Coal slag universal fluid

• US 5,337,824 A
• Filed: 06/28/1993
• Issued: 08/16/1994
• Est. Priority Date: 06/28/1993
• Status: Expired due to Term

• Current Assignee: Shell Oil Company (Shell Plc)
• Original Assignee: Shell Oil Company (Shell Plc)
• Inventors: Cowan, Kenneth M.
• Primary Examiner(s): Suchfield, George A.
• Application Number:
  US08/084,659
• Time in Patent Office: 414 Days
• Field of Search: 166/292, 166/293, 166/300, 175/65, 175/66, 175/72, 405/128, 405/263, 507/136, 507/138, 507/139, 507/140, 507/145
• US Class Current: 166/293
• 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 18/0481 Other specific industrial waste materials not provided for elsewhere in C04B18/00
• CPC Class Codes: C04B 18/06 Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 2103/46 Water-loss or fluid-loss reducers, hygroscopic or hydrophilic agents, water retention agents
• CPC Class Codes: C04B 22/06 Oxides, Hydroxides C04B22/0013 takes precedence
• CPC Class Codes: C04B 22/08 Acids or salts thereof C04B22/0013 takes precedence
• CPC Class Codes: C04B 24/02 Alcohols; Phenols; Ethers
• CPC Class Codes: C04B 24/32 Polyethers, e.g. alkylphenol polyglycolether
• CPC Class Codes: C04B 24/383 Cellulose or derivatives thereof
• CPC Class Codes: C04B 28/021 Ash cements, e.g. fly ash cements fly ash as filler C04B18/08; Cements based on incineration residues, e.g. alkali-activated slags from waste incineration alkali-activated combustion residues as such C04B7/243; mixtures of the lime-pozzuolane type C04B28/18; Kiln dust cements
• CPC Class Codes: C04B 28/18 containing mixtures of the silica-lime type
• CPC Class Codes: C04B 40/0028 Aspects relating to the mixing step of the mortar preparation
• CPC Class Codes: C09K 8/16 characterised by the inorganic compounds other than clay
• CPC Class Codes: C09K 8/22 Synthetic organic compounds
• CPC Class Codes: C09K 8/46 containing inorganic binders, e.g. Portland cement
• CPC Class Codes: E21B 21/003 Means for stopping loss of drilling fluid plastering the borehole wall E21B33/138
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A composition suitable for drilling and cementing comprising coal slag, water and drill solids, the components of the drilling fluid being chosen so as to have a dual functionality in promoting the drilling fluid and thereafter in being functional constituents of a cementitious slurry. Also, a method for drilling using a drilling fluid containing coal slag so as to lay down a filter cake which is settable and which is compatible with a subsequent coal slag cementitious slurry.

Claims

1. A method for drilling, comprising:

drilling a wellbore, with a drill string comprising a drill pipe, utilizing a drilling fluid comprising water, drill solids and coal slag;

circulating said drilling fluid down said drill pipe and up an annulus between said drill pipe and walls of said borehole, thus laying down a filter cake on said walls of said borehole during said drilling and producing a used drilling fluid.

2. A method according to claim 1 wherein said drilling fluid comprises, in addition, a polyalcohol component and a silicate component.

3. A method according to claim 2 wherein said polyalcohol component is a polycyclicpolyetherpolyol of the formula:

##STR4## where x≧

1 and y≧

0.

4. A method according to claim 2 wherein said polyalcohol component is a mixture of a soluble polyol and an insoluble alcohol.

5. A method according to claim 2 wherein said polyalcohol component comprises an ethoxylated propoxylated polyol.

6. A method according to claim 2 wherein said polyalcohol component comprises an epoxy-containing cyclic polyetherpolyol.

7. A method according to claim 2 wherein said drilling fluid comprises, in addition, a secondary fluid loss additive, a secondary weight material, a secondary shale stabilizer, and a copolymer viscosifer.

8. A method according to claim 7 wherein said secondary fluid loss additive is selected from the group consisting of synthetic polymers, starch and bentonite clay, said secondary weight material is barite, said secondary shale stabilizer is lime and said silicate is sodium silicate.

9. A method according to claim 1 wherein said drilling fluid comprises, in addition, a viscosifier selected from the group consisting of biopolymers, silicates and starch.

10. A method according to claim 1 wherein said coal slag is water-quenched slag from the burning of lignite and has a particle size within the range of 4,000 to 9,000 cm² /g.

11. A method according to claim 1 wherein said drilling fluid is a non-lime mud and said drilling fluid is used for a time sufficient to convert said non-lime mud into a lime mud by dissolving out lime from said coal slag.

12. A method according to claim 11 wherein said non-lime mud is selected from the group consisting of seawater/lignosulfonate, seawater/gypsum, and sodium chloride/partially hydrolyzed polyacrylamide mud.

13. A method according to claim 1 further comprising circulating an activator system through said drill pipe and into contact with said filter cake to set said filter cake and thereafter carrying out additional drilling.

14. A method for drilling and cementing, comprising:

drilling a wellbore with a drill string comprising a drill pipe utilizing a drilling fluid comprising water, drill solids and coal slag;

circulating said drilling fluid down said drill pipe and up an annulus between said drill pipe and walls of said borehole, thus laying down a filter cake on said walls of said borehole during said drilling and producing a used drilling fluid;

withdrawing said drill string and inserting a pipe, thus creating an annulus between said pipe and said walls of said borehole;

incorporating an activator system into said used drilling fluid to produce a cementitious slurry; and

displacing said cementitious slurry into at least a portion of said annulus between said pipe and said walls of said borehole.

15. A method according to claim 14 wherein said activator system comprises calcium oxide.

16. A method according to claim 14 wherein said activator system comprises additional coal slag and calcium oxide or calcium hydroxide.

17. A method according to claim 16 wherein said activator system comprises, in addition, at least one of lithium hydroxide, lithium carbonate, sodium silicate, sodium fluoride, sodium silicofluoride, magnesium hydroxide, magnesium oxide, magnesium silicofluoride, zinc carbonate, zinc silicofluoride, zinc oxide, sodium carbonate, sodium bicarbonate, titanium carbonate, potassium carbonate, potassium bicarbonate, sodium hydroxide, potassium hydroxide, potassium sulfate, potassium nitrate, potassium nitrite, sodium or potassium aluminate, calcium hydroxide, sodium sulfate, copper sulfate, calcium oxide, calcium sulfate, calcium nitrate and calcium nitrite.

18. A method according to claim 14 wherein said cementitious slurry is produced by also incorporating blast furnace slag or fly ash into said used drilling fluid.

19. A method according to claim 18 wherein said blast furnace slag or fly ash is incorporated in an amount sufficient to give a weight ratio of blast furnace slag or fly ash to coal slag within the range of 1:

99 to 50;

50.

20. A method according to claim 14 wherein said coal slag is water-quenched slag from the burning of lignite.

21. A method according to claim 14 wherein said drilling fluid comprises, in addition, a polyalcohol component and a silicate.

22. A method according to claim 21 wherein said polyalcohol component is a mixture of a soluble polyalcohol and an insoluble polyalcohol.

23. A method according to claim 22 wherein said soluble polyalcohol is a polyethercyclicpolyol.

24. A method according to claim 14 wherein said drilling fluid comprises, in addition, a viscosifier selected from the group consisting of biopolymers, silicates and starch.

25. A method according to claim 14 wherein, after said circulating of said drilling fluid, said drilling fluid is displaced and an activator system circulated through said annulus between said drill pipe and said borehole wall to set said filter cake;

said activator system is displaced with drilling fluid; and

additional drilling is carried out prior to said withdrawing of said drill string.

26. A drilling fluid composition comprising water, drill solids and 1 to 100 lbs/bbl of said composition of coal slag.

27. A composition according to claim 26 comprising in addition a polyalcohol component and a silicate component and wherein said coal slag is present in an amount within the range of 20 to 50 lbs/bbl.

28. A composition according to claim 27 wherein said polyalcohol component is a polycyclicpolyetherpolyol of the formula:

##STR5## where x≧

1 and y≧

0.

29. A composition according to claim 27 wherein said polyalcohol component is a mixture of a soluble polyol and an insoluble alcohol.

30. A composition according to claim 27 wherein said polyalcohol component comprises an ethoxylated propoxylated polyol.

31. A composition according to claim 27 wherein said polyalcohol component comprises an epoxy-containing cyclic polyetherpolyol.

32. A composition according to claim 27 wherein said drilling fluid comprises, in addition, a secondary fluid loss additive, a secondary weight material, a secondary shale stabilizer, and a copolymer viscosifer.

33. A composition according to claim 32 wherein said secondary fluid loss additive is selected from the group consisting of synthetic polymers, starch and bentonite clay, said secondary weight material is barite, said secondary shale stabilizer is lime and said silicate is sodium silicate.

34. A composition according to claim 26 wherein said drilling fluid comprises, in addition, a viscosifier selected from the group consisting of biopolymers, silicates and starch.

35. A composition according to claim 26 wherein said coal slag is water-quenched slag from the burning of lignite.