Methods and compositions comprising cement kiln dust having an altered particle size

• US 8,281,859 B2
• Filed: 02/17/2012
• Issued: 10/09/2012
• 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: Roddy, Craig W., Chatterji, Jiten, Brenneis, Chad, Jarratt, Callie R.
• Primary Examiner(s): Suchfield, George
• Application Number:
  US13/399,913
• Publication Number:
  US 20120145393A1
• Time in Patent Office: 235 Days
• Field of Search: None
• US Class Current: 166/291
• CPC Class Codes: C04B 18/162 Cement kiln dust; Lime kiln dust
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C09K 8/032 Inorganic additives
• CPC Class Codes: C09K 8/467 containing additives for specific purposes
• CPC Class Codes: E21B 33/13 Methods or devices for cementing, for plugging holes, crevices or the like
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]

Abstract

Methods and compositions are disclosed that comprise cement kiln dust having a mean particle size that has been altered. An embodiment discloses a subterranean treatment method comprising: introducing a treatment fluid into a subterranean formation, wherein the treatment fluid comprises cement kiln dust having a mean particle size that has been altered from its original size by grinding, separating, or a combination thereof. Another embodiment discloses a subterranean treatment method comprising: introducing a treatment fluid into a subterranean formation, wherein the treatment fluid comprises cement kiln dust having a mean particle size that has been reduced from its original size.

Claims

1. A subterranean treatment method comprising:

introducing a treatment fluid into a subterranean formation, wherein the treatment fluid comprises cement kiln dust in an amount of at least about 30% by weight of a total amount of cementitious components present in the treatment fluid, and wherein the cement kiln dust has a mean particle size that has been altered by grinding, separating, or a combination thereof.

2. The method of claim 1 wherein the mean particle size of the cement kiln dust after altering is at least 5% greater than its original size.

3. The method of claim 1 wherein the mean particle size of the cement kiln dust after altering is at least 5% less than its original size.

4. The method of claim 1 wherein the mean particle size of the cement kiln dust after altering is in a range of about 1 micron to about 350 microns.

5. The method of claim 1 wherein the treatment fluid is a settable composition.

6. A subterranean treatment method comprising:

introducing a settable composition into a subterranean formation, wherein the settable composition comprises cement kiln dust having a mean particle size that has been reduced from its original size; and

allowing the settable composition to set in the subterranean formation, wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition of at least about 5% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

7. The method of claim 6 wherein the mean particle size of the cement kiln dust after reducing is less than about 15 microns.

8. The method of claim 6 wherein the mean particle size of the cement kiln dust after reducing is in a range of from about 5% to about 95% of its original size.

9. The method of claim 6 wherein the mean particle size of the cement kiln dust has been reduced by grinding, separating, or a combination thereof.

10. The method of claim 6 wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition of at least about 50% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

11. The method of claim 6 wherein the cement kiln dust is present in the settable composition in an amount in a range of from about 1% to 100% by weight of a total amount of cementitious components present in the settable composition.

12. The method of claim 6 wherein the cement kiln dust was prepared by a process comprising intergrinding cement kiln dust with an additional additive.

13. The method of claim 12 wherein the additional additive comprises an additive selected from the group consisting of hydraulic cement, fly ash, slag, shale, zeolite, metakaolin, pumice, perlite, lime, lime kiln dust, silica, rice-hull ash, micro-fine cement, and any combination thereof.

14. The method of claim 6 wherein water is present in the settable composition in an amount sufficient to form a pumpable slurry.

15. The method of claim 6 wherein the settable composition further comprises an additive selected from the group consisting of a set retarding additive, a strength-retrogression additive, a set accelerator, a weighting agent, a lightweight additive, a gas-generating additive, a mechanical-property-enhancing additive, a lost-circulation material, a filtration-control additive, a dispersant, a fluid-loss-control additive, a defoaming agent, a foaming agent, an oil-swellable particle, a water-swellable particle, a thixotropic additive, and any combination thereof.

16. The method of claim 6 wherein the settable composition further comprises an additive selected from the group consisting of hydraulic cement, fly ash, slag, shale, zeolite, metakaolin, pumice, perlite, lime, lime kiln dust, silica, rice-hull ash, micro-fine cement, a salt, a fiber, a hydratable clay, a microsphere, an elastomer, an elastomeric particle, a resin, a latex, and any combination thereof.

17. The method of claim 6 wherein the settable composition is introduced into a space between a pipe string and a well bore wall.

18. The method of claim 6 wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition of at least about 20% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

19. The method of claim 6 wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition of at least about 60% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

20. The method of claim 6 wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition of at least about 100% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

21. The method of claim 6 wherein the cement kiln dust is present in the settable composition in an amount of at least about 30% by weight of a total amount of cementitious components present in the settable composition.

22. The method of claim 6 wherein the cement kiln dust is present in the settable composition in an amount in a range of from about 50% to 100% by weight of a total amount of cementitious components present in the settable composition.

23. A subterranean treatment method comprising:

introducing a settable composition into a subterranean formation, wherein the settable composition comprises cement kiln dust that has been ground, wherein the cement kiln dust is present in an amount of about 50% to 100% by weight of cementitious components present in the settable composition; and

allowing the settable composition to set in the subterranean formation.

24. The method of claim 23 wherein the cement kiln dust that has been ground has a mean particle size of less than about 15 microns.

25. The method of claim 23 wherein the cement kiln dust that has been ground has a mean particle size in a range of from about 5% to about 95% of its original particle size.

26. The method of claim 23 wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition of at least about 5% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

27. The method of claim 23 wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition of at least about 50% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

28. The method of claim 23 wherein the cement kiln dust is present in the settable composition in an amount in a range of from about 80% to about 100% by weight of cementitious components in the settable composition.

29. The method of claim 23 wherein the cement kiln dust was prepared by a process comprising intergrinding cement kiln dust with an additional additive.

30. The method of claim 29 wherein the additional additive comprises an additive selected from the group consisting of hydraulic cement, fly ash, slag, shale, zeolite, metakaolin, pumice, perlite, lime, lime kiln dust, silica, rice-hull ash, micro-fine cement, and any combination thereof.

31. The method of claim 23 wherein water is present in the settable composition in an amount sufficient to form a pumpable slurry.

32. The method of claim 23 wherein the settable composition further comprises an additive selected from the group consisting of a set retarding additive, a strength-retrogression additive, a set accelerator, a weighting agent, a lightweight additive, a gas-generating additive, a mechanical-property-enhancing additive, a lost-circulation material, a filtration-control additive, a dispersant, a fluid-loss-control additive, a defoaming agent, a foaming agent, an oil-swellable particle, a water-swellable particle, a thixotropic additive, and any combination thereof.

33. The method of claim 23 wherein the settable composition further comprises an additive selected from the group consisting of hydraulic cement, fly ash, slag, shale, zeolite, metakaolin, pumice, perlite, lime, lime kiln dust, silica, rice-hull ash, micro-fine cement, a salt, a fiber, a hydratable clay, a microsphere, an elastomer, an elastomeric particle, a resin, a latex, and any combination thereof.

34. The method of claim 23 wherein the settable composition is introduced into a space between a pipe string and a well bore wall.

35. The method of claim 23 wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition of at least about 20% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

36. The method of claim 23 wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition of at least about 60% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

37. The method of claim 23 wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition of at least about 100% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

38. A method of cementing comprising:

providing a settable composition comprising cement kiln dust having a mean particle size that has been reduced from its original size; and

allowing the settable composition to set, wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition at least about 5% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

39. The method of claim 38 wherein the mean particle size of the cement kiln dust after reducing is less than about 15 microns.

40. The method of claim 38 wherein the mean particle size of the cement kiln dust after reducing is in a range of from about 5% to about 95% of its original size.

41. The method of claim 38 wherein the mean particle size of the cement kiln dust has been reduced by grinding, separating, or a combination thereof.

42. The method of claim 38 wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition of at least about 20% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

43. The method of claim 38 wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition of at least about 50% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

44. The method of claim 38 wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition of at least about 60% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

45. The method of claim 38 wherein the mean particle size of the cement kiln dust has been reduced in an amount sufficient to provide an increase in 24-hour compressive strength for the settable composition of at least about 100% as measured using an Ultrasonic Cement Analyzer while maintained at 140°

F. and 3,000 psi.

46. The method of claim 38 wherein the cement kiln dust is present in the settable composition in an amount in a range of from about 1% to 100% by weight of a total amount of cementitious components present in the settable composition.

47. The method of claim 38 wherein the cement kiln dust was prepared by a process comprising intergrinding cement kiln dust with an additional additive.

48. The method of claim 47 wherein the additional additive comprises an additive selected from the group consisting of hydraulic cement, fly ash, slag, shale, zeolite, metakaolin, pumice, perlite, lime, lime kiln dust, silica, rice-hull ash, micro-fine cement, and any combination thereof

49. The method of claim 38 wherein water is present in the settable composition in an amount sufficient to form a pumpable slurry.

50. The method of claim 38 wherein the settable composition further comprises an additive selected from the group consisting of a set retarding additive, a strength-retrogression additive, a set accelerator, a weighting agent, a lightweight additive, a gas-generating additive, a mechanical-property-enhancing additive, a lost-circulation material, a filtration-control additive, a dispersant, a fluid-loss-control additive, a defoaming agent, a foaming agent, an oil-swellable particle, a water-swellable particle, a thixotropic additive, and any combination thereof.

51. The method of claim 38 wherein the settable composition further comprises an additive selected from the group consisting of hydraulic cement, fly ash, slag, shale, zeolite, metakaolin, pumice, perlite, lime, lime kiln dust, silica, rice-hull ash, micro-fine cement, a salt, a fiber, a hydratable clay, a microsphere, an elastomer, an elastomeric particle, a resin, a latex, and any combination thereof.