Set-Delayed Cement Compositions Comprising Pumice and Associated Methods

• US 20150197033A1
• Filed: 02/28/2015
• Published: 07/16/2015
• Est. Priority Date: 03/09/2012
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Agapiou, Kyriacos, Pisklak, Thomas Jason, Morgan, Ronnie Glen, Lewis, Samuel Jason
• Granted Patent: US 10,195,764 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B28B 1/14 by simple casting, the material being neither forcibly fed nor positively compacted for molten material B28B1/54
• CPC Class Codes: B28B 1/24 by injection moulding injection moulding of ceramic slips B28B1/265; of tubular articles B28B21/38
• CPC Class Codes: B28B 13/02 Feeding the unshaped material to moulds or apparatus for producing shaped articles
• CPC Class Codes: B28B 13/021 by fluid pressure acting directly on the material, e.g. using vacuum, air pressure
• CPC Class Codes: B29C 39/003 characterised by the choice of material
• CPC Class Codes: B29C 45/02 Transfer moulding, i.e. transferring the required volume of moulding material by a plunger from a "shot" cavity into a mould cavity
• CPC Class Codes: C04B 12/04 Alkali metal or ammonium silicate cements ; Alkyl silicate cements; Silica sol cements; Soluble silicate cements alkali metal silicates per se, their preparation C01B33/32; ammonium silicates per se, their preparation C01C1/00
• CPC Class Codes: C04B 14/047 Zeolites
• CPC Class Codes: C04B 14/064 Silica aerogel
• CPC Class Codes: C04B 14/16 porous, e.g. pumice
• CPC Class Codes: C04B 2103/12 Set accelerators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/408 Dispersants
• CPC Class Codes: C04B 2103/44 Thickening, gelling or viscosity increasing agents
• CPC Class Codes: C04B 22/0013 Boron compounds
• CPC Class Codes: C04B 22/062 of the alkali or alkaline-earth metals
• CPC Class Codes: C04B 22/16 containing phosphorus in the anion, e.g. phosphates
• CPC Class Codes: C04B 24/003 Phosphorus-containing compounds
• CPC Class Codes: C04B 24/121 Amines, polyamines
• CPC Class Codes: C04B 24/163 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 24/18 : Lignin sulfonic acid or derivatives thereof, e.g. sulfite lye
• CPC Class Codes: C04B 24/22 : Condensation or polymerisation products thereof
• CPC Class Codes: C04B 24/2641 : Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 24/383 : Cellulose or derivatives thereof
• CPC Class Codes: C04B 28/18 : containing mixtures of the silica-lime type
• CPC Class Codes: C04B 40/0658 : Retarder inhibited mortars activated by the addition of accelerators or retarder-neutralising agents
• CPC Class Codes: C09K 8/467 : containing additives for specific purposes

Abstract

Disclosed is a method of forming a set cement shape. The method comprises providing a set-delayed cement composition comprising water, pumice, hydrated lime, and a set retarder; forming the set-delayed cement composition into a shape; and allowing the shaped set-delayed cement composition to set.

Claims

1. A method of forming a set cement shape comprising:

providing a set-delayed cement composition comprising water, pumice, hydrated lime, and a set retarder;

forming the set-delayed cement composition into a shape; and

allowing the shaped set-delayed cement composition to set.

2. The method of claim 1, wherein the set retarder comprises at least one retarder selected from the group consisting of a phosphate, a phosphonate, a phosphonic acid, a phosphonic acid derivative, a lignosulfonate, a salt, an organic acid, a carboxymethylated hydroxyethylated cellulose, a synthetic co- or ter-polymer comprising sulfonate and carboxylic acid groups, a borate compound, and any mixture thereof.

3. The method of claim 1, wherein the set-delayed cement composition further comprises a cement set activator selected from the group consisting of a zeolite, amine, silicate, Group IA hydroxide, Group HA hydroxide, monovalent salt, divalent salt, nanosilica, polyphosphate, and any combination thereof.

4. The method of claim 3, wherein the set-delayed cement composition comprising the cement set activator further comprises a thickening time in a range between about 30 seconds to about 10 minutes.

5. The method of claim 1, wherein the set-delayed cement composition further comprises a fiber.

6. The method of claim 1, wherein the set-delayed cement composition further comprises a dispersant selected from the group consisting of a sulfonated-formaldehyde-based dispersant, a polycarboxylated ether dispersant, and any combination thereof.

7. The method of claim 1, further comprising, prior to the forming step, storing the set-delayed cement composition for a period of at least about 1 day.

8. The method of claim 1, wherein the forming the set-delayed cement composition into a shape comprises forming the set-delayed cement composition using at least one of a mold, extruder, die, or a combination thereof.

9. The method of claim 1, wherein the method is a continuous process.

10. The method of claim 1, wherein the set shaped set-delayed cement composition comprises a shaped set-delayed cement product selected from the group consisting of a tile, flooring, underlay, a counter, a backsplash, roofing, a shingle, a shale, weatherboard, faç

ade, cladding, a prefabricated house, an exterior wall, a partition wall, acoustic insulation, thermal insulation, a soffit, a ceiling, an architrave, a brick, a monolithic shape, and any combination thereof.

11. The method of claim 1, wherein the set-delayed cement composition comprises a refractory material.

12. The method of claim 1, wherein the set-delayed cement composition comprises a dye and/or a bead.

13. A method of forming a molded set cement comprising:

providing a set-delayed cement composition comprising water, pumice, hydrated lime, and a set retarder;

introducing the set-delayed cement composition into a mold; and

allowing the set-delayed cement composition to set in the mold.

14. The method of claim 13, wherein the set retarder comprises at least one retarder selected from the group consisting of a phosphate, a phosphonate, a phosphonic acid, a phosphonic acid derivative, a lignosulfonate, a salt, an organic acid, a carboxymethylated hydroxyethylated cellulose, a synthetic co- or ter-polymer comprising sulfonate and carboxylic acid groups, a borate compound, and any mixture thereof.

15. The method of claim 13, wherein the set-delayed cement composition further comprises a cement set activator selected from the group consisting of a zeolite, amine, silicate, Group IA hydroxide, Group IIA hydroxide, monovalent salt, divalent salt, nanosilica, polyphosphate, and any combination thereof.

16. The method of claim 13, wherein the introducing the set-delayed cement composition into a mold comprises extruding the set-delayed cement composition through an extruder into the mold.

17. The method of claim 13, wherein the method is a continuous process.

18. A cementing system comprising:

a set-delayed cement composition comprising;

water,

pumice,

hydrated lime, and

a set retarder, wherein the set-delayed cement composition is capable of remaining in a pumpable fluid state for at least about one day at about 80°

F.;

a cement set activator;

a vessel capable of containing the set-delayed cement composition, and

a mold.

19. The cementing system of claim 18 further comprising an extruder.

20. The cementing system of claim 18, wherein the set-delayed cement composition further comprises a fiber.