Methods of use settable drilling fluids comprising cement kiln dust

• US 7,204,310 B1
• Filed: 04/11/2006
• Issued: 04/17/2007
• Est. Priority Date: 04/11/2006
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company), Infinidat Ltd.
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Chatterji, Jiten, King, Bobby J., Roddy, Craig W., Brenneis, D. Chad
• Primary Examiner(s): SUCHFIELD, GEORGE A
• Application Number:
  US11/403,032
• Time in Patent Office: 371 Days
• Field of Search: 166/292, 166/293, 175/64, 175/65, 175/72, 106/707, 106/716, 106/751, 106/819, 507/120, 507/140, 507/904
• US Class Current: 166/293
• CPC Class Codes: C04B 14/104 Bentonite, e.g. montmorillonite
• CPC Class Codes: C04B 14/108 Shale, slate colliery shale C04B18/125
• CPC Class Codes: C04B 2103/10 Accelerators; Activators
• 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 2103/46 Water-loss or fluid-loss reducers, hygroscopic or hydrophilic agents, water retention agents
• CPC Class Codes: C04B 22/064 of the alkaline-earth metals
• CPC Class Codes: C04B 24/26 obtained by reactions only involving carbon-to-carbon unsaturated bonds C04B24/243 takes precedence
• 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: C09K 8/12 containing synthetic organic macromolecular compounds or their precursors
• CPC Class Codes: C09K 8/16 characterised by the inorganic compounds other than clay
• CPC Class Codes: C09K 8/46 containing inorganic binders, e.g. Portland cement
• CPC Class Codes: C09K 8/467 containing additives for specific purposes
• CPC Class Codes: Y10S 507/904 Process of making fluids or additives therefor

Abstract

Settable drilling fluids comprising an aqueous-based drilling fluid and cement kiln dust. Methods of cementing in a subterranean formation comprising: providing a settable drilling fluid comprising an aqueous-based drilling fluid and cement kiln dust, introducing the settable drilling fluid into a subterranean formation, and allowing the settable drilling fluid to set in the subterranean formation. Methods of converting an aqueous-based drilling fluid to a settable drilling fluid comprising: providing the aqueous-based drilling fluid, and adding cement kiln dust to the aqueous-based drilling fluid to form the settable drilling fluid. Methods of drilling a well bore and cementing a well bore comprising: drilling a well bore, circulating an aqueous-based drilling fluid in the well bore during the step of drilling the well bore, adding cement kiln dust to the aqueous-based drilling fluid to form a settable drilling fluid, and allowing the settable drilling fluid to set in the well bore.

Claims

1. A method of cementing comprising:

providing a settable drilling fluid comprising an aqueous-based drilling fluid and cement kiln dust;

introducing the settable drilling fluid into a well bore; and

allowing the settable drilling fluid to set in the well bore.

2. The method of claim 1 comprising adding the cement kiln dust and water to the aqueous-based drilling fluid to form the settable drilling fluid.

3. The method of claim 1 wherein the cement kiln dust is added to the settable drilling fluid in an amount in the range of from about 1% to about 25% by weight of the settable drilling fluid.

4. The method of claim 1 wherein the aqueous-based drilling fluid is a bentonite mud, a lime mud, a partially hydrolyzed polyacrylamide mud, or combinations thereof.

5. The method of claim 1 wherein the aqueous-based drilling fluid is an aqueous gel comprising a viscosifier selected from the group consisting of a clay, a polymeric viscosifier, and combinations thereof.

6. The method of claim 1 wherein the aqueous-based drilling fluid is present in the settable drilling fluid in an amount in the range of from about 5% to about 40% by weight of the settable drilling fluid.

7. The method of claim 1 wherein the settable drilling fluid comprises at least one additive selected from the group consisting of an accelerator, a lost circulation material, a fluid loss control additive, a dispersant, a set retarder, calcium hydroxide, silica fume, a hydraulic cement, vitrified shale, and combinations thereof.

8. The method of claim 1 wherein the settable drilling fluid comprises silica fume in an amount in the range of from about 5% to about 20% by weight of the settable drilling fluid.

9. The method of claim 1 wherein the settable drilling fluid comprises a hydraulic cement in an amount up to about 10% by weight of the settable drilling fluid.

10. The method of claim 1 wherein the settable drilling fluid comprises vitrified shale in an amount up to about 10% by weight of the settable drilling fluid.

11. The method of claim 1 wherein the settable drilling fluid comprises calcium hydroxide in an amount in the range of from about 10% to about 30% by weight of the settable drilling fluid.

12. A method of converting an aqueous-based drilling fluid to a settable drilling fluid comprising:

providing an aqueous-based drilling fluid;

adding cement kiln dust to the aqueous-based drilling fluid to form the settable drilling fluid;

introducing the settable drilling fluid into a well bore; and

allowing the settable drilling fluid to set in the well bore.

13. The method of claim 12 further comprising the step of adding additional water to the aqueous-based drilling fluid.

14. The method of claim 12 wherein the aqueous-based drilling fluid is a bentonite mud, a lime mud, a partially hydrolyzed polyacrylamide mud, or combinations thereof.

15. The method of claim 12 wherein the cement kiln dust is added to the aqueous-based drilling fluid in an amount in the range of from about 1% to about 25% by weight of the settable drilling fluid.

16. The method of claim 12 wherein the aqueous-based drilling fluid is present in the settable drilling fluid in an amount in the range of from about 5% to about 40% by weight of the settable drilling fluid.

17. The method of claim 12 further comprising the step of adding at least one additive to the aqueous-based drilling fluid, the at least one additive selected from the group consisting of an accelerator, a lost circulation material, a fluid loss control additive, a dispersant, a set retarder, calcium hydroxide, silica fume, a hydraulic cement, vitrified shale, and combinations thereof.

24. The method of claim 12 comprising using the aqueous-based drilling fluid for drilling in a subterranean formation, prior to the adding the cement kiln dust to the aqueous-based drilling fluid.

18. A method of drilling a well bore and cementing a well bore comprising:

drilling a well bore;

circulating an aqueous-based drilling fluid in the well bore during the step of drilling the well bore;

adding cement kiln dust to the aqueous-based drilling fluid to form a settable drilling fluid; and

allowing the settable drilling fluid to set in the well bore.

19. The method of claim 18 further comprising the step of adding additional water to the aqueous-based drilling fluid.

20. The method of claim 18 wherein the aqueous-based drilling fluid is a bentonite mud, a lime mud, a partially hydrolyzed polyacrylamide mud, or combinations thereof.

21. The method of claim 18 wherein the cement kiln dust is added to the aqueous-based drilling fluid in an amount in the range of from about 1% to about 25% by weight of the settable drilling fluid.

22. The method of claim 18 wherein the aqueous-based drilling fluid is present in the settable drilling fluid in an amount in the range of from about 5% to about 40% by weight of the settable drilling fluid.

23. The method of claim 18 further comprising the step of adding at least one additive to the aqueous-based drilling fluid, the at least one additive selected from the group consisting of an accelerator, a lost circulation material, a fluid loss control additive, a dispersant, a set retarder, calcium hydroxide, silica fume, a hydraulic cement, vitrified shale, and combinations thereof.

25. A method of cementing comprising:

providing a settable drilling fluid comprising an aqueous-based drilling fluid and cement kiln dust;

introducing the settable drilling fluid into a subterranean formation; and

allowing the settable drilling fluid to set in an annulus between the subterranean formation and a pipe string located in the subterranean formation.

26. The method of claim 25 comprising adding the cement kiln dust and water to the aqueous-based drilling fluid to form the settable drilling fluid.

27. The method of claim 25 wherein the cement kiln dust is added to the settable drilling fluid in an amount in the range of from about 1% to about 25% by weight of the settable drilling fluid.

28. The method of claim 25 wherein the aqueous-based drilling fluid is a bentonite mud, a lime mud, a partially hydrolyzed polyacrylamide mud, or combinations thereof.

29. The method of claim 25 wherein the aqueous-based drilling fluid is an aqueous gel comprising a viscosifier selected from the group consisting of a clay, a polymeric viscosifier, and combinations thereof.

30. The method of claim 25 wherein the aqueous-based drilling fluid is present in the settable drilling fluid in an amount in the range of from about 5% to about 40% by weight of the settable drilling fluid.

31. The method of claim 25 wherein the settable drilling fluid comprises at least one additive selected from the group consisting of an accelerator, a lost circulation material, a fluid loss control additive, a dispersant, a set retarder, calcium hydroxide, silica flume, a hydraulic cement, vitrified shale, and combinations thereof.

32. The method of claim 25 wherein the settable drilling fluid comprises silica fume in an amount in the range of from about 5% to about 20% by weight of the settable drilling fluid.

33. The method of claim 25 wherein the settable drilling fluid comprises a hydraulic cement in an amount up to about 10% by weight of the settable drilling fluid.

34. The method of claim 25 wherein the settable drilling fluid comprises vitrified shale in an amount up to about 10% by weight of the settable drilling fluid.

35. The method of claim 25 wherein the settable drilling fluid comprises calcium hydroxide in an amount in the range of from about 10% to about 30% by weight of the settable drilling fluid.