Calcium phosphate cement compositions comprising pumice and/or perlite and associated methods

• US 9,499,731 B2
• Filed: 12/29/2014
• Issued: 11/22/2016
• Est. Priority Date: 11/21/2011
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Karcher, Jeffery D., Brenneis, D. Chad, Brothers, Lance E.
• Primary Examiner(s): Green, Anthony J
• Application Number:
  US14/584,281
• Publication Number:
  US 20150107490A1
• Time in Patent Office: 694 Days
• US Class Current: 1/1
• CPC Class Codes: C04B 14/16 porous, e.g. pumice
• CPC Class Codes: C04B 14/18 Perlite
• CPC Class Codes: C04B 14/185 expanded
• CPC Class Codes: C04B 2/06 with addition of substances, e.g. hydrophobic agents ; Slaking in the presence of other compounds
• CPC Class Codes: C04B 2103/0088 Compounds chosen for their latent hydraulic characteristics, e.g. pozzuolanes
• CPC Class Codes: C04B 22/16 containing phosphorus in the anion, e.g. phosphates
• CPC Class Codes: C04B 28/00 Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
• CPC Class Codes: C04B 28/06 Aluminous cements monolithic refractories or refractory mortars C04B35/66
• CPC Class Codes: C04B 28/34 containing cold phosphate binders
• CPC Class Codes: C04B 28/344 the phosphate binder being present in the starting composition solely as one or more phosphates
• CPC Class Codes: C04B 7/32 Aluminous cements
• CPC Class Codes: C09K 8/46 containing inorganic binders, e.g. Portland cement

Abstract

Methods and compositions are provided that related to cementing operations. Methods and compositions that include pumice and/or perlite as a replacement for fly ash.

Claims

1. A well cement composition comprising:

calcium aluminate;

sodium polyphosphate in an amount of about 2% to about 20% by weight of the cement composition;

an additive comprising pumice, wherein the additive has a mean particle size of less than about 15 microns; and

water in an amount sufficient to form a pumpable slurry;

wherein the additive is present in an amount that will increase a compressive strength of the well cement composition by at least 20% compared to the well cement composition comprising a comparable amount of fly ash instead of the additive.

2. The composition of claim 1 wherein the calcium aluminate is present in an amount of about 15% to about 60% by weight of the well cement composition.

3. The composition of claim 1 wherein the sodium polyphosphate comprises a polyphosphate selected from the group consisting of sodium hexametaphosphate, sodium triphosphate, a vitreous sodium phosphate, and any combination thereof.

4. The composition of claim 1 wherein the sodium polyphosphate is present in an amount of about 5% to about 20% by weight of the well cement composition.

5. The composition of claim 1 further comprising calcium alumino silicate.

6. The composition of claim 5 wherein the pumice has a mean particle size of about 0.01 microns to about 20 microns.

7. The composition of claim 5 wherein the pumice is present in an amount of about 15% to about 60% by weight of the well cement composition.

8. The composition of claim 1 wherein the well cement composition further comprises a second additive selected from the group consisting of an expansive additive, a set retarder, a foaming agent, a foam stabilizer, a set accelerator, a surfactant, a fluid loss control additive, a weighting agent, a lightweight additive, a dispersant, an elastic particle, a gas-generating additive, a lost circulation material, a defoaming additive, an extending additive, and any combination thereof.

9. The method of claim 1 wherein the well cement composition is essentially free of fly ash.

10. The composition of claim 1 wherein the well cement composition has a thickening time from 3 hours to about 12 hours and 47 minutes.

11. A well cement composition comprising:

calcium aluminate in an amount of about 15% to about 60% by weight of the cement composition;

sodium polyphosphate in an amount of about 2% to about 20% by weight of the cement composition;

pumice in an amount of about 15% to about 60% by weight of the cement composition, wherein the pumice has a mean particle size of less than about 15 microns;

a cement set retarder; and

water in an amount sufficient to form a pumpable slurry;

wherein the pumice is present in an amount that will increase a compressive strength of the well cement composition by at least 20% compared to the well cement composition comprising a comparable amount of fly ash instead of the pumice.

12. The composition of claim 11 wherein the calcium aluminate is present in an amount of about 15% to about 45% by weight of the well cement composition, wherein the sodium polyphosphate is present in an amount of about 2% to about 10% by weight of the well cement composition, wherein the pumice is present in an amount of about 15% to about 45% by weight of the well cement composition, and wherein the cement composition is essentially free of fly ash.

13. The composition of claim 11 wherein the sodium polyphosphate comprises a polyphosphate selected from the group consisting of sodium hexametaphosphate, sodium triphosphate, a vitreous sodium phosphate, and any combination thereof.

14. The composition of claim 11 wherein the cement set retarder is present in an amount up to about 2% by weight of the well cement composition.

15. The composition of claim 11 wherein the well cement composition further comprises an additive selected from the group consisting of an expansive additive, a set retarder, a foaming agent, a foam stabilizer, a set accelerator, a surfactant, a fluid loss control additive, a weighting agent, a lightweight additive, a dispersant, an elastic particle, a gas-generating additive, a lost circulation material, a defoaming additive, an extending additive, and any combination thereof.

16. The composition of claim 11 wherein the well cement composition has a thickening time from 3 hours to about 12 hours and 47 minutes.