Extended settable compositions comprising cement kiln dust and associated methods

• US 7,674,332 B2
• Filed: 01/07/2009
• Issued: 03/09/2010
• 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, Jilen, King, Bobby J., Roddy, Craig W., Brenneis, D. Chad
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US12/349,676
• Publication Number:
  US 20090114126A1
• Time in Patent Office: 426 Days
• Field of Search: 106/716, 106/600, 106/692, 106/696, 106/707, 106/713, 106/714, 106/726, 106/823
• US Class Current: 106/716
• 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 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 18/162 Cement kiln dust; Lime kiln dust
• CPC Class Codes: C04B 2103/12 Set accelerators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 22/002 Water
• CPC Class Codes: C04B 22/124 Chlorides of ammonium or of the alkali or alkaline earth metals, e.g. calcium chloride
• CPC Class Codes: C04B 24/04 Carboxylic acids; Salts, anhydrides or esters thereof
• CPC Class Codes: C04B 24/06 containing hydroxy groups
• CPC Class Codes: C04B 24/122 Hydroxy amines
• CPC Class Codes: C04B 24/18 Lignin sulfonic acid or derivatives thereof, e.g. sulfite lye
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 Portland 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: 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 the present invention includes a method of cementing in a subterranean formation comprising: providing an extended settable composition comprising hydraulic cement, cement kiln dust, water, and a set retarding additive, wherein the extended settable composition is capable of remaining in a pumpable fluid state for at least about 1 day; adding a cement set accelerator to the extended settable composition; introducing the extended settable composition into a well bore; and allowing the extended settable composition to set. Another embodiment of the present invention includes a method of cementing in a subterranean formation comprising: providing an extended settable composition comprising hydraulic cement, cement kiln dust, water, and a set retarding additive; storing the extended settable composition; adding a cement set accelerator to the extended settable composition; introducing the extended settable composition into a well bore; and allowing the extended settable composition to set.

Claims

1. An extended settable composition comprising:

hydraulic cement in an amount of about 25% to about 75% by weight, wherein the hydraulic cement comprises a cement selected from the group consisting of Portland cement, pozzolana cement, gypsum cement, high alumina content cement, slag cement, silica cement, and any combination thereof,

cement kiln dust in an amount of about 25% to about 75% by weight,

a set retarding additive in an amount of about 0.1% to about 5% by weight, and

water, wherein the extended settable composition is capable of remaining in a pumpable fluid state for at least about 1 day.

2. The extended settable composition of claim 1 wherein the extended settable composition is capable of remaining in a pumpable fluid state for at least about 5 days.

3. The extended settable composition of claim 1 wherein the density of the extended settable composition is in the range of from about 8 pounds per gallon to about 16 pounds per gallon.

4. The extended settable composition of claim 1 wherein the water comprises water selected from the group consisting of freshwater, saltwater, brine, seawater, and any combination thereof.

5. The extended settable composition of claim 1 wherein the water is present in the extended settable composition in an amount in the range of from about 40% to about 150% by weight.

6. The extended settable composition of claim 1 wherein the set retarding additive comprises a set retarding additive selected from the group consisting of an organic acid, a lignosulfonate, a synthetic retarder, and any combination thereof.

7. The extended settable composition of claim 1 wherein the set retarding additive comprises tartaric acid.

8. The extended settable composition of claim 1 wherein the set retarding additive comprises a sulfomethylated lignin.

9. The extended settable composition of claim 1 wherein the extended settable composition comprises an additive selected from the group consisting of fly ash, slag cement, shale, zeolite, metakaolin, and any combination thereof.

18. The extended settable composition of claim 1 wherein the hydraulic cement comprises the Portland cement.

19. The extended settable composition of claim 1 wherein the extended settable composition further comprises a fluid loss control additive.

20. The extended settable composition of claim 1 wherein the extended settable composition further comprises an additive selected from the group consisting of a weight reducing additive, a heavyweight additive, a lost circulation material, a filtration control additive, a dispersant, a suspending agent, and any combination thereof.

10. An extended settable composition comprising:

hydraulic cement in an amount of about 25% to about 75% by weight, wherein the hydraulic cement comprises a cement selected from the around consisting of Portland cement, pozzolana cement, gypsum cement, high alumina content cement, slag cement, silica cement, and any combination thereof,

cement kiln dust in an amount of about 25% to about 75% by weight,

a set retarding additive in an amount of about 0.1% to about 5% by weight, wherein the set retarding additive comprises tartaric acid, and

water, wherein the extended settable composition is capable of remaining in a pumpable fluid state for at least about 5 days.

11. The extended settable composition of claim 10 wherein the density of the composition is in the range of from about 8 pounds per gallon to about 16 pounds per gallon.

12. The extended settable composition of claim 10 wherein the water comprises water selected from the group consisting of freshwater, saltwater, brine, seawater, and any combination thereof.

13. The extended settable composition of claim 10 wherein the water is present in the composition in an amount in the range of from about 40% to about 150% by weight.

14. The extended settable composition of claim 10 wherein the extended settable composition comprises an additive selected from the group consisting of fly ash, slag cement, shale, zeolite, metakaolin, and any combination thereof.

15. The extended settable composition of claim 10 wherein the hydraulic cement comprises the Portland cement.

16. The extended settable composition of claim 10 wherein the extended settable composition further comprises a fluid loss control additive.

17. The extended settable composition of claim 10 wherein the extended settable composition further comprises an additive selected from the group consisting of a weight reducing additive, a heavyweight additive, a lost circulation material, a filtration control additive, a dispersant, a suspending agent, and any combination thereof