CA2621829A1 - Foamed settable compositions comprising cement kiln dust, and methods of using them - Google Patents

Foamed settable compositions comprising cement kiln dust, and methods of using them Download PDF

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Publication number
CA2621829A1
CA2621829A1 CA 2621829 CA2621829A CA2621829A1 CA 2621829 A1 CA2621829 A1 CA 2621829A1 CA 2621829 CA2621829 CA 2621829 CA 2621829 A CA2621829 A CA 2621829A CA 2621829 A1 CA2621829 A1 CA 2621829A1
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CA
Canada
Prior art keywords
settable composition
surfactant
foamed settable
foamed
cement
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA 2621829
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French (fr)
Other versions
CA2621829C (en
Inventor
Craig W. Roddy
Jiten Chatterji
Darrell Chad Brenneis
Bobby J. King
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Halliburton Energy Services Inc
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Individual
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Filing date
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Publication of CA2621829A1 publication Critical patent/CA2621829A1/en
Application granted granted Critical
Publication of CA2621829C publication Critical patent/CA2621829C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • 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
    • 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
    • C04B28/08—Slag 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
    • 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
    • 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 provides settable compositions that comprise water and cement kiln dust. The settable compositions optionally may comprise an additive that comprises at least one of the following group: fly ash; shale;
slag cement; zeolite; metakaolin; and combinations thereof. The settable compositions optionally may be foamed with a gas. Methods of cementing also are provided that comprise: providing the settable composition; introducing the settable composition into a location to be cemented; and allowing the settable composition to set therein. The location to be cemented may be above ground or in a subterranean formation.

Claims (43)

1. A foamed settable composition comprising:
water;
cement kiln dust;
a gas; and a surfactant.
2. The foamed settable composition of claim 1 wherein the water comprises at least one of the following group: freshwater; saltwater; a brine; seawater;
and combinations thereof.
3. The foamed settable composition of claim 1 wherein the cement kiln dust is present in the foamed settable composition in an amount in the range of from about 5% to 100% by weight.
4. The foamed settable composition of claim 1 wherein the cement kiln dust is present in the foamed settable composition in an amount in the range of from about 10% to about 50% by weight.
5. The foamed settable composition of claim 1 wherein the foamed settable composition further comprises a hydraulic cement.
6. The foamed settable composition of claim 5 wherein the hydraulic cement comprises at least one of the following group: a Portland cement; a pozzolana cement; a gypsum cement; a high alumina content cement; a slag cement; a silica cement; and combinations thereof.
7. The foamed settable composition of claim 1 wherein the hydraulic cement is present in the foamed settable composition in an amount in the range of from about 0% to about 95% by weight.
8. The foamed settable composition of claim 1 wherein the hydraulic cement is present in the foamed settable composition in an amount in the range of from about 50% to about 90% by weight.
9. The foamed settable composition of claim 1 wherein the foamed settable composition further comprises at least one of the following group: fly ash;
shale; zeolite; slag cement; metakaolin; and combinations thereof.
10. The foamed settable composition of claim 1 wherein the gas comprises at least one of the following group: air; nitrogen; and combinations thereof.
11. The foamed settable composition of claim 1 wherein the gas is present in the foamed settable composition in an amount in the range of from about 10% to about 80% by volume of the foamed cement composition.
12. The foamed settable composition of claim 1 wherein the surfactant comprises a foaming and stabilizing surfactant composition.
13. The foamed settable composition of claim 12 wherein the foaming and stabilizing surfactant composition comprises at least one of the following group: a mixture of an ammonium salt of an alkyl ether sulfate, a cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water; a mixture of an ammonium salt of an alkyl ether sulfate surfactant, a cocoamidopropyl hydroxysultaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water; a hydrolyzed keratin; a mixture of an ethoxylated alcohol ether sulfate surfactant, an alkyl or alkene amidopropyl betaine surfactant, and an alkyl or alkene dimethylamine oxide surfactant;
an aqueous solution of an alpha-olefinic sulfonate surfactant and a betaine surfactant; and combinations thereof.
14. The foamed settable composition of claim 1 wherein the foamed settable composition further comprises at least one of the following group: a set retarding additive; an accelerator; a lost circulation material; a filtration control additive; a dispersant; and combinations thereof.
15. A foamed settable composition comprising:
water;
cement kiln dust in an amount in the range of from about 10% to about 50% by weight;

Portland cement in an amount in the range of from about 50% to about 90% by weight;
a gas; and a foaming and stabilizing surfactant composition.
16. The foamed settable composition of claim 15 wherein the foamed settable composition further comprises at least one of the following group: fly ash;
shale; zeolite; slag cement; metakaolin; and combinations thereof.
17. The foamed settable composition of claim 15 wherein the gas comprises at least one of the following group: air; nitrogen; and combinations thereof.
18. The foamed settable composition of claim 15 wherein the foaming and stabilizing surfactant composition comprises at least one of the following group: a mixture of an ammonium salt of an alkyl ether sulfate, a cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water; a mixture of an ammonium salt of an alkyl ether sulfate surfactant, a cocoamidopropyl hydroxysultaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water; a hydrolyzed keratin; a mixture of an ethoxylated alcohol ether sulfate surfactant, an alkyl or alkene amidopropyl betaine surfactant, and an alkyl or alkene dimethylamine oxide surfactant;
an aqueous solution of an alpha-olefinic sulfonate surfactant and a betaine surfactant; and combinations thereof.
19. The foamed settable composition of claim 15 wherein the foaming and stabilizing surfactant composition comprises a mixture an ammonium salt of an alkyl ether sulfate, a cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water.
20. The foamed settable composition of claim 15 wherein the foaming and stabilizing surfactant composition is present in the foamed settable composition in an amount in the range of from about 0.8% to about 5% by volume of the water present in the foamed settable composition.
21. A method of cementing comprising:
providing a foamed settable composition comprising water, cement kiln dust, a gas, and a surfactant;

introducing the foamed settable composition into a location to be cemented; and allowing the foamed settable composition to form a hardened mass therein.
22. The method of claim 21 wherein the water comprises at least one of the following group: freshwater; saltwater; a brine; seawater; and combinations thereof.
23. The method of claim 21 wherein the cement kiln dust is present in the foamed settable composition in an amount in the range of about 5% to 100% by weight.
24. The method of claim 21 wherein the foamed settable composition further comprises a hydraulic cement.
25. The method of claim 24 wherein the hydraulic cement is present in the foamed settable composition in an amount in the range of from about 0% to about 95% by weight.
26. The method of claim 21 wherein the foamed settable composition further comprises at least one of the following group: fly ash; shale; zeolite; slag cement; metakaolin;
and combinations thereof.
27. The method of claim 21 wherein the gas comprises at least one of the following group: air; nitrogen; and combinations thereof.
28. The method of claim 21 wherein the surfactant comprises a foaming and stabilizing surfactant composition.
29. The method of claim 28 wherein the foaming and stabilizing surfactant composition comprises at least one of the following group: a mixture of an ammonium salt of an alkyl ether sulfate, a cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water; a mixture of an ammonium salt of an alkyl ether sulfate surfactant, a cocoamidopropyl hydroxysultaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water; a hydrolyzed keratin; a mixture of an ethoxylated alcohol ether sulfate surfactant, an alkyl or alkene amidopropyl betaine surfactant, and an alkyl or alkene dimethylamine oxide surfactant; an aqueous solution of an alpha-olefinic sulfonate surfactant and a betaine surfactant; and combinations thereof.
30. The method of claim 21 wherein the foamed settable composition further comprises at least one of the following group: a set retarding additive; an accelerator; a lost circulation material; a filtration control additive; a dispersant; and combinations thereof.
31. The method of claim 21:
wherein the cement kiln dust is present in the foamed settable composition in an amount in the range of from about 10% to about 50% by weight;
wherein the foamed settable composition further comprises Portland cement in an amount in the range of from about 50% to about 90% by weight;
wherein the surfactant comprises a mixture of an ammonium salt of an alkyl ether sulfate, a cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water; and wherein the surfactant is present in the foamed settable composition in an amount in the range of from about 0.8% to about 5% by volume of the water present in the foamed settable composition.
32. The method of claim 21 wherein the location to be cemented is above ground or within a subterranean formation.
33. The method of claim 21 wherein the step of introducing the foamed settable composition into the location to be cemented comprises:
introducing the foamed settable composition into an annulus between pipe string disposed in a well bore and a wall of the well bore.
34. The method of claim 21 wherein the step of introducing the foamed settable composition into the location to be cemented comprises:
introducing the foamed settable composition into a portion of a gravel pack or a portion of a subterranean formation wherein hardened mass seals the portion of the gravel pack or the portion of the subterranean formation.
35. The method of claim 21 wherein the step of introducing the foamed settable composition into the location to be cemented comprises:
introducing the foamed settable composition into a void in a pipe string disposed in a well bore or in a cement sheath located in an annulus between the pipe string and a wall of the well bore wherein the hardened mass seals the void.
36. The method of claim 21 further comprising:
drilling a hole in the hardened mass, wherein the hardened mass is located in a subterranean formation; and drilling of a well bore through the hole in the hardened mass.
37. A method of cementing a pipe string disposed in a well bore comprising:
providing a foamed settable composition comprising water, cement kiln dust, a gas, and a surfactant;
introducing the foamed settable composition into an annulus between the pipe string and a wall of the well bore; and allowing the foamed settable composition to set in the annulus.
38. The method of claim 37 wherein the foamed settable composition further comprises at least one of the following group: a hydraulic cement; fly ash;
shale; zeolite; slag cement; metakaolin; and combinations thereof.
39. The method of claim 37:
wherein the cement kiln dust is present in the foamed settable composition in an amount in the range of from about 10% to about 50% by weight;
wherein the foamed settable composition further comprises Portland cement in an amount in the range of from about 50% to about 90% by weight;
wherein surfactant comprises a mixture an ammonium salt of an alkyl ether sulfate, a cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water; and wherein the surfactant is present in the foamed settable composition in an amount in the range of from about 0.8% to about 5% by volume of the water present in the foamed settable composition.
40. The method of claim 37 wherein the hardened mass fixes the pipe string in the well bore.
41. A method of cementing comprising:
providing a settable composition comprising water, cement kiln dust, and a surfactant;
foaming the settable composition with a gas to form a foamed settable composition;
introducing the foamed settable composition into a location to be cemented; and allowing the foamed settable composition to set therein.
42. The method of claim 41 wherein the foamed settable composition further comprises at least one of the following group: a hydraulic cement; fly ash;
shale; zeolite; slag cement; metakaolin; and combinations thereof.
43. The method of claim 41:
wherein the cement kiln dust is present in the foamed settable composition in an amount in the range of from about 10% to about 50% by weight;
wherein the foamed settable composition further comprises Portland cement in an amount in the range of from about 50% to about 90% by weight;
wherein the surfactant comprises a mixture an ammonium salt of an alkyl ether sulfate, a cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water; and wherein the surfactant is present in the foamed settable composition in an amount in the range of from about 0.8% to about 5% by volume of the water present in the foamed settable composition.
CA 2621829 2005-09-09 2006-08-24 Foamed settable compositions comprising cement kiln dust, and methods of using them Expired - Fee Related CA2621829C (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US11/223,703 2005-09-09
US11/223,485 US7395860B2 (en) 2005-09-09 2005-09-09 Methods of using foamed settable compositions comprising cement kiln dust
US11/223,485 2005-09-09
US11/223,703 US7387675B2 (en) 2005-09-09 2005-09-09 Foamed settable compositions comprising cement kiln dust
PCT/GB2006/003160 WO2007028950A1 (en) 2005-09-09 2006-08-24 Foamed settable compositions comprising cement kiln dust, and methods of using them

Publications (2)

Publication Number Publication Date
CA2621829A1 true CA2621829A1 (en) 2007-03-15
CA2621829C CA2621829C (en) 2011-07-26

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US (2) US7395860B2 (en)
EP (1) EP1924668B1 (en)
CA (1) CA2621829C (en)
DK (1) DK1924668T3 (en)
NO (1) NO20081137L (en)
RU (1) RU2407714C2 (en)
WO (1) WO2007028950A1 (en)

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