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

• US 9,550,934 B2
• Filed: 11/21/2011
• Issued: 01/24/2017
• 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 Dwane, Brenneis, Chad, Brothers, Lance E.
• Primary Examiner(s): Hutton, Jr., Doug
• Assistant Examiner(s): VARMA, ASHISH K
• Application Number:
  US13/301,747
• Publication Number:
  US 20130126166A1
• Time in Patent Office: 1,891 Days
• Field of Search: 166/292
• 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 method of cementing comprising:

introducing a calcium phosphate cement composition into a subterranean formation, wherein the calcium phosphate cement composition is free of cement kiln dust, wherein the calcium phosphate cement composition is unfoamed, and wherein the calcium phosphate cement composition comprises;

calcium aluminate;

wherein the calcium aluminate is present in an amount of greater than 20% to about 60% by weight of the calcium phosphate cement composition;

sodium polyphosphate;

an additive selected from the group consisting of pumice, perlite, and any combination thereof, wherein the additive has a mean particle size of less than about 20 microns; and

water; and

allowing the calcium phosphate cement composition to set, wherein the calcium phosphate cement composition increases a compressive strength by at least 20% compared to a composition comprising a comparable amount of fly ash instead of pumice.

2. The method 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.

3. The method of claim 1 wherein the sodium polyphosphate is present in an amount of about 0.5% to about 20% by weight of the calcium phosphate cement composition.

4. The method of claim 1 wherein the additive comprises the pumice.

5. The method of claim 4 wherein the pumice has a mean particle size of about 0.01 microns to about 2,000 microns.

6. The method of claim 4 wherein the pumice has a mean particle size of less than about 15 microns.

7. The method of claim 4 wherein the pumice is present in an amount of about 15% to about 60% by weight of the calcium phosphate cement composition.

8. The method of claim 1 wherein the additive comprises the perlite.

9. The method of claim 1 wherein calcium phosphate cement composition further comprises an additive selected from the group consisting of an expansive additive, a set retarder, a set accelerator, a surfactant, a fluid loss control additive, a weighting agent, a lightweight additive, a dispersant, an elastic particle, a lost circulation material, a defoaming additive, an extending additive, and any combination thereof.

10. The method of claim 1 wherein the introducing a calcium phosphate cement composition into the subterranean formation comprises introducing the calcium phosphate cement composition into a space between a well bore wall and a conduit.

11. The method of claim 1 wherein the calcium phosphate cement composition is free of fly ash.

12. A method of cementing comprising:

introducing an unfoamed calcium phosphate cement composition into a space between a well bore wall and a conduit, wherein the calcium phosphate cement composition comprises;

calcium aluminate in an amount of greater than 20% to about 60% by weight of the calcium phosphate cement composition;

sodium polyphosphate in an amount of about 5% to about 20% by weight of the calcium phosphate cement composition;

pumice in an amount of about 15% to about 60% by weight of the calcium phosphate cement composition, wherein the pumice has a mean particle size equal to or less than about 20 microns, and wherein the calcium phosphate cement composition is free of cement kiln dust;

a cement set retarder; and

water in an amount sufficient to form a pumpable slurry; and

allowing the calcium phosphate cement composition to set, wherein the calcium phosphate cement composition increases a compressive strength by at least 20% compared to a composition comprising a comparable amount of fly ash instead of pumice.

13. The method of claim 12 wherein the calcium phosphate cement composition is characterized by a seven-day compressive strength at 140°

F. that is at least about 30% higher than the same calcium phosphate cement composition comprising fly ash instead of the pumice.

14. The method of claim 12 wherein the calcium aluminate is present in an amount of greater than 20% to about 45% by weight of the calcium phosphate cement composition, wherein the sodium polyphosphate is present in an amount of about 1% to about 10% by weight of the calcium phosphate cement composition, wherein the pumice is present in an amount of about 15% to about 45% by weight of the calcium phosphate cement composition, and wherein the calcium phosphate cement composition is free of fly ash.

15. The method of claim 12 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.

16. The method of claim 12 wherein the pumice has a mean particle size of less than about 15 microns.

17. The method of claim 12 wherein the calcium phosphate cement composition further comprises perlite.

18. The method of claim 12 wherein calcium phosphate cement composition further comprises an additive selected from the group consisting of an expansive additive, a set retarder, a set accelerator, a surfactant, a fluid loss control additive, a weighting agent, a lightweight additive, a dispersant, an elastic particle, a lost circulation material, a defoaming additive, an extending additive, and any combination thereof.