Foamed cement compositions comprising oil-swellable particles

• US 8,030,253 B2
• Filed: 08/20/2009
• Issued: 10/04/2011
• 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: Chatterji, Jiten, King, Bobby J., Roddy, Craig W., Brenneis, D. Chad
• Primary Examiner(s): Kugel; Timothy J.
• Application Number:
  US12/544,915
• Publication Number:
  US 20090312445A1
• Time in Patent Office: 775 Days
• Field of Search: 507/269, 507/203, 507/217, 507/221, 507/224, 507/252, 106/672, 106/677, 106/678, 106/820, 106/823
• US Class Current: 507/269
• 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 2103/40 Surface-active agents, dispersants
• CPC Class Codes: C04B 24/163 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 24/2611 Polyalkenes
• CPC Class Codes: C04B 24/2623 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 24/2676 Polystyrenes
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• 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 8/473 Density reducing additives, e.g. for obtaining foamed cement compositions
• CPC Class Codes: C09K 8/487 Fluid loss control additives; Additives for reducing or preventing circulation loss
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

Of the many compositions provided herein, an embodiment includes a foamed cement composition comprising a cementitious component, an oil-swellable particle comprising at least one swellable elastomer selected from the group consisting of acrylate butadiene rubber, polyacrylate rubber, isoprene rubber, choloroprene rubber, butyl rubber, brominated butyl rubber, chlorinated butyl rubber, chlorinated polyethylene, neoprene rubber, styrene butadiene block copolymer, sulphonated polyethylene, ethylene acrylate rubber, epichlorohydrin ethylene oxide copolymer, ethylene-propylene rubber, ethylene vinyl acetate copolymer, fluorosilicone rubber, silicone rubber, and combinations thereof, a foaming and stabilizing surfactant, gas, and water. Another embodiment includes a foamed cement composition comprising a cementitious component, an oil-swellable particle comprising a block copolymer of styrene butadiene rubber, a foaming and stabilizing surfactant, and gas.

Claims

1. A foamed cement composition comprising:

a cementitious component,

an oil-swellable particle comprising at least one swellable elastomer selected from the group consisting of acrylate butadiene rubber, polyacrylate rubber, isoprene rubber, chloroprene rubber, butyl rubber, brominated butyl rubber, chlorinated butyl rubber, chlorinated polyethylene, neoprene rubber, styrene butadiene block copolymer, sulphonated polyethylene, ethylene acrylate rubber, epichlorohydrin ethylene oxide copolymer, ethylene-propylene rubber, ethylene vinyl acetate copolymer, fluorosilicone rubber, silicone rubber, and combinations thereof,

a foaming and stabilizing surfactant,

a gas, and

water.

2. The foamed cement composition of claim 1 wherein the cementitious component comprises cement kiln dust.

3. The foamed cement composition of claim 1 wherein the cementitious component comprises hydraulic cement.

4. The foamed cement composition of claim 1 wherein the cementitious component comprises cement kiln dust in an amount of about 1% to about 75% by weight of the cementitious component.

5. The foamed cement composition of claim 1 wherein the oil-swellable particle is present in the foamed cement composition in an amount of about 1% to about 27% by weight of the cementitious component.

6. The foamed cement composition of claim 1 wherein the oil-swellable particle is capable of swelling by at least 10% at downhole conditions.

7. The foamed cement composition of claim 1 wherein the foaming and stabilizing surfactant comprises at least one surfactant 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.

8. The foamed cement composition of claim 1 wherein the foamed cement composition comprises at least one additive selected from the group consisting of fly ash, slag, metakaolin, shale, zeolite, a crystalline silica compound, amorphous silica, salt, fiber, hydratable clay, a microsphere, pozzolan lime, latex cement, a thixotropic additive, and combinations thereof.

9. The foamed cement composition of claim 1 wherein the foamed cement composition comprises at least one additive selected from the group consisting of a set retarding additive, an accelerator, a weight reducing additive, a heavyweight additive, a lost circulation material, a filtration control additive, a dispersant, and combinations thereof.

10. The foamed cement composition of claim 1 wherein the foamed cement composition has a density of about 8 pounds per gallon to about 13 pounds per gallon, and wherein the gas is present in an amount of about 10% to about 80% by volume of the foamed cement composition.

11. A foamed cement composition comprising:

a cementitious component,

an oil-swellable particle comprising a block copolymer of styrene butadiene rubber,

a foaming and stabilizing surfactant, and

a gas.

12. The foamed cement composition of claim 11 wherein the cementitious component comprises cement kiln dust.

13. The foamed cement composition of claim 11 wherein the cementitious component comprises hydraulic cement.

14. The foamed cement composition of claim 11 wherein the cementitious component comprises cement kiln dust in an amount of about 1% to about 75% by weight of the cementitious component.

15. The foamed cement composition of claim 11 wherein the oil-swellable particle is present in the foamed cement composition in an amount of about 1% to about 27% by weight of the cementitious component.

16. The foamed cement composition of claim 11 wherein the oil-swellable particle is capable of swelling by at least 10% at downhole conditions.

17. The foamed cement composition of claim 11 wherein the foaming and stabilizing surfactant comprises at least one surfactant 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.

18. The foamed cement composition of claim 11 wherein the foamed cement composition comprises at least one additive selected from the group consisting of fly ash, slag, metakaolin, shale, zeolite, a crystalline silica compound, amorphous silica, salt, fiber, hydratable clay, a microsphere, pozzolan lime, latex cement, a thixotropic additive, and combinations thereof.

19. The foamed cement composition of claim 11 wherein the foamed cement composition comprises at least one additive selected from the group consisting of a set retarding additive, an accelerator, a weight reducing additive, a heavyweight additive, a lost circulation material, a filtration control additive, a dispersant, and combinations thereof.

20. The foamed cement composition of claim 11 wherein the foamed cement composition has a density of about 8 pounds per gallon to about 13 pounds per gallon, and wherein the gas is present in an amount of about 10% to about 80% by volume of the foamed cement composition.