Cement compositions comprising particulate foamed elastomers and associated methods

• US 8,592,352 B2
• Filed: 04/23/2012
• Issued: 11/26/2013
• Est. Priority Date: 06/15/2009
• Status: Expired due to Fees

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Karcher, Jeffery D., Iverson, Benjamin J., Gordon, Christopher L., Darbe, Robert P.
• Primary Examiner(s): Toscano, Alicia
• Application Number:
  US13/453,727
• Publication Number:
  US 20120202901A1
• Time in Patent Office: 582 Days
• Field of Search: 507/219, 507/224, 166/305.1
• US Class Current: 507/224
• CPC Class Codes: C04B 16/08 porous, e.g. expanded polystyrene beads or microballoons
• CPC Class Codes: C04B 16/082 other than polystyrene based, e.g. polyurethane foam
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C09K 8/467 containing additives for specific purposes
• CPC Class Codes: E21B 33/13 Methods or devices for cementing, for plugging holes, crevices or the like

Abstract

Methods of subterranean cementing involving cement compositions comprising particulate foamed elastomers and associated methods are provided. In one embodiment, the cement composition comprises a hydraulic cement, a particulate foamed elastomer, and an aqueous fluid. In one embodiment, the particulate foamed elastomer may comprise polyurethane foam.

Claims

1. A cement composition comprising:

a hydraulic cement,

a particulate foamed swellable elastomer, wherein the particulate foamed swellable elastomer has an open cell structure, and wherein the particulate foamed swellable elastomer swells when contacted by gas, hydrocarbons, and/or water for providing self-healing properties when the cured cement composition is damaged or cracked, and

an aqueous fluid.

2. The cement composition of claim 1 wherein the particulate foamed swellable elastomer comprises polyurethane foam.

3. The composition of claim 1 wherein the particulate foamed swellable elastomer comprises at least one foamed oil-swellable elastomer selected from the group consisting of ethylene propylene diene M-class rubber, polyamide, polypropylene, polyethylene, styrene butadiene, styrene, divinylbenzene, natural rubber, acrylate butadiene rubber, polyacrylate rubber, isoprene rubber, chloroprene rubber, butyl rubber, brominated butyl rubber, chlorinated butyl rubber, chlorinated polyethylene, neoprene rubber, styrene butadiene copolymer rubber, sulphonated polyethylene, ethylene acrylate rubber, epichlorohydrin ethylene oxide copolymer, ethylene-propylene rubber, ethylene-propylene-diene terpolymer rubber, ethylene vinyl acetate copolymer, fluorosilicone rubbers, silicone rubbers, poly 2,2,1-bicyclo heptene (polynorborneane), alkylstyrene, nitrile rubber, hydrogenated nitrile rubber, fluoro rubbers, perfluoro rubbers, tetrafluorethylene/propylene, and any combination thereof.

4. The composition of claim 1 wherein the particulate foamed swellable elastomer comprises at least one foamed water-swellable elastomer selected from the group consisting of isobutylene maleic anhydride, starch-polyacrylate acid graft copolymer and salts thereof, polyethylene oxide polymer, carboxymethyl cellulose type polymers, polyacrylamide, poly(acrylic acid) and salts thereof, poly(acrylic acid-co-acrylamide) and salts thereof, graft-poly(ethylene oxide) of poly(acrylic acid) and salts thereof, poly(2-hydroxyethyl methacrylate), and poly(2-hydroxypropyl methacrylate), and any combination thereof.

5. The composition of claim 1 wherein the particulate foamed swellable elastomer is present in the cement composition in an amount of from about 0.5% to about 30% by weight of the hydraulic cement.

6. The composition of claim 1 wherein the particulate foamed swellable elastomer is present in the cement composition in an amount of from about 2% to about 10% by weight of the hydraulic cement.

7. The composition of claim 1 wherein the particulate foamed swellable elastomer comprises particulates with a size of from about 40 to about 1000 microns.

8. The composition of claim 1 wherein the hydraulic cement comprises at least one hydraulic cement selected from the group consisting of a Portland cement, a pozzolana cement, a gypsum cement, a high-alumina-content cement, a slag cement, a silica cement, cement kiln dust, and combinations thereof.

9. The composition of claim 1 wherein the particulate foamed swellable elastomer comprises particulates with a size of from about 60 to about 600 microns.

10. The composition of claim 1 wherein the particulate foamed swellable elastomer comprises styrene butadiene.

11. A cement composition comprising:

a hydraulic cement,

a particulate foamed swellable elastomer, wherein the particulate foamed swellable elastomer has an open cell structure, and wherein the particulate foamed swellable elastomer swells when contacted by gas, hydrocarbons, and/or water for providing self-healing properties when the cured cement composition is damaged or cracked, and

a filtration control additive, and

an aqueous fluid.

12. The composition of claim 11 wherein the particulate foamed elastomer comprises at least one foamed oil-swellable elastomer selected from the group consisting of ethylene propylene diene M-class rubber, polyamide, polypropylene, polyethylene, styrene butadiene, styrene, divinylbenzene, natural rubber, acrylate butadiene rubber, polyacrylate rubber, isoprene rubber, chloroprene rubber, butyl rubber, brominated butyl rubber, chlorinated butyl rubber, chlorinated polyethylene, neoprene rubber, styrene butadiene copolymer rubber, sulphonated polyethylene, ethylene acrylate rubber, epichlorohydrin ethylene oxide copolymer, ethylene-propylene rubber, ethylene-propylene-diene terpolymer rubber, ethylene vinyl acetate copolymer, fluorosilicone rubbers, silicone rubbers, poly 2,2,1-bicyclo heptene (polynorborneane), alkylstyrene, nitrile rubber, hydrogenated nitrile rubber, fluoro rubbers, perfluoro rubbers, tetrafluorethylene/propylene, and any combination thereof.

13. The composition of claim 11 wherein the particulate foamed elastomer is present in the cement composition in an amount of from about 0.5% to about 30% by weight of the hydraulic cement.

14. The composition of claim 11 wherein the particulate foamed elastomer is present in the cement composition in an amount of from about 2% to about 10% by weight of the hydraulic cement.

15. The composition of claim 11 wherein the particulate foamed elastomer comprises particulates with a size of from about 40 to about 1000 microns.

16. The composition of claim 11 wherein the hydraulic cement comprises at least one hydraulic cement selected from the group consisting of a Portland cement, a pozzolana cement, a gypsum cement, a high-alumina-content cement, a slag cement, a silica cement, cement kiln dust, and combinations thereof.

17. The composition of claim 11 wherein the particulate foamed elastomer comprises particulates with a size of from about 60 to about 600 microns.

18. The composition of claim 11 wherein the particulate foamed elastomer comprises styrene butadiene.