IN SITU REFRACTORY BINDER COMPOSITIONS

• US 20160289531A1
• Filed: 12/20/2013
• Published: 10/06/2016
• Est. Priority Date: 12/20/2013
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Agapiou, Kyris, Iverson, Ben
• Granted Patent: US 9,796,903 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: C04B 14/04 Silica-rich materials; Silicates
• CPC Class Codes: C04B 14/041 Aluminium silicates other than clay
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 14/386 Carbon carbon nanotubes C04B14/026
• CPC Class Codes: C04B 18/22 Rubber , e.g. ground waste tires
• CPC Class Codes: C04B 20/002 Hollow or porous granular materials
• CPC Class Codes: C04B 2103/0088 Compounds chosen for their latent hydraulic characteristics, e.g. pozzuolanes
• CPC Class Codes: C04B 2103/10 Accelerators; Activators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/40 Surface-active agents, dispersants
• CPC Class Codes: C04B 2103/408 Dispersants
• CPC Class Codes: C04B 2103/46 Water-loss or fluid-loss reducers, hygroscopic or hydrophilic agents, water retention agents
• CPC Class Codes: C04B 2103/50 Defoamers, air detrainers
• CPC Class Codes: C04B 22/064 of the alkaline-earth metals
• CPC Class Codes: C04B 22/12 containing halogen in the anion
• CPC Class Codes: C04B 22/16 containing phosphorus in the anion, e.g. phosphates
• CPC Class Codes: C04B 28/18 containing mixtures of the silica-lime type
• CPC Class Codes: C04B 28/34 containing cold phosphate binders
• CPC Class Codes: C04B 38/02 by adding chemical blowing agents
• CPC Class Codes: C04B 38/10 by using foaming agents C04B38/02 takes precedenceor by using mechanical means, e.g. adding preformed foam
• CPC Class Codes: C04B 7/32 : Aluminous cements
• CPC Class Codes: C09K 8/44 : containing organic binders only
• CPC Class Codes: C09K 8/46 : containing inorganic binders, e.g. Portland cement
• CPC Class Codes: C09K 8/473 : Density reducing additives, e.g. for obtaining foamed cement compositions
• CPC Class Codes: C09K 8/487 : Fluid loss control additives; Additives for reducing or preventing circulation loss
• CPC Class Codes: E21B 33/14 : for cementing casings into boreholes
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

Corrosion-resistant refractory binder compositions may be formed with a calcium ion source, high-alumina refractory aluminosilicate pozzolan, and water. Any one or more of such components may individually be non-cementitious. Examples of high-alumina refractory aluminosilicate pozzolan include crushed firebrick; firebrick grog; and mixtures of silicate and any one or more of corundum, high-alumina ceramic, and bauxite; refractory mortar; fire clay; mullite; fused mullite; and combinations thereof, among others. A binder composition may be mixed with sufficient amount of water to form a slurry, which slurry may be introduced into a subterranean formation (e.g., via a wellbore penetrating the subterranean formation). A plurality of the non-cementitious components may react in the presence of water when exposed to suitable conditions so as to enable the binder composition to set. Such compositions, once set, may exhibit enhanced corrosion and/or heat resistance as compared to other binder compositions.

Claims

1. A binder composition comprising:

water;

a non-cementitious calcium ion source; and

a non-cementitious high-alumina refractory aluminosilicate pozzolan.

2. The binder composition of claim 1 wherein the calcium ion source comprises a compound selected from the group consisting of:

hydrated lime, quick lime, a calcium salt in the presence of a hydroxide ion source, and combinations thereof.

3. The binder composition of claim 1 wherein the high-alumina refractory aluminosilicate pozzolan comprises mullite in an amount greater than 50% by weight of the high-alumina refractory aluminosilicate pozzolan.

4. The binder composition of claim 3 wherein the high-alumina refractory aluminosilicate pozzolan is substantially free of amorphous material.

5. The binder composition of claim 1 wherein the high-alumina refractory aluminosilicate pozzolan comprises a compound selected from the group consisting of:

crushed firebrick, firebrick grog, a mixture of silicate and corundum, a mixture of silicate and high-alumina ceramic, a mixture of silicate and bauxite, corundum, high-alumina ceramic, mullite, fused mullite, and combinations thereof.

6. The binder composition of claim 1 wherein the high-alumina refractory aluminosilicate pozzolan comprises particulates sized 20 U.S. mesh size and smaller.

7. The binder composition of claim 1 further comprising a phosphate compound.

9. The binder composition of claim 1 further comprising an accelerant that comprises a compound selected from the group consisting of:

calcium chloride;

calcium bromide;

calcium iodide;

phosphate, hexametaphosphate, tripolyphosphate, orthophosphate, metaphosphate, polyphosphate, a salt of any one of the foregoing, and combinations thereof.

10. The binder composition of claim 9 wherein:

the calcium ion source is present in the binder composition in an amount in the range of from about 20% to about 70% by weight of the high-alumina refractory aluminosilicate pozzolan; and

the accelerant is present in the binder composition in an amount in the range of from about 1% to about 30% by weight of the high-alumina refractory aluminosilicate pozzolan.

8. (canceled)

11. (canceled)

12. A method of cementing comprising:

introducing a binder composition into a subterranean formation, wherein the binder composition comprises a slurry comprising;

water,

a non-cementitious calcium ion source, and

a non-cementitious high-alumina refractory aluminosilicate pozzolan;

allowing one or more components of the binder composition to react to form a settable binder composition; and

allowing the settable binder composition to set within the subterranean formation.

13. The method of claim 12 wherein the one or more components of the binder composition react to form a settable binder composition in the subterranean formation.

14. The method of claim 12 wherein:

the non-cementitious calcium ion source comprises a compound selected from the group consisting of;

hydrated lime, quick lime, a calcium salt in the presence of a hydroxide ion source, and combinations thereof; and

the non-cementitious high-alumina refractory aluminosilicate pozzolan comprises a compound selected from the group consisting of;

firebrick, firebrick grog, a mixture of silicate and corundum, a mixture of silicate and high-alumina ceramic, a mixture of silicate and bauxite, corundum, high-alumina ceramic, and combinations thereof.

15. The method of claim 12 wherein the binder composition further comprises a phosphate compound.

17. The method of claim 12 wherein the binder composition further comprises an accelerant selected from the group consisting of:

calcium chloride;

calcium bromide;

calcium iodide;

phosphate, hexametaphosphate, tripolyphosphate, orthophosphate, metaphosphate, polyphosphate, and combinations thereof.

18. The method of claim 17 wherein:

the non-cementitious calcium ion source is present in the binder composition in an amount in the range of from about 20% to about 70% by weight of the non-cementitious high-alumina refractory aluminosilicate pozzolan; and

the accelerant is present in the binder composition in an amount in the range of from about 1% to about 30% by weight of the high-alumina refractory aluminosilicate pozzolan.

19. The method of claim 12 wherein allowing the non-cementitious calcium ion source and non-cementitious high-alumina refractory aluminosilicate pozzolan to set comprises exposing the binder composition to temperatures in excess of 100°

F.

20. The method of claim 12 wherein allowing the binder composition to set comprises allowing the binder composition to set at a temperature of about 200°

F. or lower.

21. The method of claim 18 further comprising curing the binder composition at a temperature of about 400°

F. or higher subsequent to allowing the binder composition to set.

22. The method of claim 12 further comprising mixing one or more of the non-cementitious calcium ion source, and the non-cementitious high-alumina refractory aluminosilicate pozzolan with the water using mixing equipment.

23. The method of claim 12 wherein the binder composition is introduced into a subterranean formation using one or more pumps.

16. (canceled)