Settable compositions comprising a natural pozzolan and associated methods

• US 7,631,692 B2
• Filed: 04/08/2009
• Issued: 12/15/2009
• 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, Roddy, Craig W., Morgan, Ronnie G., Brenneis, D. Chad
• Primary Examiner(s): SUCHFIELD, GEORGE A
• Application Number:
  US12/420,630
• Publication Number:
  US 20090200029A1
• Time in Patent Office: 251 Days
• Field of Search: None
• US Class Current: 166/250.14
• CPC Class Codes: C04B 14/047 Zeolites
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/08 Diatomaceous earth
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/108 Shale, slate colliery shale C04B18/125
• CPC Class Codes: C04B 14/14 Minerals of vulcanic origin granite C04B14/048
• CPC Class Codes: C04B 14/16 porous, e.g. pumice
• CPC Class Codes: C04B 14/18 Perlite
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/101 Burned rice husks or other burned vegetable material
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 18/162 Cement kiln dust; Lime kiln dust
• CPC Class Codes: C04B 20/002 Hollow or porous granular materials
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2103/12 Set accelerators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/50 Defoamers, air detrainers
• CPC Class Codes: C04B 22/064 of the alkaline-earth metals
• CPC Class Codes: C04B 24/24 : Macromolecular compounds C04B24/14 takes precedence; macromolecular compounds comprising sulfonate or sulfate groups C04B24/16
• CPC Class Codes: C04B 24/2611 : Polyalkenes
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• 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 28/04 : Portland cements
• CPC Class Codes: C04B 28/184 : based on an oxide other than lime
• CPC Class Codes: C04B 38/02 : by adding chemical blowing agents
• CPC Class Codes: C04B 38/08 : by adding porous substances
• 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 7/02 : Portland cement
• 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: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

An embodiment of a method of cementing comprises: introducing a cement composition into a subterranean formation, wherein the cement composition comprises cement kiln dust, a natural pozzolan, and water; and allowing the cement composition to set. Another embodiment of a method comprises: introducing a cement composition into a subterranean formation, wherein the cement composition comprises a cement, a natural pozzolan, and water, wherein the cement comprises Portland cement interground with burned shale; and allowing the cement composition to set. Another embodiment includes a cement composition comprising at least one additive selected from the group consisting of cement, cement kiln dust, Portland cement interground with burned shale, and a combination thereof; a natural pozzolan; and water.

Claims

1. A method of cementing in a subterranean formation comprising:

introducing a cement composition into the subterranean formation, wherein the cement composition comprises;

Portland cement interground with burned shale,

cement kiln dust,

a natural pozzolan, and

water; and

allowing the cement composition to set.

2. The method of claim 1 wherein the introducing the cement composition into the subterranean formation comprises introducing the cement composition into a space between a pipe string and the subterranean formation.

3. The method of claim 2 comprising introducing the pipe string into a well bore penetrating the subterranean formation.

4. The method of claim 1 wherein the cement composition is foamed and further comprises a gas and a surfactant.

5. The method of claim 1 wherein the cement composition comprises at least one cement selected from the group consisting of a pozzolana cement, a gypsum cement, a high alumina content cement, a slag cement, a silica cement, and a combination thereof.

6. The method of claim 1 wherein the natural pozzolan comprises pumicite.

7. The method of claim 1 wherein the natural pozzolan is present in an amount of about 0.1% to about 50% by weight of cementitious components.

8. The method of claim 1 wherein the cement composition comprises at least one additive selected from the group consisting of a strength-retrogression additive, a set accelerator, a set retarder, a weighting agent, a lightweight additive, a weighting additive, a gas-generating additive, a mechanical property enhancing additive, a lost-circulation material, a filtration-control additive, a dispersant, a defoaming agent, a foaming agent, a thixotropic additive, and a combination thereof.

9. The method of claim 1 wherein the cement composition comprises at least one additive selected from the group consisting of fly ash, slag, metakaolin, shale, zeolite, lime, crystalline silica, amorphous silica, fumed silica, a salt, fiber, hydratable clay, a microsphere, rice husk ash, an elastomer, a resin, latex, and combinations thereof.

10. The method of claim 1 comprising:

determining one or more desired cement composition parameters for at least one property selected from the group consisting of compressive strength, pump time, fluid loss, free water content, rheology, and a combination thereof

determining a component cost for at least one additive selected from the group consisting of the cement kiln dust, the natural pozzolan, a lightweight material, and a combination thereof; and

designing the cement composition to have the one or more desired cement composition parameters by adjusting the amount of the cement kiln dust, the natural pozzolan, and/or the lightweight material in the cement composition.

11. The method of claim 10 wherein adjusting the amount comprises adjusting the amount of the cement kiln dust and the lightweight material in the cement composition.

12. The method of claim 10 wherein adjusting the amount comprises adjusting the amount of the cement kiln dust and the natural pozzolan in the cement composition.

13. The method of claim 1 wherein the cement composition is extended and further comprises a set retarding additive.

14. A method of cementing in a subterranean formation comprising:

introducing a cement composition into the subterranean formation, wherein the cement composition comprises;

Portland cement interground with burned shale,

cement kiln dust,

a natural pozzolan comprising at least one pozzolan selected from the group consisting of pumicite, diatomaceous earth, volcanic ash, opaline shale, tuff, and a combination thereof, and

water; and

allowing the cement composition to set.

15. The method of claim 14 wherein the introducing the cement composition into the subterranean formation comprises introducing the cement composition into a space between a pipe string and the subterranean formation.

16. The method of claim 15 further comprising introducing the pipe string into a well bore penetrating the subterranean formation.

17. The method of claim 14 wherein the cement composition is foamed and further comprises a gas and a surfactant.

18. The method of claim 14 wherein the cement composition further comprises at least one cement selected from the group consisting of, a pozzolana cement, a gypsum cement, a high alumina content cement, a slag cement, a silica cement, and a combination thereof.

19. The method of claim 14 wherein the natural pozzolan is present in an amount of about 0.1% to about 50% by weight of cementitious components.

20. The method of claim 14 wherein the cement composition further comprises at least one additive selected from the group consisting of a strength-retrogression additive, a set accelerator, a set retarder, a weighting agent, a lightweight additive, a weighting additive, a gas-generating additive, a mechanical property enhancing additive, a lost-circulation material, a filtration-control additive, a dispersant, a defoaming agent, a foaming agent, a thixotropic additive, and a combination thereof.

21. The method of claim 14 wherein the cement composition further comprises at least one additive selected from the group consisting of fly ash, slag, metakaolin, shale, zeolite, lime, crystalline silica, amorphous silica, fumed silica, a salt, fiber, hydratable clay, a microsphere, rice husk ash, an elastomer, a resin, latex, and a combination thereof.

22. The method of claim 14 further comprising:

determining one or more desired cement composition parameters for at least one property selected from the group consisting of compressive strength, pump time, fluid loss, free water content, rheology, and a combination thereof

determining a component cost for at least one additive selected from the group consisting of the cement kiln dust, the pumicite, a lightweight material, and a combination thereof; and

designing the cement composition to have the one or more desired cement composition parameters by adjusting the amount of the cement kiln dust, the natural pozzolan, and/or the lightweight material in the cement composition.

23. The method of claim 22 wherein adjusting the amount comprises adjusting the amount of the cement kiln dust and the lightweight material in the cement composition.

24. The method of claim 22 wherein adjusting the amount comprises adjusting the amount of the cement kiln dust and the natural pozzolan in the cement composition.

25. The method of claim 14 wherein the cement composition is extended and further comprises a set retarding additive.

26. A method of cementing in a subterranean formation comprising:

providing a cement composition that comprises;

Portland cement interground with burned shale,

cement kiln dust,

pumicite,

lime, and

water;

introducing the cement composition into the subterranean formation; and

allowing the cement composition to set.