Settable compositions comprising interground perlite and hydraulic cement

• US 9,376,609 B2
• Filed: 12/30/2013
• Issued: 06/28/2016
• 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 Dwane, Brenneis, D. Chad, Roddy, Craig W., Benkley, James R.
• Primary Examiner(s): Bland, Alicia
• Application Number:
  US14/144,147
• Publication Number:
  US 20140123879A1
• Time in Patent Office: 911 Days
• Field of Search: None
• US Class Current: 1/1
• 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 composition comprising interground perlite and hydraulic cement. Another embodiment provides a composition comprising: interground unexpanded perlite and Portland cement, the interground having a mean particle size of about 0.5 microns to about 10 microns; and water.

Claims

1. A composition consisting of:

an interground mixture consisting of unexpanded perlite and Portland cement,

wherein the interground mixture has a mean particle size between about 0.5 microns and about 10 microns,

wherein the perlite is present in an amount of about 40% to about 80% by weight of the perlite and Portland cement,

wherein the Portland cement is present in an amount of about 20% to about 60% by weight of the perlite and Portland cement; and

a hydraulic cement blended with the interground mixture.

2. The composition of claim 1 wherein the interground mixture has a mean particle size of about 0.1 microns to about 400 microns.

8. The method of claim 1 wherein the Portland cement comprises least one of Class A, Class C, Class H, Class G, ASTM Type III, or ASTM Type V.

18. The composition of claim 1 wherein the interground mixture has a bimodal particle size distribution with a first peak from about 1 microns to about 7 microns and a second peak from about 7 microns to about 15 microns.

3. A method of preparing a composition comprising:

intergrinding components consisting of unexpanded perlite and Portland cement to form an interground mixture, wherein the perlite is present in an amount of about 40% to about 80% by weight of the perlite and Portland cement, and wherein the Portland cement is present in an amount of about 20% to about 60% by weight of the perlite and Portland cement; and

combining the interground mixture with at least one component comprising water to form the composition, wherein the water is present in an amount of about 100 percent to about 200 percent by weight of cementitious components present in the composition.

4. The method of claim 3 wherein the composition further comprises cement kiln dust.

5. The method of claim 3 wherein the comprises pumicite.

6. The method of claim 3 wherein the 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.

7. The method of claim 3 wherein the Portland cement comprises least one of Class A, Class C, Class H, Class G, ASTM Type III, or ASTM Type V.

12. The method of claim 3, wherein the interground mixture has a bimodal particle size distribution with a first peak from about 1 microns to about 7 microns and a second peak from about 7 microns to about 15 microns.

13. The method of claim 3, wherein the interground mixture has mean particle size between about 0.5 microns and about 10 microns.

14. The composition of claim 3, further comprising blending the interground mixture with a hydraulic cement.

9. A method of preparing a composition comprising:

intergrinding components consisting of unexpanded perlite and Portland cement to form an interground mixture, wherein the interground mixture has a bimodal particle size distribution with a first peak from about 1 microns to about 7 microns and a second peak from about 7 microns to about 15 microns, wherein the interground mixture has mean particle size between about 0.5 microns and about 10 microns, wherein the perlite is present in an amount of about 40% to about 80% by weight of the perlite and Portland cement, and wherein the Portland cement is present in an amount of about 20% to about 60% by weight of the perlite and Portland cement;

blending the interground mixture with hydraulic cement to form a mixture; and

combining the mixture with at least water to form the composition, wherein the water is present in an amount of about 100 percent to about 200 percent by weight of cementitious components present in the composition,

wherein the composition has a density of about 8 pounds per gallon to about 13 pounds per gallon.

10. The method of claim 9 wherein the first peak of the bimodal particle size distribution is about 3 microns to about 5 microns, and wherein the second peak of the bimodal particle size distribution is about 9 microns to about 11 microns.

11. The method of claim 9 wherein the first peak of the bimodal particle size distribution is about 4 microns, and wherein the second peak of the bimodal particle size distribution is about 10 microns.

15. A composition consisting of:

an interground mixture consisting of unexpanded perlite and Portland cement,

wherein the interground mixture has a mean particle size between about 0.5 microns and about 10 microns,

wherein the perlite is present in an amount of about 40% to about 80% by weight of the perlite and Portland cement,

wherein the Portland cement is present in an amount of about 20% to about 60% by weight of the perlite and Portland cement;

a hydraulic cement blended with the interground mixture; and

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.

16. The composition of claim 15 wherein the interground mixture has a mean particle size of about 0.1 microns to about 400 microns.

17. The composition of claim 15 wherein the interground mixture has a bimodal particle size distribution with a first peak from about 1 microns to about 7 microns and a second peak from about 7 microns to about 15 microns.