CA2555348A1 - Cement compositions with improved corrosion resistance and methods of cementing in subterranean formations - Google Patents

Cement compositions with improved corrosion resistance and methods of cementing in subterranean formations Download PDF

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Publication number
CA2555348A1
CA2555348A1 CA 2555348 CA2555348A CA2555348A1 CA 2555348 A1 CA2555348 A1 CA 2555348A1 CA 2555348 CA2555348 CA 2555348 CA 2555348 A CA2555348 A CA 2555348A CA 2555348 A1 CA2555348 A1 CA 2555348A1
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Prior art keywords
cement
cement composition
present
weight
range
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CA 2555348
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French (fr)
Inventor
Lance E. Brothers
Anthony V. Palmer
William J. Caveny
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Halliburton Energy Services Inc
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Halliburton Energy Services, Inc.
Lance E. Brothers
Anthony V. Palmer
William J. Caveny
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Publication of CA2555348A1 publication Critical patent/CA2555348A1/en
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/42—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
    • C09K8/46—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement
    • C09K8/467—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement containing additives for specific purposes
    • C09K8/473—Density reducing additives, e.g. for obtaining foamed cement compositions
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
    • C04B14/10—Clay
    • C04B14/108—Shale, slate
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/06—Aluminous cements
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/42—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
    • C09K8/46—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/60—Agents for protection against chemical, physical or biological attack
    • C04B2103/61—Corrosion inhibitors
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Abstract

The present invention relates to subterranean well cementing operations, and more particularly, to cement compositions having improved corrosion resistance and methods of using such compositions in subterranean formations. The cement compositions generally include an unhydrated cement that includes a high alumina cement, a silica source, and a soluble phosphate; and a set retarder that includes a water soluble carbolic acid. Optionally, other additives may be included, such as accelerants, dispersants, weighting agents, and the like.

Description

CEMENT COMPOSITIONS WITH IMPROVED CORROSION RESISTANCE AND
METHODS OF CEMENTING IN SUBTERRANEAN FORMATIONS
BACKGROUND OF THE INVENTION
The present invention relates to subterranean well cementing operations, and more particularly, to cement compositions demonstrating improved corrosion resistance, and methods of using such cement compositions in subterranean formations.
Hydraulic cement compositions are commonly utilized in subterranean operations, particularly subterranean well completion and remedial operations.
For example, hydraulic cement compositions are used in primary cementing operations whereby pipe strings such as casings and liners are cemented in well bores. In performing primary cementing, hydraulic cement compositions are pumped into an annular space between the walls of a well bore and the exterior surface of a pipe string disposed therein. The cement composition is permitted to set in the annular space, thereby forming an annular sheath of hardened substantially impermeable cement therein that substantially supports and positions the pipe string in the well bore and bonds the exterior surfaces of the pipe string to the walls of the well bore. Hydraulic cement compositions also are used in remedial cementing operations such as plugging highly permeable zones or fractures in well bores, plugging cracks and holes in pipe strings, and the like.
Portland cement is commonly used in subterranean cementing applications.
Drawbacks may exist to using Portland cements in certain applications, however, because they are prone to corrosive attacks by carbonic acid (H2CO3). Carbonic acid may be naturally present in a subterranean formation, or it may be produced in the formation by the reaction of subterranean water and carbon dioxide (COz), when the latter has been injected into the formation, e.g., as in a COz-enhanced recovery operation. Carbonic acid is believed to react with calcium hydroxide that is present in Portland cement, which reaction may cause the cement to become a soft amorphous gel. This is problematic because, inter alia, it may increase the permeability of the cement. As a result, chloride and hydrogen sulfide ions, which may be present in the subterranean formation, may penetrate the cement sheath and adversely affect, or react with, the casing. The degradation of the cement can cause, inter alia, loss of support for the casing and undesirable interzonal communication of fluids.
The susceptibility of some cements, including Portland cements, to degradation by carbonic acid may be especially problematic in typical geothermal wells, which typically involve very high temperatures, pressures and carbon dioxide concentrations.
In such wells, cement failures may occw in less than five years, causing the collapse of the well casing. This, in turn, may cause lost production and may necessitate expensive casing repairs.
SUMMARY OF THE INVENTION
The present invention relates to subterranean well cementing operations, and more particularly, to cement compositions demonstrating improved corrosion resistance, and methods of using such compositions in subterranean formations.
An example of a method of the present invention comprises providing a cement composition that comprises: an unhydrated cement comprising a high alumina cement, a silica source, and a soluble phosphate; and a set retarder comprising a water soluble carboxylic acid; placing the cement composition in a subterranean formation;
and allowing the cement composition to set therein.
An example of a composition of the present invention is a cement composition that comprises: an unhydrated cement comprising a high alumina cement, a silica source, and a soluble phosphate; and a set retarder that includes a water-soluble carboxylic acid.
The features and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of the exemplary embodiments, which follows.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
The present invention relates to subterranean well cementing operations, and more particularly, to cement compositions demonstrating improved corrosion resistance, and methods of using such compositions in subterranean formations.
The cement compositions of the present invention generally comprise an unhydrated cement comprising a high alumina cement, a silica source, and a soluble phosphate; a set retarder, and water sufficient to form a pumpable slurry. The cement compositions of the present invention generally have a density that may range from about 6 lb/gallon to about 23 Ib/gallon. In certain exemplary embodiments, the density of the cement compositions of the present invention may range from about 14 Ib/gallon to about 16 lb/gallon. In certain exemplary embodiments, the cement compositions of the present invention can be low-density cement compositions, e.g., foamed cement compositions or cement compositions comprising microspheres.
The cement compositions of the present invention comprise an unhydrated cement that comprises a high alumina cement, a silica source, and a soluble phosphate. Any high alumina cements that are suitable for use in subterranean applications may be suitable for use in the cement compositions of the present invention. As referred to herein, the term "high alumina cement" will be understood to mean a cement having an alumina concentration within the range of about 40% to about 80% of the weight of the high alumina cement. An example of a suitable high alumina cement is commercially available under the trade designation "SECAR-60," available from the LaFarge Corporation of Chesapeake, Virginia.
Generally, the high alumina cement is present in the cement compositions of the present invention in an amount in the range of from about 20% to about 80% by weight of the unhydrated cement. In certain exemplary embodiments, the high alumina cement may be present in the cement compositions of the present invention in an amount in the range of from about 30% to about 70% by weight of the unhydrated cement.
Generally, the silica source used in accordance with the present invention comprises vitrified shale, fly ash, or a mixture thereof. Generally speaking, the silica source is present in the cement compositions of the present invention in an amount sufficient to provide a desired degree of corrosion resistance. In certain exemplary embodiments, the silica source may be present in the cement compositions of the present invention in an amount in the range of from about 20% to about 80% by weight of the unhydrated cement.
In certain exemplary embodiments, the silica source may be present in the cement compositions of the present invention in an amount in the range of from about 30% to about 70% by weight of the unhydrated cement. Where the silica source comprises vitrified shale, any type of vitrified shale may be used in the cement compositions of the present invention.
An example of a suitable vitrified shale is commercially available under the tradename of "PRESSUR.-SEAL~ FINE LCM" from TXI Energy Services, Inc., in Houston, Texas.
As noted previously, the silica source also may comprise fly ash. The term "fly ash" will be understood to refer to the finely divided residue that results from the combustion of ground or powdered coal and that is carned by flue gases generated by power plants. In certain exemplary embodiments of the present invention where the silica source comprises fly ash, the fly ash may be ASTM class F fly ash, which is a fine particle size ASTM
class F fly ash having a Blaine fineness of about 10,585 cm2/gram that is commercially available from Halliburton Energy Services, Inc., of Houston, Texas, under the trade designation "POZMIX~'."
Any type of soluble phosphate may be used in the cement compositions of the present invention, including, but not limited to, vitreous sodium phosphates, sodium hexametaphosphate, sodium polyphosphate, or mixtures thereof. An example of a suitable soluble phosphate is commercially available from Calgon Corporation in Pittsburgh, Pennsylvania, under the tradename of "CALGON." In general, the soluble phosphate is present in the cement compositions that are of the present invention in an amount sufficient to provide a desired degree of corrosion resistance. The soluble phosphate can be included in the cement compositions of the present invention in an amount in the range of from about 1%
to about 10% by weight of the unhydrated cement. When included, it is believed that, inter alia, the soluble phosphate combines with calcium aluminate that may be present in the high alumina cement to form calcium phosphate in the form of hydroxyapatite. This reaction product may be resistant to corrosion.
The set retarders used in the cement compositions of the present invention.
generally comprise a water-soluble carboxylic acid. Examples of suitable water-soluble carboxylic acids include, but are not limited to, malic acid, lactic acid, acetic acid, tartaric acid, citric acid, and formic acid. Generally, the set retarder is included in the cement compositions of the present invention in an amount sufficient to retard the setting of the cement composition until a desired time after the cement composition has been placed in a subterranean formation. More particularly, the set retarder may be included in the cement compositions of the present invention in an amount in the range of from about 0.1% to about 5% by weight of the unhydrated cement.
The cement compositions of the present invention further comprise water, which may be from any source provided that it does not contain an excess of compounds that adversely affect other compounds in the cement composition. For example, a cement composition of the present invention may comprise fresh water, salt water (e.g., water containing one or more salts dissolved therein), brine, or seawater. The water may be present in an amount sufficient to form a pumpable slurry. More particularly, the water may be present in the cement compositions of the present invention in an amount in the range of from about 30% to about 50% by weight of the unhydrated cement. In certain exemplary embodiments, the water may be present in the cement compositions of the present invention S
in an amount in the range of from about 35% to about 45% by weight of the unhydrated cement.
Optionally, the cement compositions of the present invention may be low-density cement compositions. For example, the cement compositions of the present invention may comprise foamed cement compositions. When foamed, the cement compositions may include an expanding additive present in an amount sufficient to foam the cement composition to a desired density. Optionally, where the cement composition is foamed, foaming agents and/or foam stabilizing agents may be included in the cement composition in order to facilitate the foaming. An example of a suitable foaming agent is "ZONESEAL
2000TM," commercially available from Halliburton Energy Services, Inc., of Houston, Texas, which is described in U.S. Pat. No. 6,063,738, the relevant disclosure of which is incorporated herein by reference. When used, the foaming agent and/or foam stabilizing agent may be present in the cement compositions of the present invention in an amount sufficient to generate a stable foam. In certain exemplary embodiments, the foaming agent and/or foam stabilizing agent may be present in the cement compositions of the present invention in an amount in the range of from about 1% to about 2% by weight of the water in the composition.
Optionally, the cement compositions of the present invention may further comprise an expanding additive utilized to foam the cement composition. A gas such as air, nitrogen, or a mixture of both, may be used. In certain exemplary embodiments, nitrogen may be used. Where included, the expanding additive may be present in the cement composition in an amount sufficient to adjust the density of the cement composition to a desired value. In certain exemplary embodiments of the present invention where an expanding additive has been added to the cement composition, a density in the range of from about 10 to about 14 pounds per gallon may be suitable. In certain exemplary embodiments, the expanding additive may be present in the cement compositions of the present invention in an amount in the range of from about 5% to about 40% by volume of the cement composition.
Optionally, microspheres may be added, inter alia, to reduce the density of the cement composition. Any microspheres that are compatible with a subterranean cement composition, e.g., that are chemically stable over time upon incorporation into the cement composition, may be used. An example of a suitable microsphere is commercially available from Halliburton Energy Services, Inc., of Houston, Texas, under the tradename "SPHERELITE." Where included, the microspheres may be present in the cement compositions of the present invention in an amount sufficient to provide a cement composition having a density in a desired range. In certain exemplary embodiments, the microspheres may be present in the cement compositions of the present invention in an amount in the range of from about 10% to about 80% by weight of the unhydrated cement.
The microspheres may be added to the cement compositions of the present invention by any suitable method, including by dry blending with the cement before the addition of a fluid such as water, by mixing with the fluid to be added to the cement, or by mixing with the cement slurry consecutively with, or after, the addition of the fluid. The microspheres may be pre-suspended in water and injected into the cement mix fluid or into the cement slurry as an aqueous slurry. In certain exemplary embodiments, the microspheres may be dry blended with the cement before the addition of water.
Optionally, the cement compositions of the present invention may include inert ground rubber particles, inter alia, to provide elasticity and ductility. In certain exemplary embodiments, such ground rubber particles are produced from tires, and are commercially available from Four D Corporation of Duncan, Oklahoma. In certain exemplary embodiments, the ground rubber particles have a mean length of less than about 1/4", and can pass through a filter having a mesh size of 10/20 and 20/30.
Where included, the ground rubber particles may be present in the cement compositions of the present invention in an amount sufficient to provide a desired degree of ductility to the cement composition. In certain exemplary embodiments, the ground rubber particles may be present in the cement compositions of the present invention in an amount in the range of from about 10% to about 30% by weight of the unhydrated cement.
Optionally, the cement compositions of the present invention may include carbon fibers, in order to, inter alia, increase the tensile strength of the cement composition.
Where added, the carbon fibers preferably have a high tensile strength andlor a high tensile modulus. In certain exemplary embodiments, to achieve certain of the advantages associated with the present invention, the tensile modulus of the fibers may exceed 180 GPa, and the tensile strength of the fibers may exceed 3000 MPa. The fibers preferably have a mean length of about 1 mm or less. In certain exemplary embodiments, the mean length of the carbon fibers is from about 50 to about 500 microns. Most preferably, the fibers have a mean length in the range of about 100 to about 200 microns. Preferably, they are milled carbon fibers. An example of suitable carbon fibers includes "AGM-94" carbon fibers commercially available from Asbury Graphite Mills, Inc., of Asbury, New Jersey. AGM-94 fibers have a mean length of about 1 SO microns and a diameter of about 7.2 microns. Another example of suitable carbon fibers includes the "AGM-99" carbon fibers, also available from Asbury Graphite Mills, Inc., which have a mean length of about 150 microns and a diameter of about 7.4 microns. Generally, the carbon fibers may be present in the cement compositions of the present invention in an amount sufficient to enable the set cement to achieve a desired tensile strength. In certain exemplary embodiments, the carbon fibers may be present in the cement compositions of the present invention in an amount in the range of from about 1% to about 15% by weight of the unhydrated cement.
Optionally, the cement compositions of the present invention may comprise suitable additives, including, but not limited to, accelerants, surfactants, fluid loss control additives, weighting materials, dispersants, or the like. An example of a suitable fluid loss control additive is a styrene-butadiene latex commercially available from Halliburton Energy Services, Inc., of Duncan, Oklahoma, under the trade designation "LATEX 2000."
Another example of a suitable fluid loss control additive is a cationic starch that is commercially available from National Starch, Inc., under the tradename "REDI BOND 5330."
An example of a method of the present invention comprises providing a cement composition that comprises: an unhydrated cement comprising a high alumina cement, a silica source, and a soluble phosphate; and a set retarder comprising a water soluble carboxylic acid; placing the cement composition in a subterranean formation;
and allowing the cement composition to set therein.
To facilitate a better understanding of the present invention, the following examples of some of the exemplary embodiments are given. In no way should such examples be read to limit the scope of the invention.

A series of sample cement compositions of the present invention were prepared and tested as follows.
Sample Composition No. 1 comprised an unhydrated cement that comprised 47.5% SECAR 60 cement by weight, 4?.5% fly ash by weight, and 5% sodium g hexametaphosphate by weight. Water was added to this unhydrated cement in the amount of 39% by weight of the unhydrated cement.
Sample Composition No. 2 comprised an unhydrated cement that comprised 47.5% SECAR 60 cement by weight, 47.5% fly ash by weight, and 5% sodium hexametaphosphate by weight. Citric acid and tartaric acid were added to this unhydrated cement, each in the amount of 1.4% by weight of the unhydrated cement. Sample Composition No. 2 further comprised 39% water by weight of the unhydrated cement.
Sample Composition No. 3 comprised an unhydrated cement that comprised 47.5% SECAR 60 cement by weight, 47.5% vitrified shale by weight, and 5%
sodium hexametaphosphate by weight. Sample Composition No. 3 further comprised 39%
water by weight of the unhydrated cement.
Sample Composition No. 4 comprised an unhydrated cement that comprised 47.5% SECAR 60 cement by weight, 47.5% vitrified shale by weight, and 5%
sodium hexametaphosphate by weight. Citric acid and tartaric acid were added to this unhydrated cement, each in the amount of 1.4% by weight of the unhydrated cement. Sample Composition No. 4 further comprised 39% water by weight of the unhydrated cement.
Sample Composition No. 5 comprised an unhydrated cement that comprised 47.5% SECAR 60 cement by weight, 47.5% vitrified shale by weight, and 5%
sodium hexametaphosphate by weight. Citric acid and malic acid were added to this unhydrated cement, each in the amount of 1.4% by weight of the unhydrated cement. Sample Composition No. 5 further comprised 39% water by weight of the unhydrated cement.
The sample compositions were prepared at room temperature and subjected to thickening time and seven-day compressive strength testing at 220°F per API Specification 10, except that thickening time measurements were not performed for either of Sample Composition Nos. 1 and 3. The results are set forth in the table below.

Sample Silica % Citric% Tartaric% Malic Thickening Compressive DescriptionSource Acid Acid Acid Time Strength hours:minutessi Sample Fly 0 0 0 Not Determined5260 ash Composition No. 1 Sample Fly 1.4% 1.4% 0 15+ 4340 ash Composition No. 2 Sample Shale 0 0 0 Not Determined4930 Composition No. 3 Sample Shale 1.4% 1.4% 0 4:13 64 Composition No. 4 Sample Shale 1.4% 0 1.4% 3:52 4800 Composition No. 5 The above example illustrates, inter alia, that cement compositions of the present invention comprising malic acid are suitable for use in subterranean cementing applications.

Sample cement compositions of the present invention were prepared comprising an unhydrated cement that comprised 380 grams of vitrified shale from TXI
Energy Services, 380 grams of SECAR 60 cement from LaFarge Corporation, and 40 grams of sodium phosphate. The sample cement compositions further comprised 311 grams of deionized water, and varying amounts of lactic acid from Sigma-Aldrich.
The sample compositions were prepared at room temperature and subjected to thickening time testing at 140°F per API Specification 10. The results are set forth in the table below.

Sample Description Lactic Acid Thickening Time (% by weight of the (hours:minutes) unh drated cement Sample Composition 1.0 0:48 No. 6 Sample Composition 1.2 0:59 No. 7 Sample Composition 1.3 1:17 No. 8 Sample Composition 1.4 9:15 No. 9 Sample Composition 1.5 12:18 No.10 The above example illustrates, Inter alia, that lactic acid retards the hydration of cement compositions of the present invention.

Sample cement compositions of the present invention were prepared comprising an unhydrated cement that comprised 380 grams of vitrified shale from TXI
Energy Services, 380 grams of SECAR 60 cement from LaFarge Corporation, and 40 grams of sodium phosphate. The sample cement compositions further comprised 311 grams of deionized water, and varying amounts of malic acid. The sample compositions were prepared at room temperature and subjected to thickening time testing at 140°F per API
Specification 10. The results are set forth in the table below.

Malic Acid Thickening Time Sample Description (% by weight of the (hours:minutes) unh drated cement Sample Composition 1.4 6:12 No. 11 Sample Composition 1.5 6:39 No.12 The above example illustrates, inter alia, that malic acid retards the hydration of cement compositions of the present invention.

Sample cement compositions of the present invention were prepared comprising an unhydrated cement that comprised 380 grams of vitrified shale from TXI
Energy Services, 380 grams of SECAR 60 cement from LaFarge Corporation, and 40 gams of sodium phosphate. The sample cement compositions further comprised 311 grams of deionized water, and varying amounts of acetic acid from J.T. Baker. The sample compositions were prepared at room temperature and subjected to thickening time testing per API Specification 10. The results are set forth in the table below.

Sample DescriptionAcetic Acid Thickening Time Thickening Time Test (% by weight of Temperature (hours:minutes) the unh drated cementF

Sample Composition0.5 140 0:42 No.13 Sample Composition0.6 140 0:52 No.14 Sample Composition0.7 140 1:16 No.15 Sample Composition0.71 140 1:21 No. 16 Sample Composition0.73 140 1:26 No. 17 Sample Composition0.7375 140 7:25 No.18 Sample Composition0.74 140 7:55 No.19 Sample Composition0.75 140 9:34 No. 20 Sample Composition0.8 140 12:04 No. 21 Sample Composition1.0 200 16:04 No. 22 Sample Composition2.0 200 0:15 gelled No. 23 Sample Composition1.0 240 8:28 No. 24 The term "gelled," as used in the above example, signifies that Sample Composition No. 23 experienced an increase in viscosity to such a state that it could not be pumped or tested.
The above example illustrates, inter alia, that acetic acid retards the hydration of cement compositions of the present invention.

Sample cement compositions of the present invention were prepared comprising an unhydrated cement that comprised 380 grams of vitrified shale from TXI
Energy Services, 380 grams of SECAR 60 cement from LaFarge Corporation, and 40 grams of sodium phosphate. The sample cement compositions further comprised 311 grams of deionized water, and varying amounts of FE-2 (citric acid), HR-25 (tartaric acid), and malic acid. The sample compositions were prepared at room temperature and subjected to thickening time testing at 200°F per API Specification 10. The results are set forth in the table below.

Sample Citric Acid Malic Acid Tartaric Acid Thickening Description (% by weight (% by weight (% by weight Time of of of the unhydratedthe unhydratedthe unhydrated(hours:minutes) cement cement cement Sample 1.0 0.5 0.5 2:31 Composition No. 25 Sample 1.2 0.6 0.6 3:56 Composition No. 26 Sample 1.5 0.75 0.75 10:OS

Composition No. 27 The above example illustrates, inter alia, that citric acid, malic acid, and tartaric acid, in combination, retards the hydration of cement compositions of the present invention.

Sample cement compositions of the present invention were prepared comprising an unhydrated cement that comprised 380 grams of vitrified shale from TXI
Energy Services, 380 grams of SECAR 60 from LaFarge Corporation, and 40 grams of sodium phosphate. The sample cement compositions further comprised 311 grams of deionized water, varying amounts of "FE-2" (citric acid), and varying amounts of acetic acid from J.T. Baker. The sample compositions were prepared at room temperature and subjected to thickening time testing at 200°F per API Specification 10. The resulting thickening times are set forth in the table below.

Sample DescriptionCitric Acid Acetic Acid Thickening Time (% by weight of (% by weight (hours:minutes) the of the unhydrated cement)unhydrated cement) Sample Composition1.0 0.5 1:09 No. 28 Sample Composition1.0 0.7 1:41 No. 29 The above example illustrates, inter alia, that citric acid and acetic acid, in combination, retards the hydration of cement compositions of the present invention.

Sample cement compositions of the present invention were prepared comprising an unhydrated cement that comprised 380 grams of vitrified shale from TXI
Energy Services, 380 grams of SECAR 60 from LaFarge Corporation, and 40 grams of sodium phosphate. The sample cement compositions further comprised 311 grams of deionized water, varying amounts of "FE-2" (citric acid), and varying amounts of malic acid.
The sample compositions were prepared at room and subjected to thickening time testing per API Specification 10. The results are set forth in the table below.

Sample Citric Acid Malic Acid Thickening Thickening Description (% by weight (% by weight Time Test Time of of the unhydratedthe unhydratedTemperature (hours:minutes) cement) cement) (F) Sample 1.5 1.5 200 11:05 Composition No. 30 Sample 1.6 1.6 200 10:07 Composition No. 31 Sample 1.4 1.4 220 4:3 8 Composition No. 32 The above example illustrates, inter alia, that citric acid and malic acid, in combination, retards the hydration of cement compositions of the present invention.

Sample cement compositions of the present invention were prepared comprising an unhydrated cement that comprised 380 grams of vitrified shale from TXI
Energy Services, 380 grams of SECAR 60 from LaFarge Corporation, and 40 grams of sodium phosphate. The sample cement compositions further comprised 311 grams of deionized water, and varying amounts of formic acid from Sigma-Aldrich. The sample compositions were prepared at room temperature and subjected to twenty-four hour compressive strength testing and thickening time testing at 140°F per API Specification 10.
The results are set forth in the table below.

Sample DescriptionFormic Acid Compressive Thickening Time (% by weight of Strength (hours:minutes) the unh drated cementsi Sample Composition0.625 652 1:51 No. 33 Sample Composition0.650 262 7:47 No. 34 Sample Composition0.687 291 8:21 No. 35 Sample Composition0.750 Not Determined 11:22 No. 36 The compressive strength of the samples was measured in a water bath at atmospheric pressure. No compressive strength measurement was made of Sample Composition No. 36.
The above example illustrates, inter alia, that formic acid retards the hydration of cement compositions of the present invention while maintaining acceptable compressive strength.

Sample cement compositions of the present invention were prepared comprising an unhydrated cement that comprised 380 grams of vitrified shale from TXI
Energy Services, 380 grams of SECAR 60 from LaFarge Corporation, and 40 grams of sodium phosphate. The sample cement compositions further comprised 311 grams of deionized water, and varying amounts of "FE-2" and "HR-25." The sample compositions were prepared at room temperature and subjected to thickening time testing per API
Specification 10. The samples were also subjected to twenty-four hour compressive strength testing at 140°F per API Specification 10. The results are set forth in the table below.

Sample Citric AcidTartaric Thickening CompressiveThickening Description(% by weightAcid Time Test Strength Time (hours:

of the (% by weightTemperature(psi) minutes) unhydrated of the (F) cement) unhydrated cement Sample 0.9 0.9 110 2710 11:45 Composition No. 37 Sample 0.7 0.7 140 2479 1:20 Composition No. 38 Sample 0.8 0.8 140 877 1:56 Composition No. 39 Sample 0.9 0.9 140 Not 4:56 Composition Determined No. 40 Sample 1.0 1.0 140 277 6:07 Composition No. 41 Sample 1.4 1.4 140 313 6:50 Composition No. 42 The compressive strength of the samples was measured in a water bath at atmospheric pressure. No compressive strength measurement was made of Sample Composition No. 44.
The above example illustrates, inter alia, that citric acid and tartaric acid, in combination, retards the hydration of cement compositions of the present invention while maintaining acceptable compressive strength.

Sample cement compositions of the present invention were prepared comprising an unhydrated cement that comprised 380 grams of vitrified shale from TXI
Energy Services, 380 grams of SECAR 60 from LaFarge Corporation, and 40 grams of sodium phosphate. The sample cement compositions further comprised 311 grams of deionized water, and varying amounts of "FE-2" (citric acid). The sample compositions were prepared at room temperature and subjected to thickening time testing at 110°F and twenty-four hour compressive strength testing at 140°F per API Specification 10. The results are set forth in the table below.

Sample DescriptionCitric Acid Compressive Thickening Time (% by weight of Strength (psi) (hours:minutes) the unh drated cement Sample Composition1.3 Not Determined 2:21 No. 43 Sample Composition1.4 2280 2:29 No. 44 The compressive strength of Sample Composition No. 48 was measured in a water bath at atmospheric pressure. No compressive strength measurement was made of Sample Composition No. 47.
The above example illustrates, inter alia, that citric acid retards the hydration of cement compositions of the present invention while maintaining acceptable compressive strength.

Sample cement compositions of the present invention were prepared comprising an unhydrated cement that comprised 380 grams of vitrified shale from TXI
Energy Services, 380 grams of SECAR 60 from LaFarge Corporation, and 40 grams of sodium phosphate. The sample cement compositions further comprised 311 grams of deionized water, and varying amounts of "HR-25" (tartaric acid). The sample compositions were prepared at room temperature and subjected to thickening time testing at 110°F and twenty-four hour compressive strength testing at 140°F per API
Specification 10. The results are set forth in the table below.

Sample DescriptionTartaric Acid Compressive Thickening Time (% by weight of Strength (psi) (hours:minutes) the unh drated cement Sample Composition1.3 Not Determined 2:38 No. 45 Sample Composition1.4 1118 3:13 No. 46 No compressive strength measurement was made of Sample Composition No.
49.
The above example illustrates, inter alia, that tartaric acid retards the hydration of cement compositions of the present invention while maintaining acceptable compressive strength.
Therefore, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned as well as those that are inherent therein. While the invention has been depicted, described, and is defined by reference to exemplary embodiments of the invention, such a reference does not imply a limitation on the invention, and no such limitation is to be inferred. The invention is capable of considerable modification, alternation, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent arts and having the benefit of this disclosure. The depicted and described embodiments of the invention are exemplary only, and are not exhaustive of the scope of the invention. Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects.

Claims (48)

1. A method of cementing in a subterranean formation comprising the steps of:
providing a cement composition comprising an unhydrated cement that comprises a high alumina cement, a silica source, and a soluble phosphate; and a set retarder comprising a water soluble carboxylic acid;
placing the cement composition into the subterranean formation;
permitting the cement composition to set therein.
2. The method of claim 1 wherein the high alumina cement has an alumina concentration in the range of from about 40% to about 80% of the weight of the high alumina cement.
3. The method of claim 1 wherein the high alumina cement is present in the cement composition in an amount in the range of from about 20% to about 80% of the weight of the unhydrated cement.
4. The method of claim 1 wherein the silica source comprises vitrified shale.
5. The method of claim 4 wherein the silica source further comprises fly ash.
6. The method of claim 1 wherein the silica source is present in the cement composition in an amount in the range of from about 20% to about 80% by the weight of the unhydrated cement.
7. The method of claim 1 wherein the soluble phosphate is present in the cement composition in an amount in the range of from about 1% to about 10% by the weight of the unhydrated cement.
8. The method of claim 1 wherein the soluble phosphate comprises sodium hexametaphosphate, sodium polyphosphate, vitreous sodium phosphate, or mixtures thereof.
9. The method of claim 1 wherein the set retarder comprising the water-soluble carboxylic acid is present in the cement composition in an amount in the range of from about 0.1% to about 5% by weight of the unhydrated cement.
10. The method of claim 1 wherein the cement composition further comprises a fluid loss control additive, a weighting agent, a defoamer, a surfactant, mica, fumed silica, a salt, a dispersant, a formation conditioning agent, an expanding additive, microspheres, or an accelerant.
11. The method of claim 1 wherein the cement composition further comprises water.
12. The method of claim 11 wherein the water is fresh water, salt water, brine, sea water, or a mixture thereof.
13. The method of claim 11 wherein the water is present in the cement composition in an amount sufficient to form a pumpable slurry.
14. The method in claim 11 wherein the water is present in the cement composition in an amount in the range of from about 30% to about 50% by the weight of the unhydrated cement.
15. The method of claim 1 wherein the cement composition has a density in the range of from about 6 pounds per gallon to about 23 pounds per gallon.
16. The method of claim 1 wherein the cement composition further comprises carbon fibers.
17. The method of claim 16 wherein the carbon fibers have a mean length of about 150 microns.
18. The method of claim 16 wherein the carbon fibers are present in the cement composition in an amount in the range of from about 1% to about 15% by weight of the unhydrated cement.
19. The method of claim 1 wherein the cement composition further comprises rubber particles.
20. The method of claim 19 wherein the rubber particles are present in the cement composition in an amount in the range of from about 10% to about 30% by weight of the unhydrated cement.
21. The method of claim 19 wherein the rubber particles have a mean length of less than about 1/4".
22. The method of claim 1 wherein the cement composition is a low-density cement composition.
23. The method of claim 1 wherein the high alumina cement has an alumina concentration in the range of from about 40% to about 80% of the weight of the high alumina cement; wherein the high alumina cement is present in the cement composition in an amount in the range of from about 20% to about 80% by weight of the unhydrated cement; wherein the silica source comprises vitrified shale; wherein the silica source is present in the cement composition in an amount in the range of from about 20% to about 80% by weight of the unhydrated cement; wherein the soluble phosphate is sodium hexametaphosphate present in the cement composition in an amount in the range of from about 1% to about 10%
by weight of the unhydrated cement; and wherein the set retarder is present in the cement composition in an amount in the range of from about 0.1% to about 5% by weight of the unhydrated cement.
24. A cement composition comprising:
an unhydrated cement comprising:
a high alumina cement, a silica source, and a soluble phosphate; and a set retarder comprising a water soluble carboxylic acid.
25. The cement composition of claim 24 wherein the high alumina cement has an alumina concentration in the range of from about 40% to about 80% of the weight of the high alumina cement.
26. The cement composition of claim 24 wherein the high alumina cement is present in the cement composition in an amount in the range of from about 20%
to about 80%
by weight of the unhydrated cement.
27. The cement composition of claim 24 wherein the silica source is present in the cement composition in an amount sufficient to provide a desired level of corrosion resistance.
28. The cement composition of claim 24 wherein the silica source comprises vitrified shale.
29. The cement composition of claim 28 wherein the silica source further comprises fly ash.
30. The cement composition of claim 24 wherein the silica source is present in the cement composition in an amount in the range of from about 20% to about 80% by weight of the unhydrated cement.
31. The cement composition of claim 24 wherein the soluble phosphate is present in the cement composition in an amount sufficient to provide a desired level of corrosion resistance.
32. The cement composition of claim 24 wherein the soluble phosphate is present in the cement composition in an amount in the range of from about 1% to about 10% by weight of the unhydrated cement.
33. The cement composition of claim 24 wherein the soluble phosphate comprises sodium hexametaphosphate, sodium polyphosphate, vitreous sodium phosphate, or mixtures thereof.
34. The cement composition of claim 24 wherein the set retarder is present in the cement composition in an amount sufficient to prevent the cement from setting until a desired time after the cement has been placed in a subterranean formation.
35. The cement composition of claim 24 wherein the set retarder is present in the cement composition in an amount in the range of from about 0.1% to about 5% by weight of the unhydrated cement.
36. The cement composition of claim 24 further comprising a fluid loss control additive, a weighting agent, a defoamer, a surfactant, mica, fumed silica, a salt, a dispersant, a formation conditioning agent, an expanding additive, microspheres, or an accelerant.
37. The cement composition of claim 24 further comprising water in an amount sufficient to form a pumpable slurry.
38. The cement composition of claim 37 wherein the water is present in the cement composition in an amount in the range of from about 30% to about 50% by weight of the unhydrated cement.
39. The cement composition of claim 37 wherein the water is fresh water, salt water, brine, sea water, or a mixture thereof.
40. The cement composition of claim 24 wherein the cement composition further comprises carbon fibers, present in the cement composition in an amount sufficient to achieve a desired tensile strength for the set cement.
41. The cement composition of claim 40 wherein the carbon fibers have a mean length of 150 microns.
42. The cement composition of claim 40 wherein the carbon fibers are present in the cement composition in an amount in the range of from about 1% to about 15%
by weight of the unhydrated cement.
43. The cement composition of claim 24 wherein the cement composition further comprises inert ground rubber particles, present in an amount sufficient to achieve a desired degree of ductility for the set cement.
44. The cement composition of claim 43 wherein the rubber particles have a mean length of less than about 1/4".
45. The cement composition of claim 43 wherein the rubber particles are present in the cement composition in an amount in the range of from about 10% to about 30% by weight of the unhydrated cement.
46. The cement composition of claim 24 wherein the density of the cement composition is in the range of from about 6 to about 23 pounds per gallon.
47. The cement composition of claim 24 wherein the cement composition is a low-density cement composition.
48. The cement composition of claim 24 wherein the high alumina cement has an alumina concentration in the range of from about 40% to about 80% of the weight of the high alumina cement; wherein the high alumina cement is present in the cement composition in an amount in the range of from about 20% to about 80% by weight of the unhydrated cement;
wherein the silica source comprises vitrified shale; wherein the silica source is present in the cement composition in an amount in the range of from about 20% to about 80% by weight of the unhydrated cement; wherein the soluble phosphate is sodium hexametaphosphate present in the cement composition in an amount in the range of from about 1% to about 10% by weight of the unhydrated cement; and wherein the set retarder is present in an amount in the range of from about 0.1% to about 5% by weight of the unhydrated cement.
CA 2555348 2004-02-09 2004-12-17 Cement compositions with improved corrosion resistance and methods of cementing in subterranean formations Abandoned CA2555348A1 (en)

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CN111993571B (en) * 2020-08-28 2021-06-08 云浮市豪野材料科技有限公司 Production method of high-strength corrosion-resistant set cement

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US20040211562A1 (en) 2004-10-28

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