Settable compositions comprising cement kiln dust and swellable particles

• US 7,927,419 B2
• Filed: 09/11/2009
• Issued: 04/19/2011
• 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: Brenneis, D. Chad, Chatterji, Jiten, King, Bobby J., Roddy, Craig W.
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US12/558,097
• Publication Number:
  US 20090320720A1
• Time in Patent Office: 585 Days
• Field of Search: 106/716, 106/718
• US Class Current: 106/716
• CPC Class Codes: C04B 16/085 expanded in situ, i.e. during or after mixing the mortar, concrete or artificial stone ingredients
• CPC Class Codes: C04B 18/162 Cement kiln dust; Lime kiln dust
• CPC Class Codes: C04B 2103/0049 Water-swellable polymers
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 24/2676 Polystyrenes
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C09K 8/426 for plugging
• CPC Class Codes: C09K 8/428 for squeeze cementing, e.g. for repairing
• 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

A variety of methods and compositions are disclosed herein, including, in one embodiment, a method comprising: introducing a settable composition into a subterranean formation, wherein the settable composition comprises: a cementitious component comprising a hydraulic cement and cement kiln dust; a swellable particle; and water; and allowing the settable composition to set in the subterranean formation. Another embodiment comprises a settable composition comprising: a cementitious component comprising a hydraulic cement and cement kiln dust, a swellable particle, and water.

Claims

1. A settable composition comprising:

a cementitious component comprising a hydraulic cement and cement kin dust;

a swellable particle, wherein the swellable particle comprises at least one water-swellable polymer selected from the group consisting of starch-polyacrylate acid graft copolymer, polyethylene oxide polymer, carboxymethyl cellulose polymer, polyacrylamide, poly(acrylic acid), poly(acrylic acid-co-acrylamide), graft-poly(ethylene oxide) of poly(acrylic acid), poly(2-hydroxyethyl methacrylate), and poly(2-hydroxypropyl methacrylate), salts thereof, and combinations thereof; and

water.

4. The settable composition of claim 1 wherein the swellable particle comprises the salt of the polyacrylic acid, wherein the salt of the polyacrylic acid comprises a sodium salt of polyacrylic acid.

5. The settable composition of claim 1 wherein the swellable particle comprises the salt of the graft-poly(ethylene oxide) of poly(acrylic acid), wherein the salt of the graft-poly(ethylene oxide) of poly(acrylic acid) comprises a sodium salt graft-poly(ethylene oxide) of poly(acrylic) acid.

6. The settable composition of claim 1 wherein the settable composition further comprises at least one additive selected from the group consisting of fly ash, metakaolin, shale, zeolite, gas, crystalline silica, amorphous silica, salt, fiber, hydratable clay, microspheres, pozzolan, lime, latex cement, and combinations thereof.

17. The settable composition of claim 1 wherein the hydraulic cement is present in an amount of at least about 80% by weight of the cementitious component.

18. The settable composition of claim 1 wherein the settable composition has a density of about 8 pounds per gallon to about 16 pounds per gallon.

19. The settable composition of claim 1 wherein the hydraulic cement comprises at least one hydraulic cement selected from the group consisting of Portland cement, pozzolana cement, gypsum cement, high alumina content cement, slag cement, silica cement, and combinations thereof.

20. The settable composition of claim 1 wherein the cement kiln dust is present in the settable composition in an amount of about 25% to about 75% by weight of the cementitious component, and wherein the hydraulic cement is present in the settable composition in an amount of about 25% to about 75% by weight of the cementitious component.

21. The settable composition of claim 1 wherein the swellable particle is present in the settable composition in an amount of 5% to about 25% by weight of the cementitious component.

2. A settable composition comprising:

a cementitious component comprising a hydraulic cement and cement kiln dust;

a swellable particle, wherein the swellable particle comprises at least one swellable elastomer selected from the group consisting of natural rubber, acrylate butadiene rubber, polyacrylate rubber, isoprene rubber, chloroprene rubber, butyl rubber, brominated butyl rubber, chlorinated butyl rubber, chlorinated polyethylene, neoprene rubber, styrene butadiene copolymer rubber, sulphonated polyethylene, ethylene acrylate rubber, epichlorohydrin ethylene oxide copolymer, ethylene-propylene rubber, ethylene-propylene-diene terpolymer rubber, ethylene vinyl acetate copolymer, fluorosilicone rubber, silicone rubber, poly 2,2,1-bicyclo heptene (polynorborneane), alkylstyrene, nitrile rubber, hydrogenated nitrile rubber, fluoro rubber, perfluoro rubber, tetrafluorethylene/propylene, isobutylene maleic anhydride, and combinations thereof; and

water.

3. The settable composition of claim 2 wherein the swellable particle comprises a styrene butadiene rubber, wherein the styrene butadiene rubber is a block copolymer.

11. The settable composition of claim 2 wherein the settable composition has a density of about 8 pounds per gallon to about 16 pounds per gallon.

12. The settable composition of claim 2 wherein the hydraulic cement comprises at least one hydraulic cement selected from the group consisting of Portland cement, pozzolana cement, gypsum cement, high alumina content cement, slag cement, silica cement, and combinations thereof.

13. The settable composition of claim 2 wherein the cement kiln dust is present in the settable composition in an amount of about 25% to about 75% by weight of the cementitious component, and wherein the hydraulic cement is present in the settable composition in an amount of about 25% to about 75% by weight of the cementitious component.

14. The settable composition of claim 2 wherein the swellable particle is present in the settable composition in an amount of 5% to about 25% by weight of the cementitious component.

15. The settable composition of claim 2 wherein the settable composition further comprises at least one additive selected from the group consisting of fly ash, metakaolin, shale, zeolite, gas, crystalline silica, amorphous silica, salt, fiber, hydratable clay, microspheres, pozzolan, lime, latex cement, and combinations thereof.

16. The settable composition of claim 2 wherein the hydraulic cement is present in an amount of at least about 80% by weight of the cementitious component.

7. A settable composition comprising:

a cementitious component comprising a hydraulic cement and cement kiln dust,

a swellable particle comprising at least one water-swellable polymer selected from the group consisting of starch-polyacrylate acid graft copolymer, polyethylene oxide polymer, carboxymethyl cellulose polymer, polyacrylamide, poly(acrylic acid), poly(acrylic acid-co-acrylamide), graft-poly(ethylene oxide) of poly(acrylic acid), poly(2-hydroxyethyl methacrylate), and poly(2-hydroxypropyl methacrylate), salts thereof, and combinations thereof,

an additive selected from the group consisting of a foaming and stabilizing surfactant composition, a set retarding additive, an accelerator, a weight reducing additive, a heavyweight additive, a lost circulation material, a filtration control additive, a dispersant, a thixotropic additive, and combinations thereof, and

water.

8. The settable composition of claim 7 wherein the swellable particle is present in the settable composition in an amount of about 5% to about 25% by weight of the cementitious component.

9. A settable composition comprising:

a cementitious component comprising a hydraulic cement and cement kiln dust,

a swellable particle comprising at least one swellable elastomer selected from the group consisting of natural rubber, acrylate butadiene rubber, polyacrylate rubber, isoprene rubber, chloroprene rubber, butyl rubber, brominated butyl rubber, chlorinated butyl rubber, chlorinated polyethylene, neoprene rubber, styrene butadiene copolymer rubber, sulphonated polyethylene, ethylene acrylate rubber, epichlorohydrin ethylene oxide copolymer, ethylene-propylene rubber, ethylene-propylene-diene terpolymer rubber, ethylene vinyl acetate copolymer, fluorosilicone rubber, silicone rubber, poly 2,2,1-bicyclo heptene (polynorborneane), alkylstyrene, nitrile rubber, hydrogenated nitrile rubber, fluoro rubber, perfluoro rubber, tetrafluorethylene/propylene, isobutylene maleic anhydride, and combinations thereof,

an additive selected from the group consisting of a foaming and stabilizing surfactant composition, a set retarding additive, an accelerator, a weight reducing additive, a heavyweight additive, a lost circulation material, a filtration control additive, a dispersant, a thixotropic additive, and combinations thereof, and

water.

10. The settable composition of claim 9 wherein the swellable particle is present in the settable composition in an amount of about 5% to about 25% by weight of the cementitious component.

22. A settable composition comprising:

a cementitious component comprising a hydraulic cement and cement kin dust;

a swellable particle comprising a material selected from the group consisting of starch-polyacrylate acid graft copolymer, polyethylene oxide polymer, carboxymethyl cellulose polymer, polyacrylamide, poly(acrylic acid), poly(acrylic acid-co-acrylamide), graft-poly(ethylene oxide) of poly(acrylic acid), poly(2-hydroxyethyl methacrylate), and poly(2-hydroxypropyl methacrylate), natural rubber, acrylate butadiene rubber, polyacrylate rubber, isoprene rubber, chloroprene rubber, butyl rubber, brominated butyl rubber, chlorinated butyl rubber, chlorinated polyethylene, neoprene rubber, styrene butadiene copolymer rubber, sulphonated polyethylene, ethylene acrylate rubber, epichlorohydrin ethylene oxide copolymer, ethylene-propylene rubber, ethylene-propylene-diene terpolymer rubber, ethylene vinyl acetate copolymer, fluorosilicone rubber, silicone rubber, poly 2,2,1-bicyclo heptene (polynorborneane), alkylstyrene, nitrile rubber, hydrogenated nitrile rubber, fluoro rubber, perfluoro rubber, tetrafluorethylene/propylene, isobutylene maleic anhydride, salts thereof, and combinations thereof; and

water.