Acid-soluble cement compositions comprising cement kiln dust and methods of use

• US 8,950,486 B2
• Filed: 08/27/2012
• Issued: 02/10/2015
• 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: Benkley, James Robert, Brenneis, D. Chad, Roddy, Craig W.
• Primary Examiner(s): DiTrani, Angela M
• Application Number:
  US13/595,493
• Publication Number:
  US 20120318506A1
• Time in Patent Office: 897 Days
• Field of Search: None
• US Class Current: 166/292
• CPC Class Codes: C04B 14/047 Zeolites
• CPC Class Codes: C04B 14/062 Microsilica, e.g. colloïdal silica preparing microsilica slurries or suspensions C04B18/148
• 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 14/16 porous, e.g. pumice
• 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 20/002 Hollow or porous granular materials
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2103/0049 Water-swellable polymers
• CPC Class Codes: C04B 2103/12 Set accelerators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/408 Dispersants
• 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 28/32 : Magnesium oxychloride cements, e.g. Sorel cement
• 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 40/0092 : Temporary binders, mortars or concrete, i.e. materials intended to be destroyed or removed after hardening, e.g. by acid dissolution
• 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

The present invention relates to acid-soluble cement compositions that comprise cement kiln dust (“CKD”) and associated methods of use. An embodiment provides a method of cementing comprising: providing an acid-soluble cement composition comprising a kiln dust and water; allowing the acid-soluble cement composition to set to form an acid-soluble hardened mass; and contacting the acid-soluble hardened mass with an acid.

Claims

1. A method of cementing comprising:

providing an acid-soluble cement composition comprising a kiln dust and water, wherein the acid-soluble cement composition is free of any additional cementitious components other than the kiln dust;

allowing the acid-soluble cement composition to set to form an acid-soluble hardened mass; and

contacting the acid-soluble hardened mass with an acid.

2. The method of claim 1 wherein the acid-soluble cement composition has a density of about 8 pounds per gallon to about 16 pounds per gallon.

3. The method of claim 1 wherein the kiln dust comprises cement kiln dust.

4. The method of claim 1 wherein the kiln dust comprises lime kiln dust.

5. The method of claim 1 wherein the kiln dust comprises cement kiln dust present in an amount in a range of from about 1% to 100% by weight of a total amount of cementitious components present in the acid-soluble cement composition.

6. The method of claim 1 wherein the kiln dust comprises cement kiln dust present in an amount in a range of from about 50% to about 100% by weight of a total amount of cementitious components present in the acid-soluble cement composition.

7. The method of claim 1 wherein the acid-soluble cement composition is free of an acid-soluble filler.

8. The method of claim 1 wherein the acid-soluble cement composition is free of an acid-soluble filler selected from the group consisting of dolomite, magnesium carbonate, calcium carbonate, zinc carbonate, and any combination thereof.

9. The method of claim 1 wherein the acid-soluble cement composition further comprises an additive selected from the group consisting of metakaolin, crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, microsphere, rice husk ash, an elastomer, an elastomeric particle, a resin, a latex, and any combination thereof.

10. The method of claim 1 wherein the acid-soluble cement composition further comprises an 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.

11. The method of claim 1 wherein contacting the acid-soluble hardened mass with an acid comprises contacting the acid-soluble hardened mass with an aqueous acid composition, wherein the aqueous acid composition comprises hydrochloric acid present in the aqueous acid composition in an amount of about 7.5% to about 28% by weight of the aqueous acid composition.

12. The method of claim 1 further comprising:

placing the acid-soluble cement composition into a subterranean formation.

13. The method of claim 12 wherein the acid-soluble cement composition is allowed to set in a well-bore annulus in the subterranean formation, wherein the acid contacts the acid-soluble hardened mass through one or more openings in a pipe string disposed in the subterranean formation.

14. The method of claim 1 wherein the acid-soluble cement composition further comprises an acid-soluble filler.

15. A method of cementing comprising:

placing an acid-soluble cement composition in a subterranean formation, the acid-soluble cement composition comprising;

cement kiln dust in an amount of 100% by weight of a total amount of cementitious components in the acid-soluble cement composition; and

water;

allowing the acid-soluble cement composition to set to form an acid-soluble hardened mass; and

contacting the acid-soluble hardened mass with an acid.

16. The method of claim 15 wherein the acid-soluble cement composition is free of an acid-soluble filler.

17. The method of claim 15 wherein the acid-soluble cement composition is free of an acid-soluble filler selected from the group consisting of dolomite, magnesium carbonate, calcium carbonate, zinc carbonate, and any combination thereof.

18. The method of claim 15 wherein the acid-soluble cement composition further comprises an 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.

19. The method of claim 15 wherein contacting the acid-soluble hardened mass with an acid comprises contacting the acid-soluble hardened mass with an aqueous acid composition, wherein the aqueous acid composition comprises hydrochloric acid present in the aqueous acid composition in an amount of about 7.5% to about 28% by weight of the aqueous acid composition.

20. The method of claim 15 wherein the placing the acid-soluble composition comprises placing the acid-soluble composition in a well-bore annulus between a pipe string disposed in the subterranean formation and a wall of a well bore.

21. The method of claim 15 wherein the acid-soluble cement composition is allowed to set in a well-bore annulus in the subterranean formation, wherein the acid contacts the acid-soluble hardened mass through one or more openings in a pipe string disposed in the subterranean formation.

22. The method of claim 15 wherein the acid-soluble cement composition further comprises an acid-soluble filler.

23. A method of cementing comprising:

placing an acid-soluble cement composition in a subterranean formation, the acid-soluble cement composition comprising cement kiln dust and water, wherein the acid-soluble cement composition is free of any acid-soluble fillers;

allowing the acid-soluble cement composition to set to form an acid-soluble hardened mass; and

contacting the acid-soluble hardened mass with an acid.

24. The method of claim 23 wherein the acid-soluble cement composition further comprises a 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 cement, and any combination thereof.

25. The method of claim 23 wherein the cement kiln dust is present in an amount in a range of from about 1% to 100% by weight of a total amount of cementitious components present in the acid-soluble cement composition.

26. The method of claim 23 wherein the cement kiln dust is present in an amount of about 100% by weight of a total amount of cementitious components present in the acid-soluble cement composition.

27. The method of claim 23 wherein the acid-soluble cement composition is free of any additional cementitious components other than the cement kiln dust.

28. The method of claim 23 wherein the acid-soluble cement composition further comprises an additive selected from the group consisting of a fly ash, a slag cement, metakaolin, shale, zeolite, crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, microsphere, rice husk ash, an elastomer, an elastomeric particle, a resin, a latex, and any combination thereof.

29. The method of claim 23 wherein the acid-soluble cement composition further comprises an 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.

30. The method of claim 23 wherein contacting the acid-soluble hardened mass with an acid comprises contacting the acid-soluble hardened mass with an aqueous acid composition, wherein the aqueous acid composition comprises hydrochloric acid present in the aqueous acid composition in an amount of about 7.5% to about 28% by weight of the aqueous acid composition.

31. The method of claim 23 wherein the acid-soluble cement composition is allowed to set in a well-bore annulus in the subterranean formation, wherein the acid contacts the acid-soluble hardened mass through one or more openings in a pipe string disposed in the subterranean formation.