  • Non-destructive methods typically may employ an Ultrasonic Cement Analyzer (“UCA”), available from Fann Instrument Company, Houston, TX. Compressive strengths may be determined in accordance with API RP 1 OB-2, Recommended Practice for Testing Well Cements, First Edition, July 2005.
  • UCA Ultrasonic Cement Analyzer
  • embodiments of the settable compositions may develop a 72-hour compressive strength in the subterranean formation in a range of from about 250 psi to about 10,000 psi and, alternatively, from about 800 psi about 2,000 psi.
  • the 72-hour compressive strength may be characterized as the destructive compressive strength as measured at atmospheric pressure and temperatures in a range of from about 50°F to about 400°F, alternatively, in a range of from about 80°F to about 250°F.
  • Embodiments of the settable compositions may be used in a variety of applications, including subterranean cementing applications such as primary and remedial cementing, among others.
  • Embodiments may include providing a settable composition and allowing the settable composition to set.
  • Embodiments of the settable compositions may comprise wollastonite, kiln dust, and water. Additional additives may be included in the settable compositions, as described above, for example.
  • introducing the settable composition into a subterranean formation includes introduction into any portion of the subterranean formation, including, without limitation, into a well bore drilled into the subterranean formation, into a near well bore region surrounding the well bore, or into both.
  • introducing the settable composition into the subterranean formation is intended to encompass introduction of the settable composition into one or more subterranean formations that are penetrated by the well bore.
  • a settable composition may be introduced into a well-bore annulus and allowed to set in the well-bore annulus to form a hardened mass.
  • the well-bore annulus may include, for example, an annular space between a conduit (e.g., pipe string, surface casing, intermediate casing, production casing, liner, etc.) and a wall of a well bore or between the conduit and a larger conduit in the well bore.
  • a conduit e.g., pipe string, surface casing, intermediate casing, production casing, liner, etc.
  • the hardened mass should fix the conduit in the well bore.
  • a settable composition may be used, for example, in squeeze-cementing operations or in the placement of plugs.
  • the settable composition may be placed in a well bore to plug a void or crack in the formation, in a gravel pack, in the conduit, in the cement sheath, and/or a microannulus between the cement sheath and the conduit.
  • the settable composition may be placed into a well bore to form a plug in the well bore with the plug, for example, sealing the well bore.
  • FIG. 1 illustrates a system 2 for preparation of a settable composition and delivery to a well bore in accordance with certain embodiments.
  • the settable composition may be mixed in mixing equipment 4, such as a jet mixer, re-circulating mixer, or a batch mixer, for example, and then pumped via pumping equipment 6 to the well bore.
  • the mixing equipment 4 and the pumping equipment 6 may be disposed on one or more cement trucks as will be apparent to those of ordinary skill in the art.
  • a jet mixer may be used, for example, to continuously mix the wollastonite/pumice with the water as it is being pumped to the well bore.
  • FIG. 2A illustrates surface equipment 10 that may be used in placement of a settable composition in accordance with certain embodiments.
  • the surface equipment 10 may include a cementing unit 12, which may include one or more cement trucks.
  • the cementing unit 12 may include mixing equipment 4 and pumping equipment 6 (e.g., FIG. 1 ) as will be apparent to those of ordinary skill in the art.
  • the cementing unit 12 may pump a settable composition 14 through a feed pipe 16 and to a cementing head 18 which conveys the settable composition 14 downhole.
  • the settable composition 14 may be placed into a subterranean formation 20 in accordance with example embodiments.
  • a well bore 22 may be drilled into the subterranean formation 20. While well bore 22 is shown extending generally vertically into the subterranean formation 20, the principles described herein are also applicable to well bores that extend at an angle through the subterranean formation 20, such as horizontal and slanted well bores.
  • the well bore 22 comprises walls 24.
  • a surface casing 26 has been inserted into the well bore 22. The surface casing 26 may be cemented to the walls 24 of the well bore 22 by cement sheath 28.
  • one or more additional conduits e.g., intermediate casing, production casing, liners, etc.
  • casing 30 may also be disposed in the well bore 22.
  • One or more centralizers 34 may be attached to the casing 30, for example, to centralize the casing 30 in the well bore 22 prior to and during the cementing operation.
  • the settable composition 14 may be pumped down the interior of the casing 30.
  • the settable composition 14 may be allowed to flow down the interior of the casing 30 through the casing shoe 42 at the bottom of the casing 30 and up around the casing 30 into the well bore annulus 32.
  • the settable composition 14 may be allowed to set in the well bore annulus 32, for example, to form a cement sheath that supports and positions the casing 30 in the well bore 22.
  • other techniques may also be utilized for introduction of the settable composition 14.
  • reverse circulation techniques may be used that include introducing the settable composition 14 into the subterranean formation 20 by way of the well bore annulus 32 instead of through the casing 30.
  • the settable composition 14 may displace other fluids 36, such as drilling fluids and/or spacer fluids, that may be present in the interior of the casing 30 and/or the well bore annulus 32. At least a portion of the displaced fluids 36 may exit the well bore annulus 32 via a flow line 38 and be deposited, for example, in one or more retention pits 40 (e.g., a mud pit), as shown on FIG. 2A.
  • a bottom plug 44 may introduced into the well bore 22 ahead of the settable composition 14, for example, to separate the settable composition 14 from the fluids 36 that may be inside the casing 30 prior to cementing.
  • a diaphragm or other suitable device rupture to allow the settable composition 14 through the bottom plug 44.
  • the bottom plug 44 is shown on the landing collar 46.
  • a top plug 48 may be introduced into the well bore 22 behind the settable composition 14. The top plug 48 may separate the settable composition 14 from a displacement fluid 50 and also push the settable composition 14 through the bottom plug 44.
  • the exemplary settable compositions disclosed herein may directly or indirectly affect one or more components or pieces of equipment associated with the preparation, delivery, recapture, recycling, reuse, and/or disposal of the disclosed settable compositions.
  • the disclosed settable compositions may directly or indirectly affect one or more mixers, related mixing equipment, mud pits, storage facilities or units, composition separators, heat exchangers, sensors, gauges, pumps, compressors, and the like used generate, store, monitor, regulate, and/or recondition the exemplary settable compositions.
  • the disclosed settable compositions may also directly or indirectly affect any transport or delivery equipment used to convey the settable compositions to a well site or downhole such as, for example, any transport vessels, conduits, pipelines, trucks, tubulars, and/or pipes used to compositionally move the settable compositions from one location to another, any pumps, compressors, or motors (e.g., topside or downhole) used to drive the settable compositions into motion, any valves or related joints used to regulate the pressure or flow rate of the settable compositions, and any sensors (i.e., pressure and temperature), gauges, and/or combinations thereof, and the like.
  • any transport or delivery equipment used to convey the settable compositions to a well site or downhole
  • any transport vessels, conduits, pipelines, trucks, tubulars, and/or pipes used to compositionally move the settable compositions from one location to another
  • any pumps, compressors, or motors e.g., topside or downhole
  • any valves or related joints used to regulate the pressure or flow rate of the
  • the disclosed settable compositions may also directly or indirectly affect the various downhole equipment and tools that may come into contact with the settable compositions such as, but not limited to, wellbore casing, wellbore liner, completion string, insert strings, drill string, coiled tubing, slickline, wireline, drill pipe, drill collars, mud motors, downhole motors and/or pumps, cement pumps, surface-mounted motors and/or pumps, centralizers, turbolizers, scratchers, floats (e.g., shoes, collars, valves, etc.), logging tools and related telemetry equipment, actuators (e.g., electromechanical devices, hydromechanical devices, etc.), sliding sleeves, production sleeves, plugs, screens, filters, flow control devices (e.g., inflow control devices, autonomous inflow control devices, outflow control devices, etc.), couplings (e.g., electro-hydraulic wet connect, dry connect, inductive coupler, etc.), control lines (e.g., electrical, fiber optic, hydraulic, etc.
  • Samples 1 to 3 Three different sample settable compositions, designated Samples 1 to 3, were prepared that comprised cement kiln dust, wollastonite, Portland Class H cement and sufficient water to provide the density indicated in the table below. The samples were prepared by combining these solid components with water while mixing in a Waring blender. The concentrations of the wollastonite, cement kiln dust, and Portland Class H cement were varied as indicated in the table below.
  • the wollastonite was supplied Seaforth Mineral & Ore Co., East Liverpool, Ohio.
  • the cement kiln dust was supplied Holcem Cement Company, Ada, Oklahoma.
  • a base sample composition was prepared that comprised cement kiln dust, wollastonite, Portland Class H cement and sufficient water to have a density of 14.2 lb/gal.
  • the base sample was prepared by combining the solid components with water while mixing in a Waring blender.
  • the wollastonite was supplied Seaforth Mineral & Ore Co., East Liverpool, Ohio.
  • the cement kiln dust was supplied Holcem Cement Company, Ada, Oklahoma.
  • a foaming agent (ZoneSealantTM 2000 agent, Halliburton Energy Services, Inc.) was then added to the base sample composition in an amount of 2% bwoc.
  • the base composition was foamed down to 12.5 lb/gal by mixing in a Waring blender.
  • the sample was allowed to cure for seventy-two hours in 2" by 4" metal cylinders that were placed in a water bath at 170°F to form set cylinders and the resulting set cylinders were tested for mechanical properties in accordance with API RP 10B- 2. The result is set forth in the table below. The data reported in the table below is the average of 3 tests for the sample.
  • the abbreviation "% bwoc" indicates the weight percent of the particular component by weight of the cement components, which were the cement kiln dust, the wollastonite, and the Portland Class H Cement.
  • a sample settable composition comprising wollastonite, cement kiln dust, and hydrated lime.
  • a sample settable composition was prepared that comprised cement kiln dust, wollastonite, hydrated lime, a dispersant, and sufficient water to provide the density indicated in the table below.
  • the sample was prepared by combining the solid components with water while mixing in a Waring blender.
  • the wollastonite was supplied Seaforth Mineral & Ore Co., East Liverpool, Ohio.
  • the cement kiln dust was supplied Holcem Cement Company, Ada, Oklahoma.
  • the dispersant is available from Halliburton Energy Services, Inc., as CFR-3TM dispersant.
  • Samples 6 to 10 Five different sample settable compositions, designated Samples 6 to 10, were prepared that comprised cement kiln dust, wollastonite, Portland Class H cement, one or more optional additives and sufficient water to provide the density indicated in the table below.
  • the samples were prepared by combining the solid components with water while mixing in a Waring blender.
  • a dispersant (CFR-3 TM dispersant) was also included in Samples 6 and 10.
  • the concentrations of the wollastonite, cement kiln dust, Portland Class H cement, and optional additive(s) were varied as indicated in the table below.
  • the wollastonite was supplied Seaforth Mineral & Ore Co., East Liverpool, Ohio.
  • the cement kiln dust was supplied Holcem Cement Company, Ada, Oklahoma.
  • the optional additives included in the samples were metakaolin, fly ash, silica flour, vitrified shale, and fumed silica.
  • Sample 6 included metakaolin supplied by BASF Corporation, Floraham Park, New Jersey.
  • Sample 7 included fly ash supplied by Fairfield Poz, Fairfield, Texas.
  • Samples 8 included silica flour available from Halliburton Energy Services, as SSA-1 TM strength- stabilizing agent.
  • Sample 9 included shale available from TXI, Midloathian, TX.
  • Sample 10 included fumed silica available from Halliburton Energy Services, Inc., as Silicalite TM cement additive
  • 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 the element that it introduces.
  • ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited.
  • any numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed.
  • every range of values (of the form, "from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “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 recite.
  • every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

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Abstract

Dans des modes de réalisation, l'invention concerne des opérations de cimentation, et plus particulièrement dans certains modes de réalisation des compositions durcissables qui comprennent des poussières de four à ciment et de la wollastonite, et leurs procédés d'utilisation dans des formations souterraines. Dans un mode de réalisation, l'invention concerne un procédé de cimentation consistant à utiliser une composition durcissable comprenant des poussières de four, de la wollastonite et de l'eau; et à laisser prendre la composition durcissable.
PCT/US2014/048935 2013-07-31 2014-07-30 Compositions comprenant des poussières de four et de la wollastonite et leurs procédés d'utilisation dans des formations souterraines WO2015017564A1 (fr)

Priority Applications (6)

Application Number Priority Date Filing Date Title
CA2914252A CA2914252C (fr) 2013-07-31 2014-07-30 Compositions comprenant des poussieres de four et de la wollastonite et leurs procedes d'utilisation dans des formations souterraines
MX2016000189A MX2016000189A (es) 2013-07-31 2014-07-30 Composiciones que comprenden polvo de horno y wollastonita y metodos para usarlas en formaciones subterraneas.
AU2014296231A AU2014296231B2 (en) 2013-07-31 2014-07-30 Compositions comprising kiln dust and wollastonite and methods of use in subterranean formations
RU2016100193A RU2640621C2 (ru) 2013-07-31 2014-07-30 Композиции, содержащие печную пыль и волластонит, и способы их применения в подземных пластах
GB1520970.3A GB2529960B (en) 2013-07-31 2014-07-30 Compositions comprising kiln dust and wollastonite and methods of use in subterranean formations
NO20160020A NO20160020A1 (en) 2013-07-31 2016-01-06 Compositions comprising kiln dust and wollastonite and methods of use in subterranean formations

Applications Claiming Priority (2)

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US13/955,516 US9150773B2 (en) 2005-09-09 2013-07-31 Compositions comprising kiln dust and wollastonite and methods of use in subterranean formations
US13/955,516 2013-07-31

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US20090114126A1 (en) * 2005-09-09 2009-05-07 Roddy Craig W Extended Settable Compositions Comprising Cement Kiln Dust and Associated Methods
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GB201520970D0 (en) 2016-01-13
RU2640621C2 (ru) 2018-01-10
RU2016100193A (ru) 2017-09-04
AU2014296231A1 (en) 2016-01-21
CA2914252C (fr) 2018-08-07
MX2016000189A (es) 2016-03-09
AU2014296231B2 (en) 2017-04-20

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