Geopolymer cement compositions and methods of use

• US 9,840,653 B2
• Filed: 04/28/2016
• Issued: 12/12/2017
• Est. Priority Date: 08/16/2012
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Chatterji, Jiten, Brenneis, D. Chad, Keys, Crystal L.
• Primary Examiner(s): Green, Anthony J
• Application Number:
  US15/141,634
• Publication Number:
  US 20160244656A1
• Time in Patent Office: 593 Days
• CPC Class Codes: C04B 14/047 Zeolites
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/08 Diatomaceous earth
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/108 Shale, slate colliery shale C04B18/125
• CPC Class Codes: C04B 14/14 Minerals of vulcanic origin granite C04B14/048
• CPC Class Codes: C04B 14/18 Perlite
• 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 20/0024 expanded in situ, i.e. the material is expanded or made hollow after primary shaping of the mortar, concrete or artificial stone mixture C04B16/085 takes precedence
• CPC Class Codes: C04B 20/0048 Fibrous materials
• 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 2103/44 Thickening, gelling or viscosity increasing agents
• 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 22/00 Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators , shrinkage compensating agents
• CPC Class Codes: C04B 28/006 : containing mineral polymers, e.g. geopolymers of the Davidovits type
• 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: C09K 8/46 : containing inorganic binders, e.g. Portland cement
• CPC Class Codes: C09K 8/487 : Fluid loss control additives; Additives for reducing or preventing circulation loss
• CPC Class Codes: E21B 33/13 : Methods or devices for cementing, for plugging holes, crevices or the like
• CPC Class Codes: Y02P 40/10 : Production of cement, e.g. improving or optimising the production methods; Cement grinding
• 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 cementing operations. Methods and compositions that include pumice in geopolymer cement compositions comprising slag.

Claims

1. A geopolymer cement composition comprising:

a cementitious component consisting essentially of slag and pumice, wherein the slag is present in an amount in a range from about 40% to about 100% by weight of the cementitious component, wherein the pumice is present in an amount in a range from about 0.1% to about 60% by weight of the cementitious component;

a hydroxyl source; and

water;

wherein the geopolymer cement composition has a density in the range from about 14 lb/gal to about 20 lb/gal; and

wherein the geopolymer cement composition has a thickening time of greater than 2 hours at about 3,000 psi and temperatures in a range from about 50°

F. to about 400°

F.

2. The composition of claim 1, wherein the hydroxyl source is present in an amount in a range of from about 0.1% to about 25% by weight of the cementitious component.

3. A geopolymer cement composition comprising:

a cementitious component consisting essentially of slag and pumice, wherein the slag is present in an amount in a range from about 40% to about 100% by weight of the cementitious component, wherein the pumice is present in an amount in a range from about 0.1% to about 60% by weight of the cementitious component;

hydrated lime;

an additive selected from the group consisting of crystalline silica, amorphous silica, fumed silica, a fiber, a hydratable clay, calcined shale, vitrified shale, a microsphere, diatomaceous earth, metakaolin, ground perlite, rice husk ash, zeolite, a resin, a dispersant, a defoaming agent, a set retarder, a weighting agent, a lightweight additive, a gas-generating additive, a lost-circulation material, a filtration-control additive, a fluid-loss-control additive, a foaming additive, a thixotropic additive, and any combination thereof; and

water;

wherein the geopolymer cement composition has a density in the range from about 14 lb/gal to about 20 lb/gal; and

wherein the geopolymer cement composition has a thickening time of greater than 2 hours at about 3,000 psi and temperatures in a range from about 50°

F. to about 400°

F.

4. The composition of claim 3, wherein the geopolymer cement composition does not comprise a set accelerator.

5. The composition of claim 3, wherein the hydrated lime is present in an amount in a range of from about 0.1% to about 25% by weight of the cementitious component.

6. A geopolymer cement composition comprising:

a cementitious component comprising slag and pumice, wherein the slag is present in an amount in a range from about 40% to about 100% by weight of the cementitious component, wherein the pumice is present in an amount in a range from about 0.1% to about 60% by weight of the cementitious component;

water;

hydrated lime; and

an additive selected from the group consisting of crystalline silica, amorphous silica, fumed silica, a fiber, a hydratable clay, calcined shale, vitrified shale, a microsphere, diatomaceous earth, metakaolin, ground perlite, rice husk ash, zeolite, a resin, a dispersant, a defoaming agent, a set retarder, a weighting agent, a lightweight additive, a gas-generating additive, a lost-circulation material, a filtration-control additive, a fluid-loss-control additive, a foaming additive, a thixotropic additive, and any combination thereof;

wherein the geopolymer cement composition has a density in the range from about 14 lb/gal to about 20 lb/gal; and

wherein the geopolymer cement composition has a thickening time of greater than 2 hours at about 3,000 psi and temperatures in a range from about 50°

F. to about 400°

F.

7. The composition of claim 6, wherein the hydrated lime is present in an amount in a range of from about 0.1% to about 25% by weight of the cementitious component.

8. The composition of claim 6, wherein the geopolymer cement composition is free of any additional cementitious materials.

9. A geopolymer cement composition comprising:

a cementitious component consisting of slag in an amount in a range of from about 40% to about 60% by weight of the cementitious component and pumice in an amount in a range of from about 40% to about 60% by weight of the cementitious component, wherein the geopolymer cement composition is free of any additional cementitious component;

hydrated lime in an amount in a range of from about 0.1% to about 20% by weight of the cementitious component;

an additive selected from the group consisting of crystalline silica, amorphous silica, fumed silica, a fiber, a hydratable clay, calcined shale, vitrified shale, a microsphere, diatomaceous earth, metakaolin, ground perlite, rice husk ash, zeolite, a resin, a dispersant, a defoaming agent, a set retarder, a weighting agent, a lightweight additive, a gas-generating additive, a lost-circulation material, a filtration-control additive, a fluid-loss-control additive, a foaming additive, a thixotropic additive, and any combination thereof; and

water;

wherein the geopolymer cement composition has a density in the range from about 14 lb/gal to about 20 lb/gal; and

wherein the geopolymer cement composition has a thickening time of greater than 2 hours at about 3,000 psi and temperatures in a range from about 50°

F. to about 400°

F.

10. The composition of claim 9, wherein the geopolymer cement composition is free of any additional cementitious materials.

11. The composition of claim 9, wherein the geopolymer cement composition does not comprise a set accelerator.