Low density cementitious compositions

• US 8,394,744 B2
• Filed: 05/17/2010
• Issued: 03/12/2013
• Est. Priority Date: 05/22/2009
• Status: Expired due to Fees

• Current Assignee: Lafarge SA (Holcim Limited)
• Original Assignee: Lafarge SA (Holcim Limited)
• Inventors: Woytowich, Wes, Carruthers, Bill, Cotnoir, Benoit, Lehoux, Paul, McCorkle, Richard, Bowman, Eric
• Primary Examiner(s): Figueroa, John J
• Application Number:
  US12/781,306
• Publication Number:
  US 20100294496A1
• Time in Patent Office: 1,030 Days
• Field of Search: None
• US Class Current: 507/269
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/28 of calcium
• 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 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C09K 8/46 containing inorganic binders, e.g. Portland cement
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A manufactured cementitious binder including a hydraulic binder in an amount in the range of from about 40 to 75% by weight of the cementitious binder; metakaolin in an amount greater than about 5% by weight of the cementitious binder; silica fume in an amount up to about 15% by weight of the cementitious binder; and cement kiln dust in an amount greater than about 10% by weight of the cementitious binder, the cement kiln dust including chlorine in an amount of at least 0.1% by weight of the cement kiln dust, the cementitious binder providing a cementitious settable composition, when added with water and without a lightweight additive, that has a density lower than about 13 pounds per gallon and greater than about 11 pounds per gallon and a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi.

Claims

1. A manufactured cementitious binder comprising:

hydraulic binder in an amount in the range of from about 40 to 75% by weight of the cementitious binder;

metakaolin in an amount of at least 3% by weight of the cementitious binder;

silica fume in an amount up to about 15% by weight of the cementitious binder; and

cement kiln dust in an amount of at least 10% by weight of the cementitious binder, the cement kiln dust including chlorine in an amount greater than 0.1% by weight of the cement kiln dust,

the cementitious binder providing a cementitious settable composition when added with water, wherein for a density from about 12 pounds per gallon to about 11 pounds per gallon obtained without a lightweight additive, said cementitious settable composition exhibits a 24 hour compressive strength at 100 F, as hardened, of at least 700 psi.

2. The binder of claim 1, wherein for a non-zero amount of silica fume in the binder, the settable composition exhibits at 13 pounds per gallon, without a lightweight additive, a 24 hour compressive strength at 100 F, as hardened, of at least 800 psi.

3. The binder of claim 1, comprising microspheres in an amount less than about 16% by weight of the cementitious binder, wherein the cementitious binder provides a cementitious settable composition, when added with water, that has a density lower than 11 pounds per gallon and a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi.

4. The binder of claim 3, wherein the cementitious settable composition has a density of about 10 pounds per gallon.

5. The binder of claim 3, wherein the settable composition has a 24 hour compressive strength at 100 F, as hardened, of at least 700 psi.

6. The binder of claim 5, wherein the settable composition has a 24 hour compressive strength at 100 F, as hardened, of at least 800 psi.

7. The binder of claim 1, comprising microspheres in an amount less than about 35% by weight of the cementitious binder, wherein the cementitious binder provides a cementitious settable composition, when added with water, that has a density of about 8 pounds per gallon and a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi.

8. The binder of claim 1, wherein chlorine is present in the cement kiln dust in an amount up to 5% by weight of the cement kiln dust.

9. The binder of claim 1, wherein cement kiln dust is present in the cementitious binder in an amount in the range of from about 15 to 25% by weight of the cementitious binder.

10. The binder of claim 1, wherein metakaolin is present in the cementitious binder in an amount in the range of from about 8 to 25% by weight of the cementitious binder.

11. The binder of claim 1, wherein metakaolin is present in the cementitious binder in an amount in the range of from about 8 to 18% by weight of the cementitious binder.

12. The binder of claim 1, comprising microspheres in an amount in the range of from about 16% to 35% by weight of the cementitious binder, wherein the cementitious binder provides a cementitious settable composition, when added with water, that has a corresponding density in the range of from about 10 pounds per gallon to about 8 pounds per gallon and a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi.

13. The binder of claim 1, further comprising limestone in an amount more than 5% by weight of the cementitious binder.

14. The binder of claim 1, wherein the cement kiln dust includes free lime in an amount of at least 1% by weight of the cement kiln dust.

15. A manufactured cementitious binder comprising:

cement kiln dust in an amount of at least 10% by weight of the cementitious binder, the cement kiln dust including chlorine in an amount of greater than 0.1% by weight of the cement kiln dust,

the cementitious binder providing a cementitious settable composition when added with water, wherein for a density from about 12 pounds per gallon to about 11 pounds per gallon obtained without a lightweight additive, said cementitious settable composition exhibits a 24 hour compressive strength at 100 F, as hardened, of at least 700 psi.

16. The binder of claim 15, comprising microspheres in an amount less than about 16% by weight of the cementitious binder, wherein the cementitious binder provides a settable composition, when added with water, that has a density lower than 11 pounds per gallon and a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi.

17. The binder of claim 16, wherein the settable composition has a density of about 10 pounds per gallon.

18. The binder of claim 16, wherein the settable composition has a 24 hour compressive strength at 100 F, as hardened, of at least 700 psi.

19. The binder of claim 15, wherein chlorine is present in the cement kiln dust in an amount up to 5% by weight of the cement kiln dust.

20. A cementitious settable composition comprising:

water; and

a cementitious binder including

hydraulic binder in an amount in the range of from about 40 to 75% by weight of the cementitious binder;

metakaolin in an amount of at least 3% by weight of the cementitious binder;

silica fume in an amount up to about 15% by weight of the cementitious binder;

cement kiln dust in an amount of at least 10% by weight of the cementitious binder, the cement kiln dust including chlorine in an amount greater than 0.1% by weight of the cement kiln dust,

wherein for a density from about 12 pounds per gallon to about 11 pounds per gallon obtained without a lightweight additive, said cementitious sellable composition exhibits a 24 hour compressive strength at 100 F, as hardened, of at least 700 psi.

21. The composition of claim 20, wherein for a non-zero amount of silica fume in the binder, the settable composition exhibits at 13 pounds per gallon, without a lightweight additive, a 24 hour compressive strength at 100 F, as hardened, of at least 800 psi.

22. The composition of claim 20, wherein the cementitious binder comprises microspheres in an amount less than about 16% by weight of the cementitious binder, wherein the cementitious binder provides a cementitious settable composition, when added with water, that has a density lower than 11 pounds per gallon and a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi.

23. The composition of claim 22, wherein the settable composition has a density of about 10 pounds per gallon.

24. The composition of claim 22, wherein the settable composition has a 24 hour compressive strength at 100 F, as hardened, of at least 700 psi.

25. The composition of claim 20, wherein chlorine is present in the cement kiln dust in an amount up to 5% by weight of the cement kiln dust.

26. A method of cementing comprising:

providing a cementitious settable composition comprising;

water; and

a cementitious binder including

hydraulic binder in an amount in the range of from about 40 to 75% by weight of the cementitious binder;

metakaolin in an amount of at least 3% by weight of the cementitious binder;

silica fume in an amount up to about 15% by weight of the cementitious binder; and

cement kiln dust in an amount of at least 10% by weight of the cementitious binder, the cement kiln dust including chlorine in an amount greater than 0.1% by weight of the cement kiln dust,

the cementitious binder providing the cementitious settable composition when added with water, wherein for a density from about 12 pounds per gallon to about 11 pounds per gallon obtained without a lightweight additive, said cementitious settable, composition exhibits a 24 hour compressive strength at 100 F, as hardened, of at least 700 psi; and

introducing the cementitious settable composition into an underground formation.

27. The method of claim 26, wherein for a non-zero amount of silica fume in the binder, the settable composition exhibits at 13 pounds per gallon, without a lightweight additive, a 24 hour compressive strength at 100 F, as hardened, of at least 800 psi.

28. The method of claim 26, wherein the cementitious binder comprises microspheres in an amount less than about 16% by weight of the cementitious binder, wherein the cementitious binder provides a cementitious settable composition, when added with water, that has a density lower than 11 pounds per gallon and a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi.

29. The method of claim 26, wherein the underground formation is a well bore.

30. A manufactured cementitious binder for preparing low density cementitious settable compositions having a density lower than about 12 ppg, the binder comprising:

hydraulic binder in an amount in the range of from about 40 to 75% by weight of the cementitious binder;

metakaolin in an amount of at least 3% by weight of the cementitious binder;

silica fume in anon-zero amount up to about 15% by weight of the cementitious binder; and

cement kiln dust in an amount of at least 10% by weight of the cementitious binder, the cement kiln dust including chlorine in an amount greater than 0.1% by weight of the cement kiln dust.