Cement compositions and methods utilizing nano-clay

• US 8,603,952 B2
• Filed: 03/27/2012
• Issued: 12/10/2013
• Est. Priority Date: 05/10/2007
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Roddy, Craig W., Covington, Ricky L., Chatterji, Jiten, Brenneis, D. Chad
• Primary Examiner(s): Figueroa, John J
• Application Number:
  US13/431,701
• Publication Number:
  US 20120186494A1
• Time in Patent Office: 623 Days
• Field of Search: None
• US Class Current: 507/269
• CPC Class Codes: C04B 14/047 Zeolites
• CPC Class Codes: C04B 14/062 Microsilica, e.g. colloïdal silica preparing microsilica slurries or suspensions C04B18/148
• CPC Class Codes: C04B 14/08 Diatomaceous earth
• CPC Class Codes: C04B 14/104 Bentonite, e.g. montmorillonite
• CPC Class Codes: C04B 14/108 Shale, slate colliery shale C04B18/125
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/162 Cement kiln dust; Lime kiln dust
• CPC Class Codes: C04B 20/0024 expanded in situ, i.e. the material is expanded or made hollow after primary shaping of the mortar, concrete or artificial stone mixture C04B16/085 takes precedence
• 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 2111/00146 Sprayable or pumpable mixtures
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/08 Slag cements
• 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 2208/10 Nanoparticle-containing well treatment fluids
• CPC Class Codes: C09K 8/145 characterised by the composition of the clay
• CPC Class Codes: C09K 8/40 Spacer compositions, e.g. compositions used to separate well-drilling from cementing masses
• 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: C09K 8/487 Fluid loss control additives; Additives for reducing or preventing circulation loss
• CPC Class Codes: C09K 8/5045 : containing inorganic compounds
• CPC Class Codes: C09K 8/516 : characterised by their form or by the form of their components, e.g. encapsulated material
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

The present invention includes well treatment fluids and methods utilizing nano-particles. An embodiment of a method of the present invention may comprise introducing a treatment fluid comprising nano-clay into a subterranean formation. The treatment fluid may be selected from the group consisting of a cement composition, a drilling fluid, a spacer fluid, and a lost circulation control composition. Another embodiment of the present invention may comprise a method of cementing. The method of cementing may comprise introducing a cement composition comprising a hydraulic cement, nano-clay, and water into a subterranean formation. The method further may comprise allowing the cement composition to set in the subterranean formation. Yet another embodiment of the present invention may comprise a treatment fluid, the treatment fluid comprising nano-clay. The treatment fluid may be selected from the group consisting of a cement composition, a drilling fluid, a spacer fluid, and a lost circulation control composition.

Claims

1. A method of preparing a latex-free treatment fluid for use in a subterranean formation comprising:

providing a non-colloidal nano-clay having a length in a range of from about 1 nanometer to about 600 nanometers; and

preparing the latex-free treatment fluid, wherein the latex-free treatment fluid comprises the non-colloidal nano-clay, hydraulic cement, and water, wherein the latex-free treatment fluid is selected from the group consisting of a cement composition, a drilling fluid, a spacer fluid, and a lost circulation control composition;

wherein the non-colloidal nano-clay is present in an amount in a range of from about 0.1% to about 25% by weight of the hydraulic cement on a dry basis.

2. The method of claim 1 wherein the latex-free treatment fluid is a cement composition having a density in a range of about 4 pounds per gallon to about 20 pounds per gallon.

3. The method of claim 1 wherein the latex-free treatment fluid is a cement composition that further comprises at least one cement selected from the group consisting of Portland cement, pozzolana cement, gypsum cement, high-alumina-content cement, slag cement, silica cement, and any combination thereof.

4. The method of claim 1 wherein the non-colloidal nano-clay comprises nano-bentonite.

5. The method of claim 1 wherein the length of the non-colloidal nano-clay is in the range of from about 1 nanometer to about 400 nanometers.

6. The method of claim 1 wherein the non-colloidal nano-clay has a general plate-type structure with a thickness of less than about 10 nanometers.

7. The method of claim 1 wherein the latex-free treatment fluid is a cement composition and the non-colloidal nano-clay is present in the cement composition in an amount sufficient to reduce permeability of the set cement composition.

8. The method of claim 1 wherein the latex-free treatment fluid is a cement composition.

9. The method of claim 1 wherein the non-colloidal nano-clay comprises plate-type nano-montmorillonite having a thickness of less than about 2 nanometers and the length being in a range of about 300 nanometers to about 600 nanometers.

10. The method of claim 1 wherein the latex-free treatment fluid is a cement composition that further comprises at least one nano-particle selected from the group consisting of nano-hydraulic cement, nano-silica, nano-alumina, nano-zinc oxide, nano-boron, nano-iron oxide, and any combination thereof.

11. The method of claim 1 wherein the latex-free treatment fluid is a cement composition that further comprises at least one additive selected from the group consisting of a strength-retrogression additive, a set accelerator, a set retarder, a weighting agent, a lightweight additive, a gas-generating additive, a mechanical property enhancing additive, a lost-circulation material, a filtration-control additive, a fluid loss control additive, a dispersant, a defoaming agent, a foaming agent, a thixotropic additive, and any combination thereof.

12. The method of claim 1 wherein the latex-free treatment fluid is a cement composition that further comprises at least one additive selected from the group consisting of crystalline silica, amorphous silica, fumed silica, a salt, fiber, a hydratable clay, calcined shale, vitrified shale, a microsphere, fly ash, slag, diatomaceous earth, metakaolin, rice husk ash, natural pozzolan, zeolite, cement kiln dust, lime, an elastomer, a resin, latex, and any combination thereof.

13. The method of claim 1 wherein the non-colloidal nano-clay is encapsulated in a degradable material.

14. A method of preparing a latex-free cement composition for use in a subterranean formation comprising:

providing a non-colloidal nano-clay having a length in a range of from about 1 nanometer to about 600 nanometers;

providing a hydraulic cement; and

preparing the latex-free cement composition comprising the non-colloidal nano-clay, the hydraulic cement, and water;

wherein the non-colloidal nano-clay is present in an amount in a range of from about 0.1% to about 25% by weight of the hydraulic cement on a dry basis, and wherein the cement composition is capable of setting to form a hardened cement that prevents the migration of fluids.

15. The method of claim 14 wherein the latex-free cement composition has a density in a range of about 4 pounds per gallon to about 20 pounds per gallon.

16. The method of claim 14 wherein the hydraulic cement comprises at least one cement selected from the group consisting of Portland cement, pozzolana cement, gypsum cement, high-alumina-content cement, slag cement, silica cement, and any combination thereof.

17. The method of claim 14 wherein the non-colloidal nano-clay comprises nano-bentonite.

18. The method of claim 14 wherein the length of the non-colloidal nano-clay is in a range of from about 1 nanometer to about 400 nanometers.

19. The method of claim 14 wherein the non-collidal nano-clay has a general plate-type structure with a thickness of less than about 10 nanometers.

20. The method of claim 14 wherein the non-colloidal nano-clay is present in the cement composition in an amount sufficient to reduce permeability of the set cement composition.

21. The method of claim 14 wherein the non-colloidal nano-clay is present in the cement composition in an amount in a range of about 2% to about 10% by weight of the hydraulic cement on a dry basis.

22. The method of claim 14 wherein the non-colloidal nano-clay comprises plate-type nano-montmorillonite having a thickness of less than about 2 nanometers and the length being in a range of about 300 nanometers to about 600 nanometers.

23. The method of claim 14 wherein the latex-free cement composition further comprises at least one nano-particle selected from the group consisting of nano-hydraulic cement, nano-silica, nano-alumina, nano-zinc oxide, nano-boron, nano-iron oxide, and any combination thereof.

24. The method of claim 14 wherein the latex-free cement composition further comprises at least one additive selected from the group consisting of a strength-retrogression additive, a set accelerator, a set retarder, a weighting agent, a lightweight additive, a gas-generating additive, a mechanical property enhancing additive, a lost-circulation material, a filtration-control additive, a fluid loss control additive, a dispersant, a defoaming agent, a foaming agent, a thixotropic additive, and any combination thereof.

25. The method of claim 14 wherein the latex-free cement composition further comprises at least one additive selected from the group consisting of crystalline silica, amorphous silica, fumed silica, a salt, fiber, a hydratable clay, calcined shale, vitrified shale, a microsphere, fly ash, slag, diatomaceous earth, metakaolin, rice husk ash, natural pozzolan, zeolite, cement kiln dust, lime, an elastomer, a resin, latex, and any combination thereof.

26. The method of claim 14 wherein the non-colloidal nano-clay is encapsulated in a degradable material.

27. A method of preparing a latex-free cement composition for use in a subterranean formation comprising:

providing a non-colloidal nano-clay having a length in a range of from about 1 nanometer to about 600 nanometers;

providing a hydraulic cement;

providing at least one additive selected from the group consisting of a strength-retrogression additive, a set accelerator, a set retarder, a weighting agent, a lightweight additive, a gas-generating additive, a mechanical property enhancing additive, a lost-circulation material, a filtration-control additive, a fluid loss control additive, a dispersant, a defoaming agent, a foaming agent, a thixotropic additive, and any combination thereof; and

preparing the latex-free cement composition comprising the non-colloidal nano-clay, the hydraulic cement, the at least one additive, and water;

wherein the non-colloidal nano-clay is present in an amount in a range of from about 0.1% to about 25% by weight of the hydraulic cement on a dry basis, wherein the hydraulic cement is selected from the group consisting of Portland cement, pozzolana cement, gypsum cement, high-alumina-content cement, slag cement, silica cement, and any combination thereof, and wherein the latex-free cement composition is capable of setting to form a hardened cement that prevents the migration of fluids.

28. The method of claim 27 wherein the non-colloidal nano-clay comprises nano-bentonite.

29. The method of claim 27 wherein the non-colloidal nano-clay has a length in a range of from about 1 nanometer to about 400 nanometers.

30. The method of claim 27 wherein the non-colloidal nano-clay has a general plate-type structure with a thickness of less than about 10 nanometers.

31. The method of claim 27 wherein the non-colloidal nano-clay comprises plate-type nano-montmorillonite having a thickness of less than about 2 nanometers and a length in a range of about 300 nanometers to about 600 nanometers.

32. The method of claim 27 wherein the latex-free cement composition further comprises at least one nano-particle selected from the group consisting of nano-hydraulic cement, nano-silica, nano-alumina, nano-zinc oxide, nano-boron, nano-iron oxide, and any combination thereof.

33. The method of claim 27 wherein the non-colloidal nano-clay is encapsulated in a degradable material.