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

• US 8,399,387 B2
• Filed: 09/14/2012
• Issued: 03/19/2013
• 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): Figueroa, John J
• Application Number:
  US13/620,163
• Publication Number:
  US 20130008351A1
• Time in Patent Office: 186 Days
• Field of Search: None
• US Class Current: 507/271
• 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. Another embodiment discloses a settable composition comprising cement kiln dust, rice husk ash, and water.

Claims

1. A settable composition comprising:

cement kiln dust;

rice husk ash; and

water.

2. The composition 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, and wherein the water is present in an amount in a range of from about 40% to about 200% by weight of cementitious components.

3. The composition 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.

4. The composition of claim 1 wherein the cement kiln dust is present in an amount in a range of from about 70% to about 95% by weight of cementitious components.

5. The composition of claim 1 wherein the cement kiln dust is present in an amount in a range of from about 90% to about 95% by weight of cementitious components.

6. The composition 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.

7. The composition 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%.

8. The composition 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%.

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

10. The composition 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.

11. The composition of claim 1 wherein the settable composition further comprises at least one additive selected from the group consisting of a set-retarding additive, 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.

12. A settable composition comprising:

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

rice husk ash; and

water.

13. The composition of claim 12 wherein the partially calcined kiln feed is present in an amount in a range of from about 50% to about 95% by weight of cementitious components, and 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.

14. The composition of claim 12 wherein the partially calcined kiln feed is present in an amount in a range of from about 70% to about 95% by weight of cementitious components.

15. The composition of claim 12 wherein the partially calcined kiln feed is present in an amount in a range of from about 90% to about 95% by weight of cementitious components.

16. The composition of claim 12 wherein the partially calcined kiln feed is from the manufacture of cement.

17. The composition of claim 12 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%.

18. The composition of claim 12 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%.

19. The composition of claim 12 wherein the settable composition is essentially free of hydraulic cement in addition to the cement kiln dust.

20. The composition of claim 12 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 composition of claim 12 wherein the settable composition further comprises at least one additive selected from the group consisting of a set-retarding additive, 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 settable composition comprising:

cement kiln dust in an amount in a range of from about 50% to about 95% by weight of cementitious components;

rice husk ash 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%; and

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

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

23. The composition of claim 22 wherein the cement kiln dust is present in an amount in a range of from about 70% to about 95% by weight of cementitious components.

24. The composition 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.

25. The composition of claim 22 wherein the settable composition further comprises at least one additive selected from the group consisting of a set-retarding additive, 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.