Methods and compositions comprising kiln dust and metakaolin

• US 8,318,642 B2
• Filed: 06/27/2012
• Issued: 11/27/2012
• 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, D. Chad, King, Bobby J.
• Primary Examiner(s): Figueroa, John J
• Application Number:
  US13/535,258
• Publication Number:
  US 20120260828A1
• Time in Patent Office: 153 Days
• Field of Search: None
• US Class Current: 507/269
• 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 14/16 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 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 22/064 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 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 7/02 : Portland cement
• CPC Class Codes: C09K 8/426 : for plugging
• 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 provides settable compositions and methods of using settable compositions that comprise a hydraulic cement; a partially calcined kiln feed comprising SiO₂, Al₂O₃, Fe₂O₃, CaO, MgO, SO₃, Na₂O, and K₂O; metakaolin; and water. The location to be cemented may be above ground or in a subterranean formation.

Claims

1. A settable composition comprising:

a hydraulic cement;

a partially calcined kiln feed removed from a gas stream comprising SiO₂, Al₂O₃, Fe₂O₃, CaO, MgO, SO₃, Na₂O, and K₂O;

metakaolin; and

water.

2. The settable composition of claim 1 wherein the hydraulic cement is present in the settable composition in an amount in the range of from about 0% to about 95% by weight.

3. The settable composition of claim 1 wherein the hydraulic cement is present in the settable composition in an amount in the range of from about 20% to about 95% by weight.

4. The settable composition of claim 1 wherein the hydraulic cement is present in the settable composition in an amount in the range of from about 50% to about 90% by weight.

5. The settable composition of claim 1 wherein the hydraulic cement is selected from the group consisting of:

Portland cement, pozzolana cement, gypsum cement, high alumina content cement, slag cement, silica cement, and combinations thereof.

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

7. The settable composition of claim 1 wherein the partially calcined kiln feed is present in the settable composition in an amount of at least about 0.01% by weight.

8. The settable composition of claim 1 wherein the partially calcined kiln feed is present in the settable composition in an amount in the range of from about 5% to 80% by weight.

9. The settable composition of claim 1 wherein the partially calcined kiln feed is present in the settable composition in an amount in the range of from about 10% to 50% by weight.

10. The settable composition of claim 1 wherein the partially calcined kiln feed is collected in a dust collector.

11. The settable composition of claim 1 wherein the partially calcined kiln feed is from the manufacture of cement.

12. The settable composition of claim 1 wherein the metakaolin is present in the settable composition in an amount in the range of from about 5% to about 95% by weight.

13. The settable composition of claim 1 wherein the metakaolin is present in the settable composition in an amount in the range of from about 10% to about 50% by weight.

14. The settable composition of claim 1 wherein the water is selected from the group consisting of:

freshwater, saltwater, brine, seawater, and combinations thereof.

15. The settable composition of claim 1 wherein the settable composition further comprises at least one additive selected from the group consisting of:

a set retarding additive, an accelerator, a lost circulation material, a filtration control additive, a dispersant, and combinations thereof.

16. The settable composition of claim 1 wherein the settable composition further comprises amorphous silica.

17. The settable composition of claim 1 wherein the settable composition further comprises an accelerator.

18. The settable composition of claim 1 wherein the settable composition further comprises amorphous silica and an accelerator.

19. The settable composition of claim 1 wherein the settable composition further comprises a set retarding additive present in the settable composition in an amount in the range of from about 0.1% to about 5% by weight.

20. The settable composition of claim 1 wherein the settable composition further comprises a set retarding additive selected from the group consisting of:

ammonium, alkali metals, alkaline earth metals, metal salts of sulfoalkylated lignins, hydroxycarboxy acids, copolymers that comprise acrylic acid or maleic acid, and combinations thereof.

21. The settable composition of claim 1 wherein the settable composition further comprises fly ash.

22. The settable composition of claim 1 wherein the settable composition further comprises microspheres.

23. The settable composition of claim 1 wherein the settable composition is foamed and further comprises a gas, and a surfactant.

24. The settable composition of claim 1 wherein the settable composition further comprises at least one additive selected from the group consisting of:

fly ash, slag, shale, zeolite, micro-fine cement, settable composition combinations thereof.

25. The settable composition of claim 1 wherein the settable composition has a density in the range of from about 8 ppg to about 16 ppg.

26. The settable composition of claim 1 wherein the settable composition has a 24-hour compressive strength of at least 500 psi at a density of 13.5 ppg and a temperature of 180°

F.

27. The settable composition of claim 1 wherein the settable composition has a 24-hour compressive strength of at least 1000 psi at a density of 13.5 ppg and a temperature of 180°

F.

28. A settable composition comprising:

a hydraulic cement,

a partially calcined kiln feed removed from a gas stream comprising SiO₂, Al₂O₃, Fe₂O₃, CaO, MgO, SO₃, Na₂O, and K₂O,

metakaolin,

amorphous silica,

an accelerator, and

water.

29. The settable composition of claim 28 wherein the partially calcined kiln feed is collected in a dust collector.

30. The settable composition of claim 28 wherein the partially calcined kiln feed is from the manufacture of cement.

31. A settable composition comprising:

a hydraulic cement,

kiln dust comprising SiO₂, Al₂O₃, Fe₂O₃, CaO, MgO, SO₃, Na₂O, and K₂O present in the settable composition in an amount in the range of from about 5% to about 80% by weight,

metakaolin, and

water.

32. The settable composition of claim 31 wherein the kiln dust is from the manufacture of cement.

33. The settable composition of claim 31 wherein the settable composition further comprises at least one additive selected from the group consisting of:

a set retarding additive, an accelerator, a lost circulation material, a filtration control additive, a dispersant, and combinations thereof.

34. The settable composition of claim 31 wherein the settable composition further comprises a set retarding additive present in the settable composition in an amount in the range of from about 0.1% to about 5% by weight.

35. The settable composition of claim 31 wherein the settable composition further comprises microspheres.

36. The settable composition of claim 31 wherein the settable composition is foamed and further comprises a gas, and a surfactant.

37. The settable composition of claim 31 wherein the settable composition further comprises at least one additive selected from the group consisting of:

fly ash, slag, shale, zeolite, micro-fine cement, and combinations thereof.

38. The settable composition of claim 31 wherein the settable composition further comprises fly ash.