Cement compositions comprising sub-micron alumina and associated methods

• US 8,940,670 B2
• Filed: 03/30/2012
• Issued: 01/27/2015
• Est. Priority Date: 05/10/2007
• Status: Expired due to Fees

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Patil, Rahul Chandrakant, Reddy, B. Raghava, Deshpande, Abhimanyu, Gordon, Christopher L., Roddy, Craig W., Chatterji, Jiten, Cromwell, Roger S.
• Primary Examiner(s): Figueroa, John J
• Application Number:
  US13/435,701
• Publication Number:
  US 20120190769A1
• Time in Patent Office: 1,033 Days
• Field of Search: None
• US Class Current: 507/269
• CPC Class Codes: C04B 14/047 Zeolites
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/108 Shale, slate colliery shale C04B18/125
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 14/308 Iron oxide
• 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 20/008 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 2103/50 Defoamers, air detrainers
• CPC Class Codes: C04B 2111/00146 Sprayable or pumpable mixtures
• CPC Class Codes: C04B 2111/00215 Mortar or concrete mixtures defined by their oxide composition
• CPC Class Codes: C04B 24/161 Macromolecular compounds comprising sulfonate or sulfate groups
• CPC Class Codes: C04B 24/26 obtained by reactions only involving carbon-to-carbon unsaturated bonds C04B24/243 takes precedence
• CPC Class Codes: C04B 24/2611 Polyalkenes
• CPC Class Codes: C04B 24/2652 Nitrogen containing polymers, e.g. polyacrylamides, polyacrylonitriles
• CPC Class Codes: C04B 24/2676 Polystyrenes
• 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 8/46 : containing inorganic binders, e.g. Portland cement
• 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

Methods and compositions that comprise sub-micron alumina for accelerating setting of a cement composition. An embodiment includes a method of cementing in a subterranean formation. The method may comprise introducing a cement composition into the subterranean formation, wherein the cement composition comprises hydraulic cement, sub-micron alumina, and water. The method further may comprise allowing the cement composition to set in the subterranean formation. Another embodiment includes a cement composition that may comprise hydraulic cement, sub-micron alumina, and water.

Claims

1. A cement composition comprising:

hydraulic cement, wherein the hydraulic cement is free of fly ash;

sub-micron particles consisting of alumina, which are a separate component from the hydraulic cement, wherein the sub-micron particles have a particle size in a range of from about 150 nm to about 950 nm, and wherein the sub-micron particles are present in an amount in a range of from 0.1% to about 10% by weight of the hydraulic cement on a dry basis;

latex, wherein the latex comprises at least one material selected from the group consisting of an ethylene-propylene rubber, a styrene-butadiene rubber, a nitrile rubber, a nitrile butadiene rubber, a butyl rubber, a neoprene rubber, a polybutadiene rubber, an acrylonitrile-styrene-butadiene rubber, a polyisoprene rubber, an AMPS-styrene-butadiene rubber, and any combination thereof; and

water, in an amount in the range of about 33% to about 200% by weight of the hydraulic cement.

2. The cement composition of claim 1 wherein the hydraulic cement comprises at least one hydraulic 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

3. The cement composition of claim 1 further comprising belite in an amount in a range of from 0.1% to about 50% by weight of calcium silicates in the cement composition.

4. The cement composition of claim 1 further comprising a colloidal alumina dispersion comprising the sub-micron particles suspended in a base fluid.

5. The cement composition of claim 1 wherein the sub-micron particles have a particle size in a range of from about 400 nm to about 500 nm.

6. The cement composition of claim 1 wherein the sub-micron particles are present in the cement composition in an amount in a range of from about 0.5% to about 5% by weight of the hydraulic cement on a dry basis.

7. The cement composition of claim 1 further comprising least one additive selected from the group consisting of a latex stabilizer, 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, nano-particles, and any combination thereof.

8. The cement composition of claim 1 further comprising at least one additive selected from the group consisting of a gas, crystalline silica, amorphous silica, fumed silica, a salt, a fiber, a hydratable clay, calcined shale, vitrified shale, a microsphere, slag, diatomaceous earth, metakaolin, rice husk ash, a natural pozzolan, zeolite, cement kiln dust, lime, an elastomer, a resin, nano-silica, nano-clay, nano-silica, nano-zinc oxide, nano-boron, nano-iron oxide, nano-zirconium oxide, nano-magnesium oxide, nano-barite, and any combination thereof.

9. The cement composition of claim 1, wherein the cement composition has a density of about 13 ppg to about 20 ppg.

10. A cement composition comprising:

hydraulic 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; and

wherein the hydraulic cement is free of fly ash;

sub-micron particles consisting of alumina and having a particle size in a range of about 150 nm to about 950 nm, wherein the sub-micron alumina particles are present in an amount in a range of from about 0.1% to about 10% by weight of the hydraulic cement on a dry basis; and

wherein the sub-micron alumina particles are a separate component from the hydraulic cement;

latex, wherein the latex comprises at least one material selected from the group consisting of an ethylene-propylene rubber, a styrene-butadiene rubber, a nitrile rubber, a nitrile butadiene rubber, a butyl rubber, a neoprene rubber, a polybutadiene rubber, an acrylonitrile-styrene-butadiene rubber, a polyisoprene rubber, an AMPS-styrene-butadiene rubber, and any combination thereof; and

water, in an amount in the range of about 35% to about 70% by weight of the hydraulic cement.

11. The cement composition of claim 10 further comprising belite in an amount in a range of from 0.1% to about 50% by weight of calcium silicates in the cement composition.

12. The cement composition of claim 10 further comprising a 1 colloidal alumina dispersion comprising the sub-micron particles suspended in a base fluid.

13. The cement composition of claim 10 wherein the sub-micron particles have a particle size in a range of from about 400 nm to about 500 nm.

14. The cement composition of claim 10 wherein the sub-micron particles are present in the cement composition in an amount in a range of from about 0.5% to about 5% by weight of the hydraulic cement on a dry basis.

15. The cement composition of claim 10 further comprising least one additive selected from the group consisting of a latex stabilizer, 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, nano-particles, and any combination thereof.

16. The cement composition of claim 10 further comprising at least one additive selected from the group consisting of a gas, crystalline silica, amorphous silica, fumed silica, a salt, a fiber, a hydratable clay, calcined shale, vitrified shale, a microsphere, slag, diatomaceous earth, metakaolin, rice husk ash, a natural pozzolan, zeolite, cement kiln dust, lime, an elastomer, a resin, nano-silica, nano-clay, nano-silica, nano-zinc oxide, nano-boron, nano-iron oxide, nano-zirconium oxide, nano-magnesium oxide, nano-barite, and any combination thereof.

17. The cement composition of claim 10, wherein the cement composition has a density of about 13 ppg to about 20 ppg.

18. A cement composition comprising:

hydraulic cement, wherein the hydraulic cement is free of fly ash;

sub-micron particles consisting of alumina, which are a separate component from the hydraulic cement, wherein the sub-micron particles have a particle size in a range of from about 150 nm to about 950 nm, and wherein the sub-micron particles are present in an amount in a range of from 0.1% to about 10% by weight of the hydraulic cement on a dry basis;

latex in an amount of about 2% to about 45% by weight of the cement on a dry basis;

wherein the latex comprises at least one material selected from the group consisting of an ethylene-propylene rubber, a styrene-butadiene rubber, a nitrile rubber, a nitrile butadiene rubber, a butyl rubber, a neoprene rubber, a polybutadiene rubber, an acrylonitrile-styrene-butadiene rubber, a polyisoprene rubber, an AMPS-styrene-butadiene rubber, and any combination thereof; and

water, in an amount in the range of about 33% to about 200% by weight of the hydraulic cement.

19. The cement composition of claim 18 wherein the hydraulic cement comprises at least one hydraulic 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 cement composition of claim 18 further comprising belite in an amount in a range of from 0.1% to about 50% by weight of calcium silicates in the cement composition.

21. The cement composition of claim 18 further comprising a colloidal alumina dispersion comprising the sub-micron particles suspended in a base fluid.

22. The cement composition of claim 18 wherein the sub-microns particles have a particle size in a range of from about 400 nm to about 500 nm.

23. The cement composition of claim 18 wherein the sub-micron particles are present in the cement composition in an amount in a range of from about 1% to about 5% by weight of the hydraulic cement on a dry basis.

24. The cement composition of claim 18 wherein the latex comprises a styrene-butadiene rubber.

25. The cement composition of claim 18 further comprising least one additive selected from the group consisting of a latex stabilizer, 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, nano-particles, and any combination thereof.

26. The cement composition of claim 18 further comprising at least one additive selected from the group consisting of a gas, crystalline silica, amorphous silica, fumed silica, a salt, a fiber, a hydratable clay, calcined shale, vitrified shale, a microsphere, slag, diatomaceous earth, metakaolin, rice husk ash, a natural pozzolan, zeolite, cement kiln dust, lime, an elastomer, a resin, nano-silica, nano-clay, nano-silica, nano-zinc oxide, nano-boron, nano-iron oxide, nano-zirconium oxide, nano-magnesium oxide, nano-barite, and any combination thereof.

27. The cement composition of claim 18, wherein the cement composition has a density of about 13 ppg to about 20 ppg.