Acid-soluble cement compositions comprising cement kiln dust and/or a natural pozzolan and methods of use

• US 8,297,357 B2
• Filed: 06/28/2010
• Issued: 10/30/2012
• 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: Brenneis, D. Chad, Roddy, Craig W., Benkley, James R., DePlacido, Preston, Caveny, William J., Morgan, Rickey L., Morgan, Ronnie G.
• Primary Examiner(s): SUCHFIELD, GEORGE A
• Application Number:
  US12/825,004
• Publication Number:
  US 20100282466A1
• Time in Patent Office: 855 Days
• Field of Search: 166/285, 166/292, 166/293, 166/300, 175/72, 106/685, 106707-710, 106/716, 106/751, 507/269
• US Class Current: 166/293
• CPC Class Codes: C04B 14/047 Zeolites
• CPC Class Codes: C04B 14/062 Microsilica, e.g. colloïdal silica preparing microsilica slurries or suspensions C04B18/148
• 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 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 2103/0049 Water-swellable polymers
• CPC Class Codes: C04B 2103/12 Set accelerators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/408 Dispersants
• CPC Class Codes: C04B 2103/46 Water-loss or fluid-loss reducers, hygroscopic or hydrophilic agents, water retention agents
• CPC Class Codes: C04B 2103/50 Defoamers, air detrainers
• CPC Class Codes: C04B 2111/1037 Cement free compositions, e.g. hydraulically hardening mixtures based on waste materials, not containing cement as such
• CPC Class Codes: C04B 22/0026 : Salt water, e.g. seawater
• CPC Class Codes: C04B 22/064 : of the alkaline-earth metals
• CPC Class Codes: C04B 24/26 : obtained by reactions only involving carbon-to-carbon unsaturated bonds C04B24/243 takes precedence
• 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 28/32 : Magnesium oxychloride cements, e.g. Sorel cement
• CPC Class Codes: C04B 38/02 : by adding chemical blowing agents
• 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 40/0092 : Temporary binders, mortars or concrete, i.e. materials intended to be destroyed or removed after hardening, e.g. by acid dissolution
• CPC Class Codes: C09K 8/46 : containing inorganic binders, e.g. 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

The present invention relates to acid-soluble cement compositions that comprise cement kiln dust (“CKD”) and/or a natural pozzolan and associated methods of use. An embodiment includes a method of cementing comprising: placing an acid-soluble cement composition in a subterranean formation, wherein the acid-soluble cement composition comprises a hydraulic cement, a component selected from the group consisting of CKD, pumicite, and a combination thereof, and water; allowing the acid-soluble cement composition to set; and contacting the set acid-soluble cement composition with an acid to dissolve the set acid-soluble cement composition.

Claims

1. A method of cementing comprising:

placing an acid-soluble cement composition in a subterranean formation, the acid-soluble cement composition comprising;

0% to about 20% hydraulic cement by weight of cementitious components present in the acid-soluble cement composition,

a component selected from the group consisting of cement kiln dust, pumicite, and a combination thereof, and

water;

allowing the acid-soluble cement composition to set; and

contacting the set acid-soluble cement composition with an acid to dissolve the set acid-soluble cement composition.

2. The method of claim 1 wherein the acid-soluble cement composition has a density of about 8 pounds per gallon to about 16 pounds per gallon.

3. The method of claim 1 wherein the hydraulic cement comprises a hydraulic cement selected from the group consisting of a Portland cement, a pozzolana cement, a gypsum cement, a high alumina content cement, a slag cement, a silica cement, and any combination thereof.

4. The method of claim 1 wherein the hydraulic cement comprises a Sorel cement.

5. The method of claim 1 wherein the hydraulic cement comprises a magnesium oxide and a magnesium chloride.

6. The method of claim 1 wherein the component comprises the cement kiln dust in an amount of about 20% to about 100% by weight of the cementitious components in the acid-soluble cement composition.

7. The method of claim 1 wherein the component comprises the pumicite in an amount of about 20% to about 100% by weight of the cementitious components in the acid-soluble cement composition.

8. The method of claim 7 wherein the acid-soluble cement composition further comprises a source of calcium ions.

9. The method of claim 1 wherein the water is selected from the group consisting of freshwater, saltwater, brine, seawater, and any combination thereof.

10. The method of claim 1 wherein the water is present in an amount of about 40% to about 200% by weight of the cementitious components.

11. The method of claim 1 wherein the acid-soluble cement composition further comprises hydrated lime in an amount of about 1% to about 40% by weight of the cementitious components.

12. The method of claim 1 wherein the acid-soluble cement composition further comprises an acid-soluble filler.

13. The method of claim 1 wherein the acid-soluble cement composition further comprises an additive selected from the group consisting of fly ash, slag cement, metakaolin, shale, zeolite, crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, microsphere, rice husk ash, elastomer, elastomeric particle, resin, latex, and any combination thereof.

14. The method of claim 1 wherein the acid-soluble cement 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.

15. The method of claim 1 wherein contacting the set acid-soluble cement composition with an acid comprises contacting the set acid-soluble cement composition with an aqueous acid composition, wherein the acid comprises hydrochloric acid present in the aqueous acid composition in an amount of about 7.5% to about 28% by weight of the aqueous acid composition.

16. The method of claim 1 wherein the acid-soluble cement composition is allowed to set in a lost circulation zone in the subterranean formation.

17. The method of claim 1 wherein the acid-soluble cement composition is allowed set and form an annular plug in a well bore penetrating the subterranean formation.

18. A method of cementing comprising:

placing an acid-soluble cement composition in a subterranean formation, the acid-soluble cement composition comprising;

0% to about 20% Portland cement by weight of cementitious components present in the acid-soluble cement composition,

cement kiln dust,

an acid-soluble filler, and

water;

allowing the cement composition to set; and

contacting the set acid-soluble cement composition with an acid to dissolve the set acid-soluble cement composition.

19. The method of claim 18 wherein the acid-soluble cement composition has a density of about 8 pounds per gallon to about 16 pounds per gallon.

20. The method of claim 18 wherein the cement kiln dust is present in an amount of about 20% to about 100% by weight of the cementitious components.

21. The method of claim 18 wherein the water is selected from the group consisting of freshwater, saltwater, brine, seawater, and any combination thereof.

22. The method of claim 18 wherein the water is present in an amount of about 40% to about 200% by weight of the cementitious components.

23. The method of claim 18 wherein the acid-soluble filler comprises a material selected from the group consisting of dolomite, magnesium carbonate, calcium carbonate, zinc carbonate, and any combination thereof.

24. The method of claim 18 wherein the acid-soluble cement composition further comprises an additive selected from the group consisting of fly ash, slag cement, metakaolin, shale, zeolite, crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, microsphere, rice husk ash, elastomer, elastomeric particle, resin, latex, and any combination thereof.

25. The method of claim 18 wherein the acid-soluble cement 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.

26. The method of claim 18 wherein contacting the set acid-soluble cement composition with an acid comprises contacting the set acid-soluble cement composition with an aqueous acid composition, wherein the acid comprises hydrochloric acid present in the aqueous acid composition in an amount of about 7.5% to about 28% by weight of the aqueous acid composition.

27. The method of claim 18 wherein the acid-soluble cement composition is allowed to set in a lost circulation zone in the subterranean formation.

28. The method of claim 18 wherein the acid-soluble cement composition is allowed set and form an annular plug in a well bore penetrating the subterranean formation.

29. A method of cementing comprising:

placing an acid-soluble cement composition in a subterranean formation, the acid-soluble cement composition comprising;

hydraulic cement, wherein the hydraulic cement comprises a Sorel cement,

a component selected from the group consisting of cement kiln dust, pumicite, and a combination thereof, and

water;

allowing the acid-soluble cement composition to set; and

contacting the set acid-soluble cement composition with an acid to dissolve the set acid-soluble cement composition.

30. The method of claim 29 wherein the component comprises the cement kiln dust in an amount of about 20% to about 100% by weight of cementitious components present in the acid-soluble cement composition.

31. The method of claim 29 wherein the component comprises the pumicite in an amount of about 20% to about 100% by weight of cementitious components present in the acid-soluble cement composition.

32. The method of claim 29 wherein the acid-soluble cement composition further comprises hydrated lime in an amount of about 1% to about 40% by weight of cementitious components.

33. The method of claim 29 wherein the acid-soluble cement composition further comprises an acid-soluble filler.

34. The method of claim 29 wherein contacting the set acid-soluble cement composition with an acid comprises contacting the set acid-soluble cement composition with an aqueous acid composition, wherein the acid comprises hydrochloric acid present in the aqueous acid composition in an amount of about 7.5% to about 28% by weight of the aqueous acid composition.

35. A method of cementing comprising:

placing an acid-soluble cement composition in a subterranean formation, the acid-soluble cement composition comprising;

hydraulic cement, wherein the hydraulic cement comprises a magnesium oxide and a magnesium chloride

a component selected from the group consisting of cement kiln dust, pumicite, and a combination thereof, and

water;

allowing the acid-soluble cement composition to set; and

contacting the set acid-soluble cement composition with an acid to dissolve the set acid-soluble cement composition.

36. The method of claim 35 wherein the component comprises the cement kiln dust in an amount of about 20% to about 100% by weight of cementitious components in the acid-soluble cement composition.

37. The method of claim 35 wherein the component comprises the pumicite in an amount of about 20% to about 100% by weight of cementitious components present in the acid-soluble cement composition.

38. The method of claim 35 wherein the acid-soluble cement composition further comprises hydrated lime in an amount of about 1% to about 40% by weight of cementitious components present in the acid-soluble cement composition.

39. The method of claim 35 wherein the acid-soluble cement composition further comprises an acid-soluble filler.

40. The method of claim 35 wherein contacting the set acid-soluble cement composition with an acid comprises contacting the set acid-soluble cement composition with an aqueous acid composition, wherein the acid comprises hydrochloric acid present in the aqueous acid composition in an amount of about 7.5% to about 28% by weight of the aqueous acid composition.

41. A method of cementing comprising:

placing an acid-soluble cement composition in a subterranean formation, the acid-soluble cement composition comprising;

hydraulic cement,

pumicite in an amount of about 20% to about 100% by weight of cementitious components present in the acid-soluble cement composition, and

water;

allowing the acid-soluble cement composition to set; and

contacting the set acid-soluble cement composition with an acid to dissolve the set acid-soluble cement composition.

42. The method of claim 41 wherein the hydraulic cement comprises a hydraulic cement selected from the group consisting of a Portland cement, a pozzolana cement, a gypsum cement, a high alumina content cement, a slag cement, a silica cement, and any combination thereof.

43. The method of claim 41 wherein the acid-soluble cement composition further comprises hydrated lime in an amount of about 1% to about 40% by weight of the cementitious components present in the acid-soluble cement composition.

44. The method of claim 41 wherein the acid-soluble cement composition further comprises an acid-soluble filler.

45. The method of claim 41 wherein contacting the set acid-soluble cement composition with an acid comprises contacting the set acid-soluble cement composition with an aqueous acid composition, wherein the acid comprises hydrochloric acid present in the aqueous acid composition in an amount of about 7.5% to about 28% by weight of the aqueous acid composition.