Latex compositions comprising pozzolan and/or cement kiln dust and methods of use

• US 8,324,137 B2
• Filed: 07/27/2010
• Issued: 12/04/2012
• 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, Morgan, Ronnie G., Hudgins, Callie R.
• Primary Examiner(s): Choi, Ling
• Assistant Examiner(s): Li, Aiqun
• Application Number:
  US12/844,612
• Publication Number:
  US 20100292365A1
• Time in Patent Office: 861 Days
• Field of Search: 524/8, 507/219, 166/295, 523/130
• US Class Current: 507/219
• 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 14/18 Perlite
• 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 22/064 of the alkaline-earth metals
• CPC Class Codes: C04B 22/08 Acids or salts thereof C04B22/0013 takes precedence
• CPC Class Codes: C04B 24/163 : obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 : Portland cements
• CPC Class Codes: C04B 28/184 : based on an oxide other than lime
• 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 8/428 : for squeeze cementing, e.g. for repairing
• 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: C09K 8/493 : Additives for reducing or preventing gas migration
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

The present invention includes methods and compositions that include a latex, and at least one of a natural pozzolan or cement kiln dust. An embodiment includes a method comprising: placing a latex composition in a subterranean formation, wherein the latex composition comprises: latex, a component selected from the group consisting of a natural pozzolan, cement kiln dust, and a combination thereof, and water; and allowing the latex composition to set. Another embodiment of the present invention includes a latex composition comprising: latex, a component selected from the group consisting of a natural pozzolan, cement kiln dust, and a combination thereof.

Claims

1. A subterranean latex composition comprising:

a synthetic latex;

a cementitious component comprising cement kiln dust in an amount of about 70% to about 99% by weight of the cementitious component and hydraulic cement in an amount of about 0.1% to about 10% by weight of the cementitious component; and

water in an amount sufficient to form a pumpable slurry,

wherein the synthetic latex is present in the subterranean latex composition in an amount of about 6% to about 45% by weight of the cementitious component.

2. The subterranean latex composition of claim 1 wherein the synthetic latex comprises a rubber selected from the group consisting of an ethylene-propylene rubber, a styrene-butadiene rubber, a nitrile rubber, a nitrile butadiene rubber, a butyl rubber, a neoprene rubber, a polybutadiene rubber, an acrylonitrile-styrene-butadiene rubber, a polyisoprene rubber, an AMPS-styrene-butadiene rubber, and any combination thereof.

3. The subterranean latex composition of claim 1 wherein the synthetic latex comprises an AMPS-styrene-butadiene rubber.

4. The subterranean latex composition of claim 1 wherein the latex composition further comprises a natural pozzolan, and wherein the natural pozzolan comprises at least one pozzolan selected from the group consisting of pumicite, diatomaceous earth, volcanic ash, opaline shale, tuff, and any combination thereof.

5. The subterranean latex composition of claim 1 wherein the latex composition further comprises a natural pozzolan, and wherein the natural pozzolan comprises pumicite.

6. The subterranean latex composition of claim 1 wherein the cement kiln dust is present in an amount of about 80% to about 99% by weight of the cementitious component.

7. The subterranean latex composition of claim 1 wherein the cement kiln dust is present in an amount of about 90% to about 99% by weight of the cementitious component.

8. The subterranean latex composition of claim 1 wherein the cementitious component further comprises pumicite.

9. The subterranean latex composition of claim 1 wherein the latex composition further comprises at least one additive selected from the group consisting of fly ash, slag cement, metakaolin, shale, zeolite, as gas, crystalline silica, amorphous silica, finned silica, a salt, a fiber, a hydratable clay, a microsphere, rice husk ash, lime, and any combination thereof.

10. The subterranean latex composition of claim 1, wherein the latex composition further comprises at least one additive selected from the group consisting of a latex stabilizer, a strength-retrogression additive, a set retarder, a set accelerator, a weighting agent, a lightweight additive, a gas-generating additive, as 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.

11. The subterranean latex composition of claim 1 wherein the latex composition is foamed.

12. The subterranean latex composition of claim 1 wherein the hydraulic cement comprises at least one cement selected from the group consisting of Portland cement, pozzolana cement, gypsum cement, high alumina content cement, slag cement, silica cement, and any combination thereof.

13. The subterranean latex composition of claim 1 wherein the hydraulic cement comprises Portland cement.

14. A latex composition comprising:

a synthetic latex;

a cementitious component consisting of;

cement kiln dust; and

pumicite; and

water in an amount sufficient to form a pumpable slurry,

wherein the synthetic latex is present in an amount of about 6% to about 45% by weight of the cementitious component,

wherein the latex composition is essentially free of any additional cementitious components other than the cementitious component.

15. The latex composition of claim 14 wherein the pumicite is present in an amount of about 25% to about 75% by weight of the cementitious component.

16. The latex composition of claim 14 wherein the cement kiln dust is present in an amount of about 10% to about 30% by weight of the cementitious component.

17. The latex composition of claim 14 wherein the cement kiln dust is present in an amount of about 10% to about 50% by weight of the cementitious component.

18. A subterranean latex composition comprising:

a cementitious component consisting of cement kiln dust;

a latex;

water in an amount sufficient to form a pumpable slurry; and

a set retarder,

wherein the latex composition is essentially free of any additional cementitious components other than the cementitious component,

wherein the latex comprises a rubber selected from the group consisting of an ethylene-propylene rubber, a styrene-butadiene rubber, a nitrite rubber, a nitrite butadiene rubber, a butyl rubber, a neoprene rubber, a polybutadiene rubber, an acrylonitrile-styrene-butadiene rubber, a polyisoprene rubber, an AMPS-styrene-butadiene rubber, and any combination thereof.

19. The subterranean latex compositions of claim 18 wherein the latex comprises the AMPS-styrene-butadiene rubber.

20. The subterranean latex composition of claim 18 wherein the latex is present in an amount of about 2% to about 45% by weight of the cementitious component.

21. The subterranean latex composition of claim 18 wherein the latex composition further comprises at least one additive selected from the group consisting of gas, crystalline silica, amorphous silica, fumed silica, a salt, a fiber, a microsphere, rice husk ash, and any combination thereof.

22. The subterranean latex composition of claim 18 wherein the latex composition further comprises at least one additive selected from the group consisting of a latex stabilizer, 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, to water-swellable particle, a thixotropic additive, and any combination thereof.

23. The subterranean latex composition of claim 18 wherein the latex composition is foamed.

24. A latex composition comprising:

a cementitious component consisting of cement kiln dust;

a synthetic latex in an amount of about 6% to about 45% by weight of the cementitious component; and

water in an amount in a range of from about 40% to about 200% by weight of cementitious components,

wherein the latex composition is essentially free of any additional cementitious components other than the cementitious component,

wherein the latex composition has a density in a range of from about 8 pounds per gallon to about 16 pounds per gallon,

wherein the synthetic latex comprises a rubber selected from the group consisting of an ethylene-propylene rubber, a styrene-butadiene rubber, a nitrile rubber, a nitrile butadiene rubber, a butyl rubber, a neoprene rubber, a polybutadiene rubber, an acrylonitrile-styrene-butadiene rubber, a polyisoprene rubber, an AMPS-styrene-butadiene rubber, and any combination thereof.

25. The latex composition of claim 24 wherein the synthetic latex comprises the AMPS-styrene-butadiene rubber.

26. The latex composition of claim 24 wherein the latex composition further comprises at least one additive selected from the group consisting of gas, crystalline silica, amorphous silica, filmed silica, a salt, a fiber, a microsphere, rice husk ash, and any combination thereof.

27. The latex composition of claim 24 wherein the latex composition further comprises at least one additive selected from the group consisting of a latex stabilizer, a strength-retrogression additive, a set retarder, 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, as fluid loss control additive, a defoaming agent, a foaming agent, an oil-swellable particle, as water-swellable particle, a thixotropic additive, and any combination thereof.

28. The latex composition of claim 24 wherein the latex composition is foamed.