CORROSION-RESISTANT REFRACTORY BINDER COMPOSITIONS AND OIL WELL COMPLETION AND PRODUCTION OPERATIONS

• US 20160298016A1
• Filed: 12/18/2013
• Published: 10/13/2016
• Est. Priority Date: 12/18/2013
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Agapiou, Kyris, Iverson, Ben, Lewis, Sam
• Granted Patent: US 10,351,753 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• 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 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 2103/48 Foam stabilisers
• CPC Class Codes: C04B 2103/50 Defoamers, air detrainers
• CPC Class Codes: C04B 22/16 containing phosphorus in the anion, e.g. phosphates
• CPC Class Codes: C04B 28/06 Aluminous cements monolithic refractories or refractory mortars C04B35/66
• CPC Class Codes: C04B 28/34 containing cold phosphate binders
• CPC Class Codes: C04B 28/344 the phosphate binder being present in the starting composition solely as one or more phosphates
• 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 2208/08 Fiber-containing well treatment fluids
• CPC Class Codes: C09K 2208/32 Anticorrosion additives
• CPC Class Codes: C09K 8/467 containing additives for specific purposes
• CPC Class Codes: C09K 8/473 : Density reducing additives, e.g. for obtaining foamed cement compositions
• 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 include high alumina cement, high-alumina refractory aluminosilicate material, and phosphorous material. Examples of high-alumina refractory aluminosilicate material include crushed firebrick, firebrick grog, refractory mortar, fire clay, mullite, fused mullite, and combinations thereof. The binder composition may be mixed with sufficient amount of fluid such as water to form a slurry and introduced into a wellbore penetrating a subterranean formation, where it may be allowed to set at a point downhole. Such compositions, once set, may exhibit enhanced corrosion and heat resistance. Such compositions, once set, may additionally be cured. Curing may take place at higher temperatures and/or pressures, and may furthermore increase temperature resistance and/or strength of the set binder composition. In addition, the inclusion of high-alumina refractory aluminosilicate material may provide for enhanced consistency in such binder compositions formulated from different batches of high-alumina refractory aluminosilicate material.

Claims

1. A binder composition comprising:

water and

a cement that comprises

a high alumina cement;

a high-alumina refractory aluminosilicate material comprising alumina and silica in a ratio of alumina to silica greater than about 0.7; and

a phosphorous material.

2. The binder composition of claim 1 wherein the high alumina cement comprises a calcium aluminate.

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

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

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

crushed firebrick, firebrick grog, refractory mortar, fire clay, mullite, fused mullite, and combinations thereof.

6. The binder composition of claim 1 wherein the phosphorous material comprises a compound selected from the group consisting of:

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

7. The binder composition of claim 1 wherein:

the high alumina cement is present in the binder composition in an amount in the range of from about 20% to about 70% by weight of the cement;

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

the phosphorous material is present in the binder composition in an amount in the range of from about 1% to about 30% by weight of the cement.

8. The binder composition of claim 1 wherein the water is present in the binder composition in an amount sufficient to form a pumpable slurry comprising the binder composition.

9. The binder composition of claim 8 further comprising a set retarder.

10. The binder composition of claim 8 further comprising a first set retarder and a second set retarder.

12. The binder composition of claim 1 further comprising:

an expanding additive in an amount sufficient to foam the binder composition; and

a compound selected from the group consisting of foaming agents, foam stabilizing agents, and combinations thereof.

11. (canceled)

13. A method of cementing comprising:

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

water,

a high alumina cement,

a high-alumina refractory aluminosilicate material comprising alumina and silica in a ratio of alumina to silica greater than about 0.7, and

a phosphorous material; and

allowing the binder composition to set.

15. The method of claim 13 wherein:

the high alumina cement is present in the binder composition in an amount in the range of from about 20% to about 70% by combined weight of the high alumina cement, the high-alumina refractory aluminosilicate material, and the phosphorous material;

the high-alumina refractory aluminosilicate material is present in the binder composition in an amount in the range of from about 20% to about 70% by combined weight of the high alumina cement, the high-alumina refractory aluminosilicate material, and the phosphorous material; and

the phosphorous material is present in the binder composition in an amount in the range of from about 1% to about 30% by combined weight of the high alumina cement, the high-alumina refractory aluminosilicate material, and the phosphorous material.

16. The method of claim 13 wherein the binder composition comprises high-alumina refractory aluminosilicate particulates sized 30 U.S. mesh or smaller.

17. The method of claim 13 wherein allowing the binder composition to set comprises allowing the binder composition to set at a temperature of about 200°

F. or lower.

18. The method of claim 17 further comprising curing the binder composition at a temperature of about 400°

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

19. The method of claim 18 wherein curing the binder composition comprises allowing the binder composition to be exposed to one or more compounds produced from the subterranean formation.

20. The method of claim 18 wherein curing the binder composition comprises carrying out at least one of an enhanced oil recovery technique and a disposal operation.

21. The method of claim 13 further comprising mixing one or more of the high alumina cement, the high-alumina refractory aluminosilicate material, and the phosphorous material with the water using mixing equipment.

22. The method of claim 13 wherein the binder composition is introduced into a subterranean formation using one or more pumps.

14. (canceled)