Gelation inhibiting retarders for highly reactive calcium silicate based binder compositions and methods of making and using same

• US 7,748,454 B2
• Filed: 04/28/2008
• Issued: 07/06/2010
• Est. Priority Date: 04/28/2008
• Status: Expired due to Fees

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Fitzgerald, Russell M., Reddy, B. Raghava, Waugh, Bryan K.
• Primary Examiner(s): Bates; Zakiya W.
• Application Number:
  US12/110,885
• Publication Number:
  US 20090266543A1
• Time in Patent Office: 799 Days
• Field of Search: None
• US Class Current: 166/293
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/162 Cement kiln dust; Lime kiln dust
• CPC Class Codes: C04B 2103/20 Retarders
• CPC Class Codes: C04B 24/163 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 28/06 Aluminous cements monolithic refractories or refractory mortars C04B35/66
• CPC Class Codes: C04B 7/02 Portland cement
• CPC Class Codes: C09K 8/467 containing additives for specific purposes
• CPC Class Codes: C09K 8/5045 containing inorganic compounds
• CPC Class Codes: C09K 8/5083 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A method of servicing a wellbore comprising placing in the wellbore a composition comprising a non-API compliant reactive calcium silicate based hydraulic binder and at least one gelation inhibiting retarder, and allowing the composition to set. A method of servicing a wellbore comprising placing in a wellbore a cement composition comprising an industrial waste product selected from the group consisting of Class C Fly ash, cement kiln dust, and combinations thereof and a gelation inhibitor, and allowing the composition to set. A method of controlling the thickening time of a cementitious composition comprising contacting a material having greater than 15 wt. % of tricalcium aluminate and tetracalcium aluminoferrite with a gelation inhibitor comprising a alkylbenzene sulfonic acid, at least one methallyl sulfonic acid monomer; at least one copolymerizable nonionic monomer, and at least one copolymerizable olefinically unsaturated carboxylic acid monomer.

Claims

1. A method of servicing a wellbore comprising:

placing in the wellbore a composition comprising a non-API compliant reactive calcium silicate based hydraulic binder, wherein the non-API compliant reactive calcium silicate based hydraulic binder, when mixed with water alone, has a thickening time of less than 90 minutes, at least one gelation inhibiting retarder, and a set modifier; and

allowing the composition to set.

2. The method of claim 1 wherein the reactive calcium silicate based hydraulic binder comprises tricalcium aluminate, tetracalcium aluminoferrite, or combinations thereof.

3. The method of claim 2 wherein the total amount of tricalcium aluminate and tetracalcium aluminoferrite is greater than about 15 wt. % of the highly reactive binder.

4. The method of claim 2 wherein the ratio of tricalcium aluminate:

tetracalcium aluminoferrite is from about 5;

1 to about 0.5;

1.

5. The method of claim 1 wherein the reactive calcium silicate based hydraulic binder comprises non-API Class C flyash, cement kiln dust, blast furnace slag, or combinations thereof.

6. The method of claim 5 wherein the class C fly ash has a lime content of greater than about 15 wt. %.

7. The method of claim 5 wherein the cement kiln dust has an analytical lime content of from about 15 wt. % to about 60 wt. %.

8. The method of claim 5 wherein the blast furnace slag has a silica content of from about 25 wt. % to about 45 wt. %, an alumina content of from about 7 wt. % to about 20 wt. %, a magnesia content of from about 1 wt. % to about 20 wt. % , and an analytical lime content of from about 30 wt. % to about 50 wt. %.

9. The method of claim 1 wherein the reactive calcium silicate based hydraulic binder is present in the wellbore servicing composition in an amount of from about 30 wt. % to about 100 wt. % based on the total solid weight of the composition.

10. The method of claim 1 wherein the gelation inhibiting retarder is present in the wellbore servicing composition in an amount of from about 0.05 wt. % to about 4.0 wt. % based on the total solid weight of the composition.

11. The method of claim 1 wherein the gelation inhibiting retarder comprises a copolymer having a molecular weight of from about 1,000 Daltons to about 50,000 Daltons.

12. The method of claim 11 wherein the copolymer comprises least one sulfonated monomer, at least one carboxylated monomer, and at least one nonionic monomer.

13. The method of claim 11 wherein the copolymer comprises at least two sulfonated monomers, at least one carboxylated monomer, and at least one nonionic monomer.

14. The method of claim 11 wherein the copolymer comprises at least one allyloxybenzenesulfonic acid monomer having the general chemical structure (I),

15. The method of claim 14 wherein the methallyl sulfonic acid monomer comprises methallyl sulfonic acid, alkali metal salts of methallyl sulfonic acid, alkaline earth metal salts of methallyl sulfonic acid, ammonium salts of methallyl sulfonic acid, or combinations thereof.

16. The method of claim 14 wherein the copolymerizable nonionic monomer comprises monomers represented by the general chemical structure:

17. The method of claim 14 wherein the copolymerizable nonionic monomer comprises C₁-C₆ alkyl esters of (meth)acrylic acid, the alkali or alkaline earth metal or ammonium salts thereof, acrylamide, C₁-C₆ alkyl-substituted acrylamides, N-alkyl-substituted acrylamides, N-alkanol-substituted acyrylamides, C₁-C₆ alkyl esters of unsaturated vinylic acids, C₁-C₆ alkyl half-esters of unsaturated vinylic acids, C₁-C₆ alkyl esters of saturated aliphatic monocarboxylic acids, or combinations thereof.

18. The method of claim 14 wherein the copolymerizable olefinically unsaturated carboxylic acid monomer comprises aliphatic, branched or cyclic, mono- or dicarboxylic acids, alkali metal salts thereof;

alkaline earth metal salts thereof;

ammonium salts thereof;

anhydrides thereof;

or combinations thereof.

19. The method of claim 1 wherein the wellbore servicing composition further comprises non-API compliant Portland cement, API compliant Portland cement, or combinations thereof.

20. The method of claim 19 wherein the non-API compliant Portland cement is present in an amount of from about 20 wt. % to about 100 wt. % of the total weight of solids in the composition.

21. The method of claim 19 wherein the API compliant Portland cement is present in an amount of from about 0 wt. % to about 99 wt. % of the total weight of solids in the composition.

22. The method of claim 1 wherein the wellbore servicing composition further comprises a filler.

23. The method of claim 22 wherein the filler comprises class F fly ash, sand, silica, or combinations thereof.

24. The method of claim 22 wherein the filler comprises class F fly ash which is present in an amount of from about 5 wt. % to about 60 wt. % of the total solid weight of the composition.

25. The method of claim 1 wherein the wellbore servicing composition has a thickening time of greater than about 1 hour.

26. The method of claim 1 wherein the wellbore servicing composition has a hydration time of from 0.5 hours to 48 hours.

27. The method of claim 1 wherein the set modifier comprises organic acids, citric acid, tartaric acid, lignosulfonates, or combinations thereof.

28. A method of servicing a wellbore comprising:

placing in a wellbore a cement composition comprising a cementitious material consisting essentially of an industrial waste product selected from the group consisting of Class C Hy ash, cement kiln dust, and combinations thereof, wherein the cementitious material, when mixed with water alone, has a thickening time of less than 90 minutes and a gelation inhibitor; and

allowing the composition to set.

29. A method of servicing a wellbore comprising:

controlling the thickening time of a cementitious composition by contacting a material having from about 20% to about 40% of tricalcium aluminate and tetracalcium aluminoferrite with a gelation inhibitor comprising an alkylbenzene sulfonic acid, at least one methallyl sulfonic acid monomer, at least one copolymerizable nonionic monomer, and at least one copolymerizable olefinically unsaturated carboxylic acid monomer;

placing the composition in the wellbore; and

allowing the composition to set.

30. The method of claim 29 wherein the material is a non-API compliant Portland cement.