Settable compositions comprising unexpanded perlite and methods of cementing in subterranean formations

• US 8,440,596 B2
• Filed: 09/07/2012
• Issued: 05/14/2013
• 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: Brenneis, Chad, Karcher, Jeffery, Roddy, Craig W.
• Primary Examiner(s): Figueroa, John J
• Application Number:
  US13/606,120
• Publication Number:
  US 20120325119A1
• Time in Patent Office: 249 Days
• Field of Search: None
• US Class Current: 507/269
• 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 38/02 : 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 8/428 : 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

An embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising unexpanded perlite, cement kiln dust, and water; and allowing the settable composition to set. Another embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising ground unexpanded perlite, Portland cement interground with pumicite, and water; and allowing the settable composition to set. Yet another embodiment of the present invention comprises a settable composition comprising: ground unexpanded perlite; cement kiln dust; and water.

Claims

1. A settable composition comprising:

ground unexpanded perlite;

cement kiln dust; and

water.

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

3. The composition of claim 1 wherein the ground unexpanded perlite has a mean particle size in the range of about 1 micron to about 400 microns.

4. The composition of claim 1 wherein the ground unexpanded perlite has a mean particle size in the range of about 1 micron to about 100 microns.

5. The composition of claim 1 wherein the ground unexpanded perlite has a mean particle size in the range of about 0.5 micron to about 50 microns.

6. The composition of claim 1 wherein the ground unexpanded perlite is present in an amount in the range of about 1% to about 75% by weight of cementitious components in the settable composition.

7. The composition of claim 1 wherein the water is selected from the group consisting of freshwater, saltwater, brine, seawater, and any combination thereof.

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

9. The composition of claim 1 wherein the settable composition further comprises lime.

10. The composition of claim 1 wherein the settable composition further comprises at least one additive selected from the group consisting of fly ash, slag cement, metakaolin, shale, zeolite, crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, microsphere, rice husk ash, 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, 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.

12. A settable composition comprising:

ground unexpanded perlite present in an amount in the range of about 1% to about 75% by weight of cementitious components in the settable composition, wherein the ground unexpanded perlite has a mean particle size in the range of about 1 micron to about 100 microns;

cement kiln dust; and

water.

13. The composition of claim 12 wherein the settable composition has a density in the range of about 8 pounds per gallon to about 16 pounds per gallon.

14. The composition of claim 12 wherein the water is selected from the group consisting of freshwater, saltwater, brine, seawater, and any combination thereof and is present in an amount in the range of about 40% to about 200% by weight of cementitious components.

15. The composition of claim 12 wherein the ground unexpanded perlite has a mean particle size in the range of about 0.5 micron to about 50 microns.

16. The composition of claim 12 wherein the settable composition further comprises lime.

17. The composition of claim 12 wherein the settable composition further comprises at least one additive selected from the group consisting of fly ash, slag cement, metakaolin, shale, zeolite, crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, microsphere, rice husk ash, elastomeric particle, resin, latex, and any combination thereof.

18. 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, 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.

19. A settable composition comprising:

ground unexpanded perlite present in an amount in the range of about 1% to about 75% by weight of cementitious components in the settable composition;

cement kiln dust;

at least one additive selected from the group consisting of a set retarding additive, 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; and

water.

20. The composition of claim 19 wherein the ground unexpanded perlite has a mean particle size in the range of about 0.5 micron to about 50 microns.