Sealant compositions comprising cement kiln dust and tire-rubber particles and method of use

• US 9,676,989 B2
• Filed: 09/06/2012
• Issued: 06/13/2017
• 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: Morgan, Rickey L., Brenneis, D. Chad, Roddy, Craig W., Morgan, Ronnie G.
• Primary Examiner(s): DiTrani, Angela M
• Application Number:
  US13/605,875
• Publication Number:
  US 20120325476A1
• Time in Patent Office: 1,741 Days
• Field of Search: None
• 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 14/106 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 16/08 porous, e.g. expanded polystyrene beads or microballoons
• 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 18/22 Rubber , e.g. ground waste tires
• 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 22/064 : 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 26/02 : Macromolecular compounds
• 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 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 7/02 : Portland cement
• CPC Class Codes: C09K 8/426 : for plugging
• CPC Class Codes: C09K 8/44 : containing organic binders only
• 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 are provided that relate to sealant compositions comprising cement kiln dust, tire-rubber particles, and water. An embodiment discloses a method comprising: providing a sealant composition comprising cement kiln dust, tire-rubber particles, and water; and allowing the sealant composition to set to form a hardened mass.

Claims

1. A method comprising:

providing a sealant composition comprising kiln dust, tire-rubber particles, and water;

determining locations in a wellbore annulus where a hardenable resin or latex is to be placed to provide increased ductility;

intermittently injecting about 2 gallons to about 20 barrels of the hardenable resin or latex into the sealant composition while the sealant composition is being introduced into the well-bore annulus such that the hardenable resin or latex is placed in the locations in the wellbore annulus; and

allowing the sealant composition to set in the well-bore annulus, wherein the set sealant composition forms a hardened mass in the well-bore annulus and the resin or latex forms spaced apart rings within the hardened mass in the locations.

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

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

4. The method of claim 1 wherein the kiln dust is present in the sealant composition in an amount of at least about 70% by weight of a total amount of cementitious components present in the sealant composition.

5. The method of claim 1 wherein the kiln dust is present in the sealant composition in an amount of at least about 90% by weight of a total amount of cementitious components present in the sealant composition.

6. The method of claim 1 wherein the sealant composition is Portland-free and comprises the kiln dust in an amount of about 100% by weight of a total amount of cementitious components present in the sealant composition.

7. The method of claim 6 wherein the kiln dust comprises cement kiln dust, and wherein the tire-rubber particles are present in the sealant composition in an amount in a range of from about 2% to about 15% by weight of a total amount of cementitious components present in the sealant composition.

8. The method of claim 1 wherein the tire-rubber particles are present in the sealant composition in an amount in a range of from about 0.1% to about 50% by weight of a total amount of cementitious components present in the sealant composition.

9. The method of claim 1 wherein the sealant composition comprises at least one additive selected from the group consisting of 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, a latex stabilizer, a suspending aid, and any combination thereof.

10. The method of claim 1 wherein the sealant composition comprises at least one additive selected from the group consisting of crystalline silica, amorphous silica, fumed silica, a salt, a fiber, a hydratable clay, hematite, microspheres, rice husk ash, elastomers, an elastomeric particle, and any combination thereof.

11. The method of claim 1 wherein the sealant composition is introduced into a subterranean formation.

12. The method of claim 11 wherein the sealant composition is used in a primary-cementing method.

13. The method of claim 11 wherein the sealant composition is used in a remedial-cementing method.

14. The method of claim 11 wherein the sealant composition is used in a reverse-cementing method.

15. The method of claim 11 wherein the sealant composition is allowed to harden and form a sheath in a well-bore annulus between a conduit in the subterranean formation and a well-bore wall or between the conduit and a larger conduit in the subterranean formation.

16. A method of cementing in a subterranean formation comprising:

preparing a dry blend comprising cement kiln dust and tire-rubber particles;

mixing the dry blend with water to form a sealant composition that is pumpable, wherein the cement kiln dust is present in the sealant composition in an amount of at least about 70% by weight of a total amount of cementitious components present in the sealant composition;

determining locations in a wellbore annulus where a hardenable resin or latex is to be placed to provide increased ductility;

introducing the sealant composition into a well-bore annulus;

intermittently injecting about 2 gallons to about 20 barrels of a hardenable resin or latex into the sealant composition while the sealant composition is being introduced into the well-bore annulus such that the hardenable resin or latex is placed in the locations in the wellbore annulus; and

allowing the sealant composition to set in the well-bore annulus, wherein the set sealant composition forms a hardened mass in the well-bore annulus and the resin or latex forms spaced apart rings within the hardened mass in the locations.

17. The method of claim 16 wherein the cement kiln dust is present in the sealant composition in an amount of at least about 90% by weight of a total amount of cementitious components present in the sealant composition.

18. The method of claim 16 wherein the sealant composition is Portland-free and comprises the cement kiln dust in an amount of about 100% by weight of a total amount of cementitious components present in the sealant composition.

19. The method of claim 18 wherein the tire-rubber particles are present in the sealant composition in an amount in a range of from about 2% to about 15% by weight of a total amount of cementitious components present in the sealant composition.

20. The method of claim 16 wherein the tire-rubber particles are present in the sealant composition in an amount in a range of from about 0.1% to about 50% by weight of a total amount of cementitious components present in the sealant composition.

21. The method of claim 16 wherein the well-bore annulus is between a conduit in the subterranean formation and a well-bore wall or between the conduit and a larger conduit in the subterranean formation.

22. The method of claim 16 wherein the hardenable resin is intermittently injected into the sealant composition.

23. The method of claim 16 wherein the latex is intermittently injected into the sealant composition.