Settable compositions comprising interground perlite and hydraulic cement

• US 8,672,028 B2
• Filed: 07/11/2011
• Issued: 03/18/2014
• Est. Priority Date: 12/21/2010
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Karcher, Jeffery D., Brenneis, D. Chad, Roddy, Craig W., Benkley, James R.
• Primary Examiner(s): SUCHFIELD, GEORGE A
• Application Number:
  US13/180,238
• Publication Number:
  US 20120152539A1
• Time in Patent Office: 981 Days
• Field of Search: None
• US Class Current: 166/277
• 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 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• 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 18/162 Cement kiln dust; Lime kiln dust
• CPC Class Codes: C04B 20/0036 Microsized or nanosized
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 20/026 Comminuting, e.g. by grinding or breaking; Defibrillating fibres other than asbestos
• CPC Class Codes: C04B 2103/0049 Water-swellable polymers
• CPC Class Codes: C04B 2103/0085 Thixotropic agents
• CPC Class Codes: C04B 2103/12 Set accelerators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/24 : Hardening retarders
• CPC Class Codes: C04B 2103/408 : Dispersants
• CPC Class Codes: C04B 2103/42 : Pore formers
• 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 28/02 : containing hydraulic cements other than calcium sulfates
• 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 28/04 : Portland cements
• CPC Class Codes: C04B 28/06 : Aluminous cements monolithic refractories or refractory mortars C04B35/66
• CPC Class Codes: C04B 28/08 : Slag cements
• CPC Class Codes: C04B 28/14 : containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: C04B 28/18 : containing mixtures of the silica-lime type
• 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 40/0046 : characterised by their processing, e.g. sequence of mixing the ingredients when preparing the premixtures
• CPC Class Codes: C04B 7/02 : Portland cement
• 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 8/48 : Density increasing or weighting additives
• CPC Class Codes: C09K 8/487 : Fluid loss control additives; Additives for reducing or preventing circulation loss
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

Methods and compositions are disclosed that comprise interground perlite and hydraulic cement. An embodiment provides a method of cementing comprising: providing a settable composition comprising perlite, hydraulic cement, and water, wherein the perlite and hydraulic cement are interground prior to combination with the water to form the settable composition; and allowing the settable composition to set.

Claims

1. A method of cementing comprising:

providing a settable composition comprising perlite, hydraulic cement, and water;

wherein the water is present in an amount in a range between about 40% to about 200% by weight of cementitious components;

wherein the perlite and hydraulic cement are interground prior to combination with the water to form the settable composition; and

allowing the settable composition to set.

2. The method of claim 1 wherein the perlite comprises unexpanded perlite.

3. The method of claim 1 wherein the perlite and the hydraulic cement were interground to a mean particle about 0.1 microns to about 400 microns.

4. The method of claim 1 wherein the perlite and the hydraulic cement were interground to a mean particle about 0.5 microns to about 10 microns.

5. The method of claim 1 wherein the perlite is present in an amount of about 40% to about 80% by weight of the perlite and hydraulic cement, and wherein the hydraulic cement is present in an amount of about 20% to about 60% by weight of the perlite and hydraulic cement.

6. The method of claim 1 wherein the hydraulic cement comprises at least one 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/lime cement, and any combination thereof.

7. The method of claim 1 wherein the hydraulic cement comprises a Portland cement.

8. The method of claim 1 wherein the perlite and the hydraulic cement were interground with at least one additional component selected from the group consisting of cement kiln dust and pumicite.

9. The method of claim 1 wherein the settable composition further comprises cement kiln dust.

10. The method of claim 1 wherein the settable composition further comprises pumicite.

11. The method of claim 1 wherein the settable composition further comprises at least one additive selected from the group consisting of lime, fly ash, slag cement, metakaolin, shale, zeolite, crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, microsphere, rice husk ash, elastomer, elastomeric particle, resin, latex, and any combination thereof.

12. The method 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.

13. The method of claim 1 further comprising introducing the settable composition into a well bore.

14. The method of claim 13 wherein the settable composition is allowed to set in the well bore in an annulus between a subterranean formation and a conduit in the well bore.

15. The method of claim 13 further comprising squeezing the settable composition in an opening, the opening comprising at least one opening selected from the group consisting of an opening in a subterranean formation, an opening in a gravel pack, an opening in a conduit, and a microannulus between a cement sheath and a conduit.

16. A method of cementing comprising:

providing a settable composition comprising unexpanded perlite, hydraulic cement, and water;

wherein the water is present in an amount in a range between about 40% to about 200% by weight of cementitious components;

wherein the unexpanded perlite and hydraulic cement are interground prior to combination with the water to foiiii the settable composition;

introducing the settable composition into a well bore; and

allowing the settable composition to set.

17. The method of claim 16 wherein the perlite and hydraulic cement were interground to a mean particle about 0.5 microns to about 10 microns.

18. The method of claim 16 wherein the perlite is present in an amount of about 40% to about 80% by weight of the perlite and hydraulic cement, and wherein the hydraulic cement in an amount of about 20% to about 60% by weight of the perlite and hydraulic cement.

19. The method of claim 16 wherein the hydraulic cement comprises at least one 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/lime cement, and any combination thereof.

20. The method of claim 16 wherein the hydraulic cement comprises a Portland cement.

21. The method of claim 16 wherein the perlite and the hydraulic cement were interground with at least one additional component selected from the group consisting of cement kiln dust and pumicite.

22. The method of claim 16 wherein the settable composition further comprises cement kiln dust.

23. The method of claim 16 wherein the settable composition further comprises pumicite.

24. The method of claim 16 wherein the settable composition further comprises at least one additive selected from the group consisting of lime, fly ash, slag cement, metakaolin, shale, zeolite, crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, microsphere, rice husk ash, elastomer, elastomeric particle, resin, latex, and any combination thereof.

25. The method of claim 16 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.

26. The method of claim 16 wherein the settable composition is allowed to set in the well bore in an annulus between a subterranean formation and a conduit in the well bore.

27. The method of claim 16 further comprising squeezing the settable composition in an opening, the opening comprising at least one opening selected from the group consisting of an opening in a subterranean formation, an opening in a gravel pack, an opening in a conduit, and a microannulus between a cement sheath and a conduit.