Settable compositions comprising cement kiln dust and rice husk ash and methods of use

• US 8,327,939 B2
• Filed: 05/24/2012
• Issued: 12/11/2012
• 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, Jarratt, Callie R.
• Primary Examiner(s): Suchfield, George
• Application Number:
  US13/479,476
• Publication Number:
  US 20120234541A1
• Time in Patent Office: 201 Days
• Field of Search: None
• US Class Current: 166/293
• CPC Class Codes: C04B 14/047 Zeolites
• CPC Class Codes: C04B 14/06 Quartz; Sand
• 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 20/0036 Microsized or nanosized
• 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 38/0067 : characterised by the density of the end product
• 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: C09K 8/426 : for plugging
• CPC Class Codes: C09K 8/428 : for squeeze cementing, e.g. for repairing
• CPC Class Codes: C09K 8/46 : containing inorganic binders, e.g. Portland cement
• 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

Embodiments disclose method and compositions that comprise cement kiln dust and rice husk ash. An embodiment comprises a method of cementing comprising: placing a settable composition into a subterranean formation, the settable composition comprising cement kiln dust, rice husk ash, and water; and allowing the settable composition to set.

Claims

1. A method of cementing comprising:

preparing a settable composition comprising cement kiln dust, rice husk ash, and water, wherein the preparing comprises including the rice husk ash in the settable composition in an amount sufficient to increase compressive strength of the settable composition;

placing the settable composition into a subterranean formation; and

allowing the settable composition to set.

2. The method of claim 1 wherein the settable composition has a density in a range of from about 8 pounds per gallon to about 16 pounds per gallon.

3. The method of claim 1 wherein the cement kiln dust is present in an amount in a range of from about 0.1% to about 99% by weight of cementitious components, and wherein the rice husk ash is present in an amount in a range of from about 0.1% to about 99% by weight of cementitious components.

4. The method of claim 1 wherein the cement kiln dust is present in an amount in a range of from about 50% to about 95% by weight of cementitious components.

5. The method of claim 1 wherein the rice husk ash is present in an amount in a range of from about 5% to about 50% by weight of cementitious components.

6. The method of claim 1 wherein the rice husk ash is included in the settable composition in an amount sufficient to increase the 24-hour destructive compressive strength of the settable composition at 160°

F. and atmospheric pressure in an amount equal to or greater than about 10%.

7. The method of claim 1 wherein the rice husk ash is included in the settable composition in an amount sufficient to increase the 24-hour destructive compressive strength of the settable composition at 160°

F. and atmospheric pressure in an amount equal to or greater than about 75%.

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

9. The method of claim 1 wherein the settable composition is essentially free hydraulic cement in addition to the cement kiln dust.

10. The method of claim 1 wherein the settable composition further comprises a set retarding additive.

11. The method of claim 1 wherein the settable composition further comprises at least one additive selected from the group consisting of unexpanded perlite, pumicite, lime, fly ash, slag cement, metakaolin, shale, zeolite, crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, microsphere, elastomer, elastomeric particle, resin, latex, and any combination thereof.

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

13. The method of claim 1 wherein the settable composition is allowed to set in an annulus outside a conduit disposed in the subterranean formation.

14. The method of claim 1 wherein the settable composition is used in primary cementing.

15. The method of claim 1 wherein the settable composition is used in remedial cementing.

16. The method of claim 1 wherein the settable composition is essentially free of Portland cement.

17. A method of cementing comprising:

preparing a settable composition comprising cement kiln dust, rice husk ash, Portland cement, and water, wherein the preparing comprises including the rice husk ash in the settable composition in an amount sufficient to increase compressive strength of the settable composition;

placing the settable composition into a subterranean formation; and

allowing the settable composition to set.

18. The cementitious component of claim 17 wherein the cement kiln dust is present in an amount in a range of from about 0.1% to about 99% by weight of cementitious components, and wherein the rice husk ash is present in an amount in a range of from about 0.1% to about 99% by weight of cementitious components.

19. The cementitious component of claim 17 wherein the cement kiln dust is present in an amount in a range of from about 0.1% to about 50% by weight of cementitious components, wherein the rice husk ash is present in an amount in a range of from about 0.1% to about 50% by weight of cementitious components, and wherein the Portland cement is present in an amount in a range of from about 50% to about 99% by weight of cementitious components.

20. The method of claim 17 wherein the settable composition further comprises at least one additive selected from the group consisting of unexpanded perlite, pumicite, lime, fly ash, slag cement, metakaolin, shale, zeolite, crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, microsphere, elastomer, elastomeric particle, resin, latex, and any combination thereof.

21. The method of claim 17 wherein the settable composition further comprises at least one additive selected from the group consisting of 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.

22. A method of cementing comprising:

placing a settable composition, the settable composition comprising cement kiln dust, rice husk ash, and water,

wherein the cement kiln dust is present in an amount in a range of from about 50% to about 90% by weight of the cement kiln dust and the rice husk ash,

wherein the rice husk ash is present in an amount in a range of from about 10% to about 40% by weight of the cement kiln dust and the rice husk ash, and

wherein the water is present in an amount in a range of from about 40% to about 200% by weight of the cement kiln dust and the rice husk ash; and

allowing the settable composition to set.

23. The method of claim 22 wherein the settable composition further comprises at least one additive selected from the group consisting of unexpanded perlite, pumicite, lime, fly ash, slag cement, metakaolin, shale, zeolite, crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, microsphere, elastomer, elastomeric particle, resin, latex, and any combination thereof.

24. The method of claim 22 wherein the settable composition further comprises at least one additive selected from the group consisting of a set retarder, 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.

25. The method of claim 22 wherein the settable composition is placed in a subterranean formation.

26. The method of claim 25 wherein the settable composition is used in primary cementing.

27. The method of claim 25 wherein the settable composition is used in remedial cementing.