Pumice-containing remedial compositions and methods of use

• US 8,899,329 B2
• Filed: 04/30/2013
• Issued: 12/02/2014
• Est. Priority Date: 04/30/2013
• 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, Benkley, James R.
• Primary Examiner(s): Bates, Zakiya W
• Application Number:
  US13/873,905
• Publication Number:
  US 20140318784A1
• Time in Patent Office: 581 Days
• US Class Current: 166/293
• CPC Class Codes: C04B 14/047 Zeolites
• 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 16/085 expanded in situ, i.e. during or after mixing the mortar, concrete or artificial stone ingredients
• 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 2111/1037 Cement free compositions, e.g. hydraulically hardening mixtures based on waste materials, not containing cement as such
• CPC Class Codes: C04B 28/18 containing mixtures of the silica-lime type
• CPC Class Codes: C09K 8/428 for squeeze cementing, e.g. for repairing
• 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
• CPC Class Codes: E21B 33/138 Plastering the borehole wall; Injecting into the formation
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

Methods and compositions are provided that utilize pumice and various additives. An embodiment provides a method of remedial cementing in a subterranean formation comprising: providing a lightweight settable composition comprising pumice, a calcium activator, and water, wherein the lightweight settable composition has a density of less than about 13.5 pounds per gallon and is free of Portland cement; and using the lightweight settable composition in a remedial cementing method to seal one or more voids in a well bore. Also provided are pumice-containing remedial compositions and systems for remedial cementing.

Claims

1. A method of remedial cementing in a subterranean formation comprising:

providing a lightweight settable composition comprising pumice, a calcium activator, and water, wherein the lightweight settable composition has a density of less than about 13.5 pounds per gallon and is essentially free of any additional cementitious components, wherein the water is present in an amount in a range of from about 40% to about 200% by weight of the pumice, wherein the lightweight settable composition is foamed with a foaming additive and a gas; and

placing the lightweight settable composition into a void or crack in the subterranean formation, a gravel pack, a conduit, a cement sheath, or a microannulus.

2. The method of claim 1, wherein the calcium activator is present in an amount of about 0.1% to about 25% by weight of the pumice.

3. The method of claim 1, wherein the calcium activator comprises a material selected from the group consisting of calcium formate, lime, hydrated lime, and any combination thereof.

4. The method of claim 1, wherein the lightweight settable composition further comprises at least one additive selected from the group consisting of shale, zeolite, amorphous silica, fly ash, metakaolin, perlite, rice hull hush, a swellable particulate elastomer, and any combination thereof.

5. The method of claim 4, wherein the at least one additive is present in an amount in a range of from about 0.1% to about 100% by weight of the pumice.

6. The method of claim 4, wherein the at least one additive present in an amount in a range of from about 50% to about 100% by weight of the pumice.

7. The method of claim 1, wherein the lightweight settable composition further comprises shale in an amount of about 40% to about 100% by weight of the pumice, and wherein the light weight settable composition further comprises zeolite in an amount of about 40% to about 100% by weight of the pumice.

8. The method of claim 1, wherein the lightweight settable composition further comprises metakaolin in an amount of about 40% to about 100% by weight of the pumice.

9. The method of claim 1, where the lightweight settable composition further comprises at least one additive selected from the group consisting of strength-retrogression additives, set accelerators, set retarders, lightweight additives, gas-generating additives, mechanical property enhancing additives, lost-circulation materials, fluid loss control additives, foaming additives, defoaming additives, thixotropic additives, and any combination thereof.

10. The method of claim 1, wherein the lightweight settable composition further comprises at least one additive selected from the group consisting of crystalline silica, fumed silica, silicates, salts, fibers, hydratable clays, shale, calcined shale, vitrified shale, microspheres, diatomaceous earth, natural pozzolan, cement kiln dust, resins, and any combination thereof.

11. The method of claim 1, wherein the lightweight settable composition develops a 24-hour compressive strength of about 100 psi after mixing the pumice and the calcium activator with the water.

12. A method of remedial cementing in a subterranean formation comprising:

providing a latex-free lightweight settable composition comprising pumice, a calcium activator, shale in an amount of about 40% to about 100% by weight of the pumice, zeolite in an amount of about 40% to about 100% by weight of the pumice, and water, wherein the lightweight settable composition has a density of less than about 13.5 pounds per gallon and is essentially free of any additional cementitious components, wherein the lightweight settable composition is foamed with a foaming additive and a gas; and

placing the lightweight settable composition into a void or crack in the subterranean formation, a gravel pack, a conduit, a cement sheath, or a microannulus.

13. The method of claim 12, wherein the water is present in an amount in a range of from about 40% to about 200% by weight of the pumice.

14. The method of claim 12, wherein the calcium activator is present in an amount of about 0.1% to about 25% by weight of the pumice.

15. The method of claim 12, wherein the calcium activator comprises a material selected from the group consisting of calcium formate, lime, hydrated lime, and any combination thereof.

16. The method of claim 12, wherein the lightweight settable composition further comprises at least one additive selected from the group consisting of amorphous silica, fly ash, metakaolin, perlite, rice hull hush, a swellable particulate elastomer, and any combination thereof.