Methods and Compositions Comprising Cement Kiln Dust Having an Altered Particle Size

• US 20130008352A1
• Filed: 09/14/2012
• Published: 01/10/2013
• 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: Roddy, Craig W., Chatterji, Jiten, Brenneis, Chad, Jarratt, Callie R.
• Granted Patent: US 8,895,486 B2
• Time in Patent Office: Days
• US Class Current: 106/706
• CPC Class Codes: C04B 18/162 Cement kiln dust; Lime kiln dust
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C09K 8/032 Inorganic additives
• CPC Class Codes: C09K 8/467 containing additives for specific purposes
• CPC Class Codes: E21B 33/13 Methods or devices for cementing, for plugging holes, crevices or the like
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]

Abstract

Methods and compositions are disclosed that comprise cement kiln dust having a mean particle size that has been altered. An embodiment discloses a method of preparing cement kiln dust comprising: providing cement kiln dust having an original particle size; and altering the mean particle size of the cement kiln dust from the original size by grinding, separating, or a combination thereof. Another embodiment discloses a well treatment fluid comprising: cement kiln dust having a mean particle size that has been altered from its original size by grinding, separating, or a combination thereof; and water.

Claims

1. A method of preparing cement kiln dust comprising:

providing cement kiln dust having an original particle size; and

altering the mean particle size of the cement kiln dust from the original size by grinding, separating, or a combination thereof.

2. The method of claim 1 wherein the mean particle size of the cement kiln dust is altered to at least 5% greater than its original size.

3. The method of claim 1 wherein the mean particle size of the cement kiln dust is altered to at least 5% less than its original size.

4. The method of claim 1 wherein the mean particle size of the cement kiln dust is altered to a range of from about 1 micron to about 350 microns.

5. The method of claim 1 wherein the altering the mean particle size comprises grinding the cement kiln dust.

6. The method of claim 1 wherein the altering the mean particle size comprises intergrinding the cement kiln dust with one or more additives to a mean particle size in a range of from about 1 micron to about 350 microns.

7. The method of claim 6 wherein the one or more additives comprise at least one additive selected from the group consisting of hydraulic cement, fly ash, slag, shale, zeolite, metakaolin, pumice, perlite, lime, silica, rice-hull ash, micro-fine cement, lime kiln dust, and any combination thereof.

8. The method of claim 7 wherein the cement kiln dust is present in an amount of at least about 30% by weight of a total amount of cement kiln dust and the one or more additives.

9. The method of claim 1 further comprising using the cement kiln dust in a settable composition comprising an additive selected from the group consisting of hydraulic cement, fly ash, slag, shale, zeolite, metakaolin, pumice, perlite, lime, silica, rice-hull ash, micro-fine cement, lime kiln dust, and any combination thereof.

10. The method of claim 1 further comprising using the cement kiln dust in a settable composition comprising 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. A method of preparing a partially calcined kiln feed removed from a gas stream comprising:

providing the partially calcined kiln feed removed from a gas stream, wherein the partially calcined kiln feed has an original mean particle size and comprises SiO2, Al2O3, Fe2O3, CaO, MgO, SO3, Na2O, and K2O; and

altering the original mean particle size of the partially calcined kiln feed by grinding, separating, or a combination thereof.

12. The method of claim 11 wherein the mean particle size of the partially calcined kiln feed is altered to at least 5% greater than its original size.

13. The method of claim 11 wherein the mean particle size of the partially calcined kiln feed is altered to at least 5% less than its original size.

14. The method of claim 11 wherein the mean particle size of the partially calcined kiln feed is altered to a range of from about 1 micron to about 350 microns.

15. The method of claim 11 wherein the altering the mean particle size comprises grinding the partially calcined kiln feed.

16. The method of claim 11 wherein the altering the mean particle size comprises intergrinding the partially calcined kiln feed with one or more additives to a mean particle size in a range of from about 1 micron to about 350 microns.

17. The method of claim 16 wherein the one or more additives comprise at least one additive selected from the group consisting of hydraulic cement, fly ash, slag, shale, zeolite, metakaolin, pumice, perlite, lime, silica, rice-hull ash, micro-fine cement, and any combination thereof.

18. The method of claim 17 wherein the partially calcined kiln feed is present in an amount of at least about 30% by weight of a total amount of partially calcined kiln feed and the one or more additives.

19. The method of claim 11 further comprising using the partially calcined kiln feed in a settable composition comprising an additive selected from the group consisting of hydraulic cement, fly ash, slag, shale, zeolite, metakaolin, pumice, perlite, lime, silica, rice-hull ash, micro-fine cement, and any combination thereof.

20. The method of claim 11 further comprising using the partially calcined kiln feed in a settable composition comprising 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.

21. A method of preparing a partially calcined kiln feed removed from a gas stream comprising:

providing the partially calcined kiln feed removed from a gas stream, wherein the partially calcined kiln feed has an original mean particle size and comprises SiO2, Al2O3, Fe2O3, CaO, MgO, SO3, Na2O, and K2O; and

reducing the original mean particle size of the partially calcined kiln feed by at least about 5%.

22. The method of claim 21 wherein the reduced mean particle size of the partially calcined kiln feed is in a range of from about 1 micron to about 350 microns.

23. The method of claim 21 wherein the partially calcined kiln feed is from the manufacture of cement.

24. The method of claim 21 further comprising using the partially calcined kiln feed in a settable composition comprising an additive selected from the group consisting of hydraulic cement, fly ash, slag, shale, zeolite, metakaolin, pumice, perlite, lime, silica, rice-hull ash, micro-fine cement, and any combination thereof.

25. The method of claim 21 further comprising using the partially calcined kiln feed in a settable composition comprising 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.