Settable compositions containing metakaolin having reduced portland cement content

• US 8,627,888 B2
• Filed: 05/13/2011
• Issued: 01/14/2014
• Est. Priority Date: 05/13/2011
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Santra, Ashok K., Ravi, Krishna M., Keys, Crystal Lynne, Iverson, Benjamin, Patil, Rahul, Patil, Sandip
• Primary Examiner(s): Bates, Zakiya W
• Application Number:
  US13/107,055
• Publication Number:
  US 20120285682A1
• Time in Patent Office: 977 Days
• Field of Search: None
• US Class Current: 166/293
• CPC Class Codes: C04B 14/041 Aluminium silicates other than clay
• CPC Class Codes: C04B 14/047 Zeolites
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/28 of calcium
• 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 2103/12 Set accelerators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/40 Surface-active agents, dispersants
• CPC Class Codes: C04B 2103/44 Thickening, gelling or viscosity increasing agents
• CPC Class Codes: C04B 2103/46 Water-loss or fluid-loss reducers, hygroscopic or hydrophilic agents, water retention agents
• 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 2111/2015 Sulfate resistance
• CPC Class Codes: C04B 2111/2092 Resistance against biological degradation
• CPC Class Codes: C04B 2111/22 Carbonation resistance
• CPC Class Codes: C04B 2111/23 Acid resistance, e.g. against acid air or rain
• 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 28/18 containing mixtures of the silica-lime type
• CPC Class Codes: C04B 40/0263 Hardening promoted by a rise in temperature C04B40/024 takes precedence
• CPC Class Codes: C09K 8/426 : for plugging
• CPC Class Codes: C09K 8/467 : containing additives for specific purposes
• 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

Of the many compositions and methods provided herein, one method includes providing a settable fluid that comprises an aqueous-based medium, a lime composition, and a cementitious blend that comprises metakaolin particulates and aluminosilicate particulates, wherein the cementitious blend is essentially free of Portland cement; introducing the settable fluid into a wellbore penetrating a subterranean formation that comprises a corrosive component; and allowing the settable fluid to set therein.

Claims

1. A method of cementing, the method comprising:

providing a settable fluid that comprises an aqueous-based medium, a lime composition, and a cementitious blend that comprises metakaolin particulates and aluminosilicate particulates, wherein the cementitious blend does not comprise cement kiln dust, and

wherein the cementitious blend is essentially free of Portland cement;

introducing the settable fluid into a wellbore penetrating a subterranean formation that comprises a corrosive component; and

allowing the settable fluid to set therein.

2. The method of claim 1, wherein the corrosive component is selected from the group consisting of an acid;

dissolved carbon dioxide;

a monovalent salt;

a multivalent salt;

a sulfur containing compound;

a microorganism and a byproduct thereof; and

any combination thereof.

3. The method of claim 1, wherein the settable fluid further comprises an additive selected from the group consisting of a set retarder, a set accelerator, a viscosifier, a gas, a surfactant, a fluid loss control additive, a suspending aid, a mechanical properties modifier, a density modifier, a gas migration control aid, and any combination thereof.

4. The method of claim 1, wherein the metakaolin particulates comprise high-reactive metakaolin particulates.

5. The method of claim 1, wherein the metakaolin particulates are present in the settable fluid at about 5% to about 85% by weight of total cementitious blend.

6. The method of claim 1, wherein at least some of the aluminosilicate particulates are selected from the group consisting of a Class F fly ash particulate, a Class C fly ash particulate, a biowaste ash particulate, a zeolite particulate, a slag particulate, and any combination thereof.

7. The method of claim 1, wherein the aluminosilicate particulates are present in the settable fluid at about 15% to about 95% by weight of total cementitious blend.

8. The method of claim 1, wherein the lime composition is present in the settable fluid in an amount of about 5% to about 50% by weight of total cementitious blend.

9. The method of claim 1, wherein the settable fluid is foamed.

10. The method of claim 1, wherein the settable fluid is included in a treatment fluid selected from the group consisting of a spotting fluid, a flush fluid, a spacer fluid, a cement slurry, a squeeze fluid, a drilling fluid, and a consolidation fluid.

11. The method of claim 1, wherein the subterranean formation includes a cementitious composition that was placed therein prior to introducing the settable fluid into the wellbore.

12. The method of claim 1, wherein the subterranean formation has a bottom-hole temperature of about 30°

F. to about 230°

F.

13. The method of claim 1, wherein the settable fluid has a thickening time of about 3 hours to about 5 days as measured by high-temperature and high-pressure consistometer at a desired bottom hole circulating temperature within the range of about 80°

F. to about 650°

F.

14. The method of claim 1, wherein the settable fluid has a density greater than about 13.5 pounds per gallon.

15. The method of claim 1, wherein the settable fluid has a density less than about 13.5 pounds per gallon.

16. A method comprising:

providing a drilling fluid that comprises an aqueous-based medium, a lime composition, a set retarder, and a cementitious blend that comprises metakaolin particulates and aluminosilicate particulates,

wherein the cementitious blend does not comprise cement kiln dust,

wherein the drilling fluid is essentially free of Portland cement, and

wherein the set retarder is present at about 2% to about 15% by weight of cementitious blend; and

drilling at least a portion of a wellbore penetrating a subterranean formation with the drilling fluid.

17. The method of claim 16, wherein the drilling fluid does not set for at least about 72 hours after introduction into the wellbore.

18. The method of claim 16, wherein the drilling fluid further comprises an additive selected from the group consisting of a set retarder, a set accelerator, a viscosifier, a gas, a surfactant, a fluid loss control additive, a suspending aid, a mechanical properties modifier, a density modifier, a gas migration control aid, and any combination thereof.

19. The method of claim 16 wherein the portion of the wellbore being drilled contains a corrosive component selected from the group consisting of carbonic acid;

dissolved carbon dioxide;

a monovalent salt;

a multivalent salt;

sulfur containing compounds; and

any combination thereof.

20. A settable fluid comprising:

an aqueous-based medium;

a cementitious blend comprising;

metakaolin particulates at a concentration of about 5% to about 85% by weight of the cementitious blend and

a fly ash at a concentration of about 15% to about 95% by weight of the cementitious blend; and

a lime composition at a concentration of about 5% to about 25% by weight of the cementitious blend,

wherein the settable fluid does not include a Portland cement, cement kiln dust, or pumice.