Latex compositions comprising pozzolan and/or cement kiln dust and methods of use

• US 7,789,150 B2
• Filed: 10/30/2009
• Issued: 09/07/2010
• 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: Chatterji, Jiten, Roddy, Craig W., Morgan, Ronnie G., Brenneis, D. Chad, Hudgins, Callie R.
• Primary Examiner(s): SUCHFIELD, GEORGE A
• Application Number:
  US12/609,993
• Publication Number:
  US 20100041792A1
• Time in Patent Office: 312 Days
• Field of Search: None
• US Class Current: 166/293
• CPC Class Codes: C04B 14/047 Zeolites
• 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 14/18 Perlite
• 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 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 22/064 of the alkaline-earth metals
• CPC Class Codes: C04B 22/08 Acids or salts thereof C04B22/0013 takes precedence
• CPC Class Codes: C04B 24/163 : obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 : Portland cements
• CPC Class Codes: C04B 28/184 : based on an oxide other than lime
• 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 8/428 : for squeeze cementing, e.g. for repairing
• CPC Class Codes: C09K 8/473 : Density reducing additives, e.g. for obtaining foamed cement compositions
• CPC Class Codes: C09K 8/487 : Fluid loss control additives; Additives for reducing or preventing circulation loss
• CPC Class Codes: C09K 8/493 : Additives for reducing or preventing gas migration
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

The present invention includes methods and compositions that include a latex, and at least one of a natural pozzolan or cement kiln dust. An embodiment includes a method comprising: placing a latex composition in a subterranean formation, wherein the latex composition comprises: latex, a component selected from the group consisting of a natural pozzolan, cement kiln dust, and a combination thereof, and water; and allowing the latex composition to set. Another embodiment of the present invention includes a latex composition comprising: latex, a component selected from the group consisting of a natural pozzolan, cement kiln dust, and a combination thereof.

Claims

1. A method comprising:

placing a latex composition in a subterranean formation, wherein the latex composition comprises;

latex comprising an AMPS-styrene-butadiene rubber,

a component selected from the group consisting of a natural pozzolan, cement kiln dust, and a combination thereof, and

water; and

allowing the latex composition to set.

2. The method of claim 1 wherein the latex further comprises a rubber selected from the group consisting of an ethylene-propylene rubber, a styrene-butadiene rubber, a nitrile rubber, a nitrile butadiene rubber, a butyl rubber, a neoprene rubber, a polybutadiene rubber, an acrylonitrile-styrene-butadiene rubber, a polyisoprene rubber, and any combination thereof.

3. The method of claim 1 wherein the latex composition comprises the natural pozzolan, and wherein the natural pozzolan comprises pumicite.

4. The method of claim 1 wherein the latex composition comprises the cement kiln dust in an amount of about 1% to about 99% by weight of cementitious components in the latex composition.

5. The method of claim 1 wherein the latex composition further comprises an additive selected from the group consisting of fly ash, slag cement, metakaolin, shale, zeolite, a gas, crystalline silica, amorphous silica, fumed silica, a salt, a fiber, a hydratable clay, a microsphere, rice husk ash, lime, and any combination thereof.

6. The method of claim 1 wherein the latex composition further comprises an additive selected from the group consisting of a latex stabilizer, a strength-retrogression additive, a set accelerator, a set retarder, 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.

7. The method of claim 1 wherein the latex composition is foamed.

8. The method of claim 1 wherein allowing the latex composition to set comprises allowing the latex composition to set in an annulus between the subterranean formation and a conduit disposed in the subterranean formation.

9. The method of claim 1 wherein the cement kiln dust is present in the amount of about 1% to about 24% by weight of cementitious components in the latex composition.

10. The method of claim 1 wherein the cement kiln dust is present in the amount of about 61% to about 99% by weight of cementitious components in the latex composition.

11. A method comprising:

placing a latex composition in a subterranean formation, wherein the latex composition comprises;

latex comprising an AMPS-styrene-butadiene rubber,

a hydraulic cement,

a component selected from the group consisting of a natural pozzolan, cement kiln dust, and a combination thereof, and

water; and

allowing the latex composition to set.

12. The method of claim 11 wherein the hydraulic cement comprises Portland cement.

13. The method of claim 11 wherein the latex composition comprises the natural pozzolan, and wherein the natural pozzolan comprises pumicite.

14. The method of claim 11 wherein the latex composition comprises the cement kiln dust in an amount of about 1% to about 99% by weight of cementitious components in the latex composition.

15. The method of claim 11 wherein the latex composition further comprises an additive selected from the group consisting of fly ash, slag cement, metakaolin, shale, zeolite, a gas, crystalline silica, amorphous silica, fumed silica, a salt, a fiber, a hydratable clay, a microsphere, rice husk ash, and any combination thereof.

16. The method of claim 11 wherein the latex composition further comprises an additive selected from the group consisting of a latex stabilizer, a strength-retrogression additive, a set accelerator, a set retarder, 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.

17. The method of claim 11 wherein the latex composition is foamed.

18. The method of claim 11 wherein allowing the latex composition to set comprises allowing the latex composition to set in an annulus between the subterranean formation and a conduit disposed in the subterranean formation.

19. The method of claim 11 wherein the cement kiln dust is present in the amount of about 1% to about 24% by weight of cementitious components in the latex composition.

20. The method of claim 11 wherein the cement kiln dust is present in the amount of about 61% to about 99% by weight of cementitious components in the latex composition.

21. A method comprising:

placing a latex composition in a subterranean formation, wherein the latex composition comprises;

latex,

a component comprising a combination of a natural pozzolan and cement kiln dust, wherein the natural pozzolan comprises pumicite, and

water; and

allowing the latex composition to set.

22. The method of claim 21 wherein the latex comprises a rubber selected from the group consisting of an ethylene-propylene rubber, a styrene-butadiene rubber, a nitrile rubber, a nitrile butadiene rubber, a butyl rubber, a neoprene rubber, a polybutadiene rubber, an acrylonitrile-styrene-butadiene rubber, a polyisoprene rubber, an AMPS-styrene-butadiene rubber, and any combination thereof.

23. The method of claim 21 wherein the latex comprises an AMPS-styrene-butadiene rubber.

24. The method of claim 21 wherein the cement kiln dust is present in an amount of about 1% to less than 25% by weight of cementitious components in the latex composition.

25. The method of claim 21 wherein the cement kiln dust is present in an amount of greater than 60% to about 99% by weight of cementitious components in the latex composition.

26. The method of claim 21 wherein the latex composition further comprises an additive selected from the group consisting of fly ash, slag cement, metakaolin, shale, zeolite, a gas, crystalline silica, amorphous silica, fumed silica, a salt, a fiber, a hydratable clay, a microsphere, rice husk ash, lime, and any combination thereof.

27. The method of claim 21 wherein the latex composition further comprises an additive selected from the group consisting of a latex stabilizer, a strength-retrogression additive, a set accelerator, a set retarder, 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.

28. The method of claim 21 wherein the latex composition is foamed.

29. The method of claim 21 wherein allowing the latex composition to set comprises allowing the latex composition to set in an annulus between the subterranean formation and a conduit disposed in the subterranean formation.

30. The method of claim 21 wherein the latex composition further comprises, hydraulic cement.

31. The method of claim 30 wherein the hydraulic cement comprises a Portland cement present in an amount of about 50% to about 90% by weight of cementitious components in the latex composition, wherein the pumicite is present in an amount of about 10% to about 30% by weight of cementitious components present in the latex composition, and wherein the cement kiln dust is present in an amount of about 10% to about 30% by weight of cementitious compositions present in the latex composition.

32. The method of claim 21 wherein the latex composition further comprises a hydraulic cement selected from the group consisting of Portland cement, pozzolana cement, gypsum cement, high alumina content cement, slag cement, silica cement, and any combination thereof.

33. A method comprising:

placing a latex composition in a subterranean formation, wherein the latex composition comprises;

latex,

a cementitious component comprising;

hydraulic cement in an amount of at least about 75% by weight of the cementitious component, and

cement kiln dust in an amount of about 1% to about 24% by weight of the cementitious component, and

water; and

allowing the latex composition to set.

34. The method of claim 33 wherein the latex comprises a rubber selected from the group consisting of an ethylene-propylene rubber, a styrene-butadiene rubber, a nitrile rubber, a nitrile butadiene rubber, a butyl rubber, a neoprene rubber, a polybutadiene rubber, an acrylonitrile-styrene-butadiene rubber, a polyisoprene rubber, an AMPS-styrene-butadiene rubber, and any combination thereof.

35. The method of claim 33 wherein the latex comprises an AMPS-styrene-butadiene rubber.

36. The method of claim 33 wherein the cement kiln dust is present in the amount of about 1% to about 10% by weight of the cementitious component.

37. The method of claim 33 wherein the latex composition further comprises an additive selected from the group consisting of a latex stabilizer, a strength-retrogression additive, a set accelerator, a set retarder, 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.

38. The method of claim 33 wherein the latex composition is foamed.

39. The method of claim 33 wherein allowing the latex composition to set comprises allowing the latex composition to set in an annulus between the subterranean formation and a conduit disposed in the subterranean formation.

40. The method of claim 33 wherein the hydraulic cement comprises a cement selected from the group consisting of Portland cement, pozzolana cement, gypsum cement, high alumina content cement, slag cement, silica cement, and any combination thereof.

41. A method comprising:

placing a latex composition in a subterranean formation, wherein the latex composition comprises;

latex,

a cementitious component comprising;

hydraulic cement in an amount of at least about 80% by weight of the cementitious component, and

cement kiln dust in an amount of about 1% to about 20% by weight of the cementitious component, and

water; and

allowing the latex composition to set.

42. The method of claim 41 wherein the latex comprises a rubber selected from the group consisting of an ethylene-propylene rubber, a styrene-butadiene rubber, a nitrile rubber, a nitrile butadiene rubber, a butyl rubber, a neoprene rubber, a polybutadiene rubber, an acrylonitrile-styrene-butadiene rubber, a polyisoprene rubber, an AMPS-styrene-butadiene rubber, and any combination thereof.

43. The method of claim 41 wherein the latex comprises an AMPS-styrene-butadiene rubber.

44. The method of claim 41 wherein the latex composition further comprises an additive selected from the group consisting of a latex stabilizer, a strength-retrogression additive, a set accelerator, a set retarder, 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.

45. The method of claim 41 wherein the latex composition further comprises an additive selected from the group consisting of metakaolin, shale, zeolite, a gas, crystalline silica, amorphous silica, fumed silica, a salt, a fiber, a hydratable clay, a microsphere, rice husk ash, and any combination thereof.

46. The method of claim 41 wherein the latex composition is foamed.

47. The method of claim 41 wherein allowing the latex composition to set comprises allowing the latex composition to set in an annulus between the subterranean formation and a conduit disposed in the subterranean formation.

48. A method comprising:

placing a latex composition in a subterranean formation, wherein the latex composition comprises;

latex,

a cementitious component comprising;

hydraulic cement in an amount of at least about 75% by weight of the cementitious component, and

a component selected from the group consisting of a natural pozzolan, cement kiln dust, and a combination thereof, wherein the component is present in an amount of about 1% to about 24% by weight of the cementitious component, and

water; and

allowing the latex composition to set.

49. The method of claim 48 wherein the latex comprises a rubber selected from the group consisting of an ethylene-propylene rubber, a styrene-butadiene rubber, a nitrile rubber, a nitrile butadiene rubber, a butyl rubber, a neoprene rubber, a polybutadiene rubber, an acrylonitrile-styrene-butadiene rubber, a polyisoprene rubber, an AMPS-styrene-butadiene rubber, and any combination thereof.

50. The method of claim 48 wherein the latex comprises an AMPS-styrene-butadiene rubber.

51. The method of claim 48 wherein the latex composition further comprises an additive selected from the group consisting of a latex stabilizer, a strength-retrogression additive, a set accelerator, a set retarder, 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.

52. The method of claim 48 wherein the latex composition further comprises an additive selected from the group consisting of metakaolin, shale, zeolite, a gas, crystalline silica, amorphous silica, fumed silica, a salt, a fiber, a hydratable clay, a microsphere, rice husk ash, and any combination thereof.

53. The method of claim 48 wherein the latex composition is foamed.

54. The method of claim 48 wherein the component comprises the natural pozzolan, the natural pozzolan comprising a pozzolan selected from the group consisting of pumicite, diatomaceous earth, volcanic ash, opaline shale, tuff, and any combination thereof.

55. The method of claim 48 wherein the component comprises the natural pozzolan, the natural pozzolan comprising pumicite.

56. The method of claim 48 wherein allowing the latex composition to set comprises allowing the latex composition to set in an annulus between the subterranean formation and a conduit disposed in the subterranean formation.