Methods of using settable compositions comprising cement kiln dust and additive(s)

• US 7,353,870 B2
• Filed: 09/09/2005
• Issued: 04/08/2008
• Est. Priority Date: 09/09/2005
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• 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:
  US11/223,750
• Publication Number:
  US 20070056734A1
• Time in Patent Office: 942 Days
• Field of Search: 166/285, 166/292, 166/293, 166/309, 106/672, 106/677, 106/678, 106/681, 106/707, 106/716, 106/718, 106/751, 106/792, 106/793, 106/794, 106/811, 106/819, 507/202, 507/269
• US Class Current: 166/293
• CPC Class Codes: C04B 14/047 Zeolites
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/108 Shale, slate colliery shale C04B18/125
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 2103/10 Accelerators; Activators
• CPC Class Codes: C04B 2103/20 Retarders
• CPC Class Codes: C04B 2103/40 Surface-active agents, dispersants
• CPC Class Codes: C04B 2103/408 Dispersants
• CPC Class Codes: C04B 22/064 of the alkaline-earth metals
• CPC Class Codes: C04B 24/12 Nitrogen containing compounds organic derivatives of hydrazine hydrazine C04B22/00
• 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 38/10 by using foaming agents C04B38/02 takes precedenceor by using mechanical means, e.g. adding preformed foam
• CPC Class Codes: C04B 7/17 with calcium oxide containing activators C04B7/1535 takes precedence
• 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: Y02P 40/10 Production of cement, e.g. improving or optimising the production methods; Cement grinding
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

The present invention provides settable compositions that comprise water and cement kiln dust. The settable compositions optionally may comprise an additive that comprises at least one of the following group: fly ash; shale; slag cement; zeolite; metakaolin; and combinations thereof. The settable compositions optionally may be foamed with a gas. Methods of cementing also are provided that comprise: providing the settable composition; introducing the settable composition into a location to be cemented; and allowing the settable composition to set therein. The location to be cemented may be above ground or in a subterranean formation.

Claims

1. A method of cementing comprising:

providing a settable composition comprising water, cement kiln dust, and an additive comprising at least one material selected from the group consisting of;

shale;

zeolite;

slag cement;

metakaolin; and

combinations thereof;

introducing the settable composition into a well bore; and

allowing the settable composition to set to form a hardened mass therein.

2. The method of claim 1 wherein the cement kiln dust is present in the settable composition in an amount of about 5% to 100% by weight.

3. The method of claim 1 wherein the settable composition further comprises fly ash.

4. The method of claim 1 wherein the settable composition further comprises a hydraulic cement in an amount up to about 95% by weight.

5. The method of claim 1 wherein the shale is present in the settable composition in an amount in the range of from about 5% to about 75% by weight.

6. The method of claim 5 wherein the shale comprises vitrified shale.

7. The method of claim 1 wherein the zeolite is present in the settable composition in an amount in the range of from about 5% to about 65% by weight.

8. The method of claim 7 wherein the zeolite comprises chabazite and clinoptilolite.

9. The method of claim 1 wherein the slag cement is present in the settable composition in an amount up to about 95% by weight.

10. The method of claim 9 wherein the slag cement comprises slag and a base.

11. The method of claim 1 wherein the metakaolin is present in the settable composition in an amount in the range of from about 5% to about 95% by weight.

12. The method of claim 1 wherein the settable composition is foamed and further comprises a gas, and a surfactant.

13. The method of claim 1 wherein the settable composition further comprises at least one additive selected from the group consisting of:

a set retarding additive;

an accelerator;

a lost circulation material;

a filtration control additive;

a dispersant; and

combinations thereof.

14. The method of claim 1 wherein the settable composition is introduced into the well bore between a wall of the well bore and a pipe string disposed in the well bore.

15. A method of cementing comprising:

providing a settable composition comprising water, cement kiln dust, and an additive comprising at least one material selected from the group consisting of;

fly ash;

shale;

zeolite;

slag cement;

metakaolin; and

combinations thereof;

introducing the settable composition into a subterranean formation; and

allowing the settable composition to set to form a hardened mass therein.

16. The method of claim 15 wherein the fly ash is present in the settable composition in an amount in the range of from about 5% to about 75% by weight.

17. The method of claim 16 wherein the settable composition further comprises a source of calcium ions.

18. The method of claim 17 wherein the source of calcium ions comprises a lime.

19. The method of claim 18 wherein the lime comprises hydrated lime.

20. The method of claim 15 wherein the settable composition further comprises a hydraulic cement.

21. A method of cementing comprising

providing a foamed settable composition comprising water, cement kiln dust, a gas, a surfactant, and an additive comprising at least one material selected from the group consisting of:

fly ash;

shale;

zeolite;

slag cement;

metakaolin; and

combinations thereof;

introducing the foamed settable composition into a location to be cemented; and

allowing the foamed settable composition to set therein.

22. The method of claim 21 wherein the fly ash is present in the foamed settable composition in an amount in the range of from about 5% to about 75% by weight.

23. The method of claim 21 wherein the shale is present in the foamed settable composition in an amount in the range of from about 5% to about 75% by weight.

24. The method of claim 21 wherein the zeolite is present in the foamed settable composition in an amount in the range of from about 5% to about 65% by weight.

25. The method of claim 21 wherein the slag cement is present in the foamed settable composition in an amount up to about 95% by weight.

26. The method of claim 21 wherein the metakaolin is present in the foamed settable composition in an amount in the range of from about 5% to about 95% by weight.

27. The method of claim 21 wherein the surfactant comprises a foaming and stabilizing surfactant composition.

28. The method of claim 27 wherein the foaming and stabilizing surfactant composition comprises at least one composition selected from the group consisting of:

a mixture of an ammonium salt of an alkyl ether sulfate, a cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water;

a mixture of an ammonium salt of an alkyl ether sulfate surfactant, a cocoamidopropyl hydroxysultaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water;

a hydrolyzed keratin;

a mixture of an ethoxylated alcohol ether sulfate surfactant, an alkyl or alkene amidopropyl betaine surfactant, and an alkyl or alkene dimethylamine oxide surfactant;

an aqueous solution of an alpha-olefinic sulfonate surfactant and a betaine surfactant; and

combinations thereof.

29. The method of claim 27 wherein the foaming and stabilizing surfactant composition comprises a mixture an ammonium salt of an alkyl ether sulfate, a cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water.

30. The method of claim 21 further comprising:

providing a settable composition comprising the water;

the cement kiln dust;

the surfactant; and

the additive; and

foaming the settable composition with the gas to form the foamed settable composition.