Consolidating spacer fluids and methods of use

• US 8,691,737 B2
• Filed: 03/27/2013
• Issued: 04/08/2014
• 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: Chatterji, Jiten, Brenneis, D. Chad, Keys, Crystal L., Benkley, James R., Roddy, Craig W., Morgan, Ronnie G., Morgan, Rickey L.
• Primary Examiner(s): Figueroa, John J
• Application Number:
  US13/851,925
• Publication Number:
  US 20130210685A1
• Time in Patent Office: 377 Days
• Field of Search: None
• US Class Current: 507/269
• CPC Class Codes: C04B 12/04 Alkali metal or ammonium silicate cements ; Alkyl silicate cements; Silica sol cements; Soluble silicate cements alkali metal silicates per se, their preparation C01B33/32; ammonium silicates per se, their preparation C01C1/00
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/104 Bentonite, e.g. montmorillonite
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/108 Shale, slate colliery shale C04B18/125
• CPC Class Codes: C04B 14/14 Minerals of vulcanic origin granite C04B14/048
• CPC Class Codes: C04B 14/18 Perlite
• CPC Class Codes: C04B 14/368 Baryte
• 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 18/146 Silica fume
• CPC Class Codes: C04B 18/162 Cement kiln dust; Lime kiln dust
• CPC Class Codes: C04B 18/22 Rubber , e.g. ground waste tires
• CPC Class Codes: C04B 2103/40 Surface-active agents, dispersants
• CPC Class Codes: C04B 2103/408 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 2103/50 Defoamers, air detrainers
• CPC Class Codes: C04B 2103/61 Corrosion inhibitors
• CPC Class Codes: C04B 2111/00017 Aspects relating to the protection of the environment
• 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 24/38 : Polysaccharides or derivatives thereof C04B24/243 takes precedence
• CPC Class Codes: C04B 24/383 : Cellulose or derivatives thereof
• 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 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 2208/10 : Nanoparticle-containing well treatment fluids
• CPC Class Codes: C09K 8/40 : Spacer compositions, e.g. compositions used to separate well-drilling from cementing masses
• CPC Class Codes: C09K 8/424 : using "spacer" compositions
• 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: C09K 8/601 : using spacer compositions
• CPC Class Codes: E21B 21/002 : Down-hole drilling fluid separation systems containers comprising collecting means with a strainer E21B27/005; subsoil filtering E21B43/02; down-hole production separators E21B43/38
• CPC Class Codes: E21B 33/13 : Methods or devices for cementing, for plugging holes, crevices or the like
• CPC Class Codes: E21B 33/138 : Plastering the borehole wall; Injecting into the formation
• CPC Class Codes: E21B 49/08 : Obtaining fluid samples or testing fluids, in boreholes or wells
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

Disclosed are spacer fluids and methods of use in subterranean formations. Embodiments may include use of consolidating spacer fluids in displacement of drilling fluids from a well bore annulus.

Claims

1. A consolidating spacer fluid for separating a drilling fluid and a cement composition in a well bore, comprising:

water in an amount of about 15% to about 95% by weight of the spacer fluid;

cement kiln dust;

at least one additive selected from the group consisting of gypsum, bentonite, hydroxyethyl cellulose, sodium silicate, a hollow microsphere, gilsonite, perlite, a gas, an organic polymer, a biopolymer, latex, ground rubber, a surfactant, crystalline silica, amorphous silica, silica flour, fumed silica, nano-clay, salt, fiber, hydratable clay, rice husk ash, micro-fine cement, metakaolin, zeolite, shale, pumicite, Portland cement, Portland cement interground with pumice, barite, slag, lime, and any combination thereof;

fly ash in an amount of about 1% to about 60% by weight of the spacer fluid; and

a free water control additive in an amount of about 0.1% to about 16% by weight of the spacer fluid;

wherein the consolidating spacer fluid has a zero gel time of about 4 hours or less under predetermined well bore conditions, wherein the consolidating spacer fluid is disposed in the well bore between the drilling fluid and the cement composition.

2. The consolidating spacer fluid of claim 1 wherein the cement kiln dust is present in an amount in a range of from about 1% to about 60% by weight of the consolidating spacer fluid.

3. The consolidating spacer fluid of claim 1 wherein the consolidating spacer fluid comprises dry solids used in preparation of the consolidating spacer fluid, the dry solids comprising the cement kiln dust in an amount in a range of from about 50% to 100% by weight of the dry solids.

4. The consolidating spacer fluid of claim 1 wherein the consolidating spacer fluid comprises dry solids used in preparation of the consolidating spacer fluid, the dry solids comprising the cement kiln dust in an amount in a range of from about 80% to 100% by weight of the dry solids.

5. The consolidating spacer fluid of claim 1 wherein the consolidating spacer fluid comprises at least one additive selected from the group consisting of a a lightweight additive, a foaming agent, a supplementary cementitious material, a weighting agent of any suitable size, a viscosifying agent, a fluid loss control agent, a lost circulation material, a filtration control additive, a dispersant, a defoamer, a corrosion inhibitor, a scale inhibitor, a formation conditioning agent, a water-wetting surfactant, and any combination thereof.

6. The consolidating spacer fluid of claim 1 wherein the consolidating spacer fluid comprises the slag, the pumicite, the lime, and/or the barite.

7. The consolidating spacer fluid of claim 1 wherein the consolidating spacer fluid is foamed and has a density in a range of from about 4 pounds per gallon to about 13 pounds per gallon.

8. The consolidating spacer fluid of claim 1 wherein the consolidating spacer fluid has a transition time of about 45 minutes or less under predetermined well bore conditions.

9. The consolidating spacer fluid of claim 1 wherein the consolidating spacer fluid has a transition time of about 20 minutes or less under predetermined well bore conditions.

10. A consolidating spacer fluid for separating a drilling fluid and a cement composition in a well bore, comprising:

water in an amount of about 40% to about 65% by weight of the spacer fluid;

fly ash in an amount of about 1% to about 10% by weight of the spacer fluid;

a partially calcined kiln feed comprising SiO₂, Al₂O₃, Fe₂O₃, CaO, MgO, SO₃, Na₂O, and K₂O; and

a free water control additive in an amount of about 0.1% to about 5% by weight of the spacer fluid, wherein the free water control additive comprises at least one additive selected from the group consisting of bentonite, amorphous silica, hydroxyethyl cellulose, and any combination thereof;

wherein the consolidating spacer fluid has a zero gel time of about 4 hours or less under predetermined well bore conditions, and

wherein the consolidating spacer fluid is disposed in the well bore between the drilling fluid and the cement composition.

11. The consolidating spacer fluid of claim 10 wherein the partially calcined kiln feed is present in an amount in a range of from about 1% to about 60% by weight of the consolidating spacer fluid.

12. The consolidating spacer fluid of claim 10 wherein the consolidating spacer fluid comprises dry solids used in preparation of the consolidating spacer fluid, the dry solids comprising the partially calcined kiln feed in an amount in a range of from about 50% to 100% by weight of the dry solids.

13. The consolidating spacer fluid of claim 10 wherein the consolidating spacer fluid comprises dry solids used in preparation of the consolidating spacer fluid, the dry solids comprising the partially calcined kiln feed in an amount in a range of from about 80% to 100% by weight of the dry solids.

14. The consolidating spacer fluid of claim 10 wherein the consolidating spacer fluid comprises at least one additive selected from the group consisting of a a lightweight additive, a foaming agent, a supplementary cementitious material, a weighting agent of any suitable size, a viscosifying agent, a fluid loss control agent, a lost circulation material, a filtration control additive, a dispersant, a defoamer, a corrosion inhibitor, a scale inhibitor, a formation conditioning agent, a water-wetting surfactant, and any combination thereof.

15. The consolidating spacer fluid of claim 10 wherein the consolidating spacer fluid comprises slag, pumicite, lime, and/or barite.

16. The consolidating spacer fluid of claim 10 wherein the consolidating spacer fluid is foamed and has a density in a range of from about 4 pounds per gallon to about 13 pounds per gallon.

17. The consolidating spacer fluid of claim 10 wherein the consolidating spacer fluid has a transition time of about 45 minutes or less under predetermined well bore conditions.

18. The consolidating spacer fluid of claim 10 wherein the consolidating spacer fluid has a transition time of about 20 minutes or less under predetermined well bore conditions.