WO2013063411A1 - Slag compositions comprising latex and methods of use - Google Patents

Slag compositions comprising latex and methods of use Download PDF

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Publication number
WO2013063411A1
WO2013063411A1 PCT/US2012/062149 US2012062149W WO2013063411A1 WO 2013063411 A1 WO2013063411 A1 WO 2013063411A1 US 2012062149 W US2012062149 W US 2012062149W WO 2013063411 A1 WO2013063411 A1 WO 2013063411A1
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WO
WIPO (PCT)
Prior art keywords
slag composition
slag
rubber
additive
latex
Prior art date
Application number
PCT/US2012/062149
Other languages
French (fr)
Inventor
Jiten Chatterji
Chad Brenneis
Callie R. Jarratt
Original Assignee
Halliburton Energy Services, Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Halliburton Energy Services, Inc. filed Critical Halliburton Energy Services, Inc.
Priority to NO20140449A priority Critical patent/NO347450B1/en
Priority to CA2851539A priority patent/CA2851539C/en
Priority to BR112014008471A priority patent/BR112014008471A2/en
Priority to MX2014004871A priority patent/MX356091B/en
Priority to AU2012328603A priority patent/AU2012328603B2/en
Publication of WO2013063411A1 publication Critical patent/WO2013063411A1/en

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Classifications

    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/42Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
    • C09K8/46Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement
    • C09K8/467Compositions 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
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions 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
    • C04B28/08Slag cements
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/42Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
    • C09K8/426Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells for plugging
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/42Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
    • C09K8/428Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells for squeeze cementing, e.g. for repairing
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Definitions

  • the present invention relates to cementing operations and. more particularly, in certain embodiments, to methods and compositions that utilize a latex strength enhancer for enhancing the compressive strength of slag compositions.
  • settable compositions are commonly utilized.
  • the term "settable composition” refers to a composition) thai hydraullcally sets or otherwise develops compressive strength.
  • Settable compositions may be used in primary cementing operations whereby pip strings, such a easing and liners, are cemented in well bores. In a typical primary cementing operation, a settable composition may be pumped into an axmuhis between the walls of the well bore and the exterior surface of the pipe string disposed therein.
  • the settable composition may set in the annular space, thereby forming an annular sheath of hardened, substantially impermeable material (e.g., a cement sheath) that may support and position the pipe string in the well bor and may bond the exterior surface of the pipe string to the well bore walls.
  • a cement sheath e.g., a cement sheath
  • the cement sheath surrounding the pipe string should function to prevent the migratio of fluids in the annul us, as well as protecting the pipe string from corrosion.
  • Settable compositions also may be used in remedial cementing methods, such as in the placement of pings, and in squeeze cementing for sealing voids in a pipe string, cement sheath, gravel pack, subterranean, formation, and the like.
  • a particular challenge in cementing operations is the development of satisfactory mechanical properties in a settable composition within a reasonable time period after placement in the subterranean formation. .
  • the subterranean cement sheath undergoes numerous strain and stresses as a result of temperature effects, pressure effects, and impact effects.
  • the ability to withstand these strains and stresses is directly related to the mechanical properties of the settable composition after setting.
  • the mechanical properties are often characterized using parameters such as compressive strength, tensile strength, Young's Modulus, Poisson's Ratio, elasticity, and the like. These properties may be modified by the incl usion of additives.
  • slag cement which is typically a blend of Portland cement and. slag. Because Portland cement develops compressive strength much more rapidly than slag, the amount of slag is
  • Drawbacks to slag cement include the relatively high cost of the Portland cement as compared to the slag, which is a waste material.
  • Drawbacks to usina hi3 ⁇ 4her concentrations of ska. mav include the inability for the settable composition to develop adequate compressive strength in a reasonable time and ensure the long-term struetural integrit of the cement.
  • An embodiment discloses a method of cementing, the method comprising: providing a slag composition comprising a hydraulic cement consisting essentially of slag, a hydroxyl source, a latex strength enhancer, and water; introducing the slag composition into a subterranean formation; and allowing the slag composition to set.
  • Another embodiment discloses a method of cementing, the method comprising: preparing a base fluid comprising a latex strength enhancer, a defoaming agent, and a dispersant; preparing a dry blend comprising slag and a hydroxyl source; combining the base fluid and the dry blend to form a slag composition; introducing the slag composition into a subterranean formation; and allowing the slag composition to set.
  • a slag composition comprising: a hydraulic cement consisting essentially of slag: a hydroxyl source; a latex strength enhancer; and water.
  • Embodiments of the present invention disclose slag compositions comprising slag, a hydroxy! source, a latex strength enhancer, and water.
  • a latex strength enhancer may provide the slag compositions with adequate compressive strengths for use in subterranean applications despite the increased slag content.
  • the compressive strength of the slag compositions containing the latex-strength enhancer may be increased, by at least about 25% in one embodiment, at least abou 50% in another embodiment, and at least about 75% in yet another embodiment, as compared to the same slag compositio that does not contain the latex strength enhancer.
  • embodiments of the slag compositions may be used in a variety of subterranean applications where to, primary and remedial cementing.
  • the slag compositions may comprise slag.
  • Slag is generally a by-product in the production of various metals from their corresponding ores.
  • the production of cast, iron can produce slag as a granulated, blast furnace byproduct with the slag generally comprising the oxidized impurities found in iron ore.
  • the slag may be included in embodiments of the slag compositions in an amount suitable for a particular application.
  • the sla may be present in an amount of about 40% to about 100% by weight of cementitious components ("bwoc"), for example, about 40%, about 50%, about 60%, about 70%, about 80%, about 90%, or about 100%
  • cementitious components include those components or combinations of components of the slag compositions thai Irydraulicall set, or otherwise harden, to develop compressive strength, including, for example, slag, fly ash, hydraulic cement, and the like
  • the slag may be present in an amount greater than abou 40% bwoc, greater than about 50% bwoc, greater than about 60% bwoc, greater than about 70% bwoc, greater than about 80% bwoc, or greater than about 90% bwoc.
  • hydraulic cement included in the slag compositions may consist essentially of the slag.
  • the slag compositions may comprise a hydroxyl source.
  • the hydroxy! source is included in the slag compositions for providing hydroxyl groups for activation of the sl ag to provide a settable composition t hat will react with the water to form a hardened mass in accordance with embodiments of the present in vention .
  • Any of a variety of suitable hydroxy! sources may be used that are capable of generating hydroxyl groups (Off) when dissolved in the water.
  • suitable hydr xyl sources include basic materials, such as sodium hydroxide, sodium bicarbonate, sodium carbonate, lime, and any combination thereof.
  • the hydroxyl source may be present in the slag compositions in an amount in the range of from about 0.1% to about 25% bwoc. In further embodiments, the hydroxyl source may be included in an amount in the range of from about 1% to about 10% bwoc.
  • the slag compositions may comprise a latex strength enhancer.
  • inclusion of the latex strength enhancer in embodiments of the slag compositions of the present invention provides enhanced compressive strength as compared to slag compositions that do not contain the latex strength enhancer.
  • the latex strength enhancer may comprise any of a variety of rubber materials that are commercially available in latex form. Non-limiting examples of suitable rubber materials are available from Halliburton Energy Services, Duncan, Okia,, under the names Latex 2000' "' cement additive and Latex 3000" " cement additive.
  • Suitable rubber materials include natural rubber (e.g., cis-l ,4-polyisoprene), modified natural rubber, synthetic .rubber, and combinations thereof.
  • Synthetic rubber of various types may be utilized, including ethylene-propylene rubbers, styrene-butadiene rubbers, nitrile rubbers, nitrile butadiene rubbers, butyl rubber, neoprene rubber, polybufadtene rubbers, aerylonitrile-sty ene-butadiene rubber, polyisoprene rubber, AMPS ⁇ styrene ⁇ butadiene rubber, and any combination thereof.
  • the term "AMPS'" refers to 2-acrylamido-2-meihylpropanesulfbnic acid or salts thereof; in certain embodiments, the synthetic rubber ma comprise AMPS in m amount ranging .from about 5% to about 10% by weight, stymie in an amount ranging from about 30% to about 70% by weight, and butadiene in an amount ranging from about 30% to about 70% by weight.
  • suitable AMPS-styrene-butadiene rubbers are described in more detail in U.S. Patent Nos. 6,488,764 and. 6,184,287, the entire disclosures of which are incorporated herein by reference. Those of ordinary skill in the art will appreciate that other types of synthetic rubbers are also encompassed within the present invention.
  • the late strength enhancer comprises a water-in-oil emulsion that comprises styrene-butadiene rubber.
  • the aqueous phase of the emulsion comprises an aqueous colloidal dispersion of the styrene-butadiene copolymer.
  • the emulsion may comprise water in the range of from about 40% to about 70% by weight of the emulsion and small quantities of an emulsifier, polymerization catalysts, chain modifying agents, and the like.
  • styrene-butadiene latex is often produced as a terpolymer emulsion that may include a third, monomer to assist in stabilizing the emulsion.
  • Non-ionic groups which exhibit stearic effects and which contain long ethoxylate or hydrocarbon tails a!so may be present,
  • the weight ratio of the styrene to the butadiene in the emulsion may range from about 10:90 to about 90: iO. In some embodiments, the weight ratio of the styrene to the butadiene in the emulsion may range from about 20:80 to about 80:20.
  • An example of suitable styrene-butadiene latex has a styTene-to-biitadiene weight ratio of about 25:75 and comprises water in. an amount of about 50% by weight of the emulsion.
  • Another example of suitable styrene-butadiene latex has a styrene-to-butadiene weight ratio of about 30:70.
  • the latex strength enhancer may generally be provided in embodiments of the slag compositions in an amount sufficient for the desired application.
  • the late strength enhancer may be included in the slag compositions in an amount in the range of from about 1 % to about 45% bwoc.
  • the latex strength enhancer may be included, in the slag compositions in an amount in the range of from about 5% to about 20% bwoc, it should be understood that the concentrations of the latex strength enhancer are pro vided based on the amount of aqueous latex that may be used.
  • the slag compositions may further comprise hydraulic cement
  • hydraulic cements may be utilized in accordance with the present invention, including, but not limited to, those comprising calcium, aluminum, silicon, oxygen, iron, and/or sulfur, which set and harden b reaction with water.
  • Suitable hydraulic cements include, but are not limited to, Portland cements, pozzolana cements, gypsum cements, high alumina content cements, silica cements, and. any combination thereof
  • the hydraulic cement may comprise a Portland cement.
  • the Portland cements that are suited, for use in the present invention are classified as Classes A, C, II, and G cements according to American Petroleum Institute, API Specification for Materials and Testing for Well Cements, API Specification 10, Fifth Ed., July 1 , 1990.
  • cements suitable for use in the present invention may include cements classified as ASTM Type I, l or HI.
  • the hydraulic cement generally may be included in the slag compositions in an amount sufficient to provide the desired compressive strength, density, and/or cost.
  • the hydraulic cement may be present in the slag compositions of the present invention in an amount in the range of 0.1 % to about 60% bwoc, for example, about 10%, about 20%, about 30%, about 40%, about 50%, or about 60%.
  • the hydraulic cement may he included in an amount that does not exceed about 60% bwoc, does not exceed about 50% bwoc, does not exceed about 40% bwoc, does not exceed about 30% bwoc, does not exceed about 20% bwoc. does, not exceed about 20% bwoc, or does not exceed about 10% bwoc.
  • the slag compositions may further comprise a defoaming agent.
  • the defoaming agent should act, among other things, to prevent foaming during mixing of the slag composition.
  • the latex strength enhancer can include emulsifiers and latex stabilizers which can also functiono as foaming agents, an unstable foam can be formed when the slag is mixed with the latex strength enhancer and water.
  • the defoaming agen should prevent the formation of the unstable foam.
  • the defoaming agent can comprise any of a number of different compounds suitable for such capabilities, such as poiyols, silicon defoamers, alkyl polyaerylates, ethylene oxide/propylene oxide compounds, aeetylem ' e diols, and any combination thereo Norn limiting examples of suitable defoaming agents include those available from Halliburton. Energy Services under the names D-A1R 3000 " foamer, D-AIR 4000L ' foamer, and D ⁇ AIR 5000 ' '* foamer.
  • the deioaming agent may generally be provided in embodiments of the slag compositions in an amount sufficient for the desired application.
  • the defoaming agent may be presen in the slag compositions in an amount in the range of from about 0.1% to about 5% bwoc.
  • the defoaming additive may be included in an amount in the range of from about 0.1% to about 2% bwoc.
  • the slag compositions may further comprise a dispersant.
  • the. dispersant should act, among other things, to control the rheology of the slag composition. While a variety of dispersants known to those skilled in the art may ⁇ be used in accordance with the present invention, examples of suitable dispersaats include naphthalene sulfonic acid condensate with formaldehyde; acetone, formaldehyde, and sulfite condensate; melamme sulfonate condensed with formaldehyde; any combination thereof.
  • the dispersant should be present in embodiments of the slag compositions of the present invention in an amount sufficient to prevent gelation of the slag composition and/or improve rheologieal properties.
  • the dispersant may be present in the slag compositions in an amount in the range of from about 0.1% to about. 5% bwoc.
  • the water used in. embodiments of the slag compositions of the present invention may include- for example, freshwater, saltwater (e.g., water containing one or more salts dissolved therein), brine (e.g., saturated saltwater produced -from subterranean formations), seawaten or any combination thereof.
  • the water may be from any source, provided, for example, tit at it does not contain an excess of compounds thai may • undesirably affect other components in the slag composition.
  • the water may be included in an amount sufficient to form a pumpable slurry, in some embodiments, the water may be included in the slag compositions of the present invention in an amount of about 40% to. about 200% by dry weight of ceraentilious components ( bwoc"). In some embodiments, the water may be included in an amount of about 40% to about 150% bwoc.
  • additives suitable for use in subterranean cementing operations may also be added, to embodiments of the slag compositions, in accordance with embodiments of the present invention.
  • additives include, but are not limited to, strength- retrogression additives, set accelerators, set retarders, weighting agents, lightweight additives, gas-generating additives, mechanical property enhancing additives, lost- circulation materials, fihration-control additives, fluid lass control additives, foaming additives, thixotropic additives, and any combination thereof.
  • additives include crystalline silica, amorphous silica, fumed silica, salts, fibers, hydratable clays, calcined shale, vitrified shale, microspheres, fly ash, diafomaceous earth, metakaoHn, ground perlite, rice husk ash, natural po «zolan, zeolite, cement kiln dust, resins, any combination thereof and the like.
  • wil l readily be able to determine the type and amount of additive useful for -a particular application and desired result.
  • embodiments of the slag compositions generally should have a density suitable for a particular application.
  • embodiments of the slag compositions ' may have a density of about 12 pounds per gallon ("lb/gal") to about 20 lb/gal.
  • the slag compositions may have a density of about 14 lb/gal to abou 17 lb/gal.
  • the slag composition may be a heavyweight composition having a density of at least about 14 lb/gal.
  • the slag compositions may be prepared by combining the slag with water.
  • the latex strength enhancer and other additives may be combined with the water before it is added to the slag.
  • a base fluid may be prepared that comprises the latex strength enhancer- the defoaming additive, the dispersant, and the water, wherein the base fluid is then combined with the shut
  • the slag may be dr blended with other additives, such as the hydroxy! source andfar the hydraulic cement, to form a dry blend, wherein the dry blend may then be combined with the water or base fluid.
  • Other suitable techniques ma be used for preparation of the slag compositions as will be appreciated by those of ordinary skill, in the art in accordance with embodiments of the present invention.
  • embodiments of the slag compositions may be used in a. variety of subterranean applications, including primary and remedial cementing.
  • Embodiments may include providing a slag composition and allowing the slag composition to set.
  • Embodiments of the slag compositions may comprise, for example, slag, a hydroxy! source, a latex strength enhancer, and water.
  • Embodiments of the slag compositions may further comprise one or more of a hydraulic cement, a defoaming additive, or a dispersant. as well as a variety of other additives suitable for use in subterranean cementing applications as will be apparent to those of ordinary skill in the art.
  • a slag composition may be introduced into a subterranean formation between a conduit (e.g., pipe string, liner, etc. ⁇ and a well bore wall.
  • the slag composition may be allowed to set to form an annular sheath of hardened cement in the space between the well bore wall and the conduit Among other things, the sheath, farmed by the slag composition may form a barrier, preventing the migration of fluids in the well bore.
  • the sheath formed by the slag composition also may, for example, support the conduit in the well bore.
  • a slag composition may be used, for example, in squeeze-cementing operations or in the placement of plugs.
  • the slag composition may be placed in a well bore to plug a void or crack hi the formation, in a gravel pack, in the conduit, in the cement sheath, and/or a mieroaraiuius between the cement sheath and the conduit.
  • the slag composition may be placed into a well bore to form a plug in the well bore with the plug, for example, sealing the well, bore,
  • Samples 1-5 Five different slag compositions, designated Samples 1-5, were prepared using the indicated amounts of water, slag, lime, a latex strength enhancer, a late stabilizer, and a cement dispersant. The amounts of these components are indicated In the table below with percent by weight of cement ("% bwoc") indicating the percent of the component by weight of slag and gallon per sack ("gal'sk”) indicating the gallons of the respective component per 94-pound sack of slag.
  • the slag compositions had a density of 1 ,5 lb/gal.
  • the latex strength enhancer used was either LatexTM 2000 cement additive or LatexTM 3000 cement additive as indicated, i Table 1 below.
  • Sample 1 was a comparative composition that did not include the latex strength enhancer.
  • the latex stabilizer was Stabilizer 434DTM surfactant, from Halliburton Energy Services, inc., Duncan, Oklahoma,
  • the dispersant used was CFR-3LTM cement friction reducer, from Halliburton Energy Services, inc., Duncan, Oklahoma,
  • the slag compositions were subjected to 24-hour compressive strength tests at 340°P in accordance with API Specification 1.0,
  • Samples 6-S s were prepared using the indicated amounts of water, slag, lime, a latex strength enhancer, and a cement set retarder. The amounts of these components are indicated in the table below with % bwoc indicating the percent of the component by weight of slag and. gal/sfc indicating the gallons of the respective component per 94-pound sack of slag.
  • the slag compositions had a density of 14.5 lb/gal.
  • the latex strength enhancer used was LatexTM 3000 cement additive.
  • the cement set retarder used was HK ! ⁇ 5 retarder, from Halliburton Energy Services, Inc., Duncan, Oklahoma.
  • the slag compositions were tested to determine their thickening times at I40°F, which is the time required for the compositions to reach 70 Bearden units of consistency.
  • compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of or “consist of the various components and steps. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed.

Abstract

Methods and compositions are provided that relate to cementing operations. Methods and compositions that include a latex strength enhancer for enhancing the compressive strength of slag compositions.

Description

SLAG COMPOSITIONS COMPRISING LATEX AND METHODS OF USE
BACKGROUND
The present invention relates to cementing operations and. more particularly, in certain embodiments, to methods and compositions that utilize a latex strength enhancer for enhancing the compressive strength of slag compositions.
in cementing operations, such as well construction and remedial cementing, settable compositions are commonly utilized. As used herein, the term "settable composition" refers to a composition) thai hydraullcally sets or otherwise develops compressive strength. Settable compositions may be used in primary cementing operations whereby pip strings, such a easing and liners, are cemented in well bores. In a typical primary cementing operation, a settable composition may be pumped into an axmuhis between the walls of the well bore and the exterior surface of the pipe string disposed therein. The settable composition may set in the annular space, thereby forming an annular sheath of hardened, substantially impermeable material (e.g., a cement sheath) that may support and position the pipe string in the well bor and may bond the exterior surface of the pipe string to the well bore walls. Among other tilings, the cement sheath surrounding the pipe string should function to prevent the migratio of fluids in the annul us, as well as protecting the pipe string from corrosion. Settable compositions also may be used in remedial cementing methods, such as in the placement of pings, and in squeeze cementing for sealing voids in a pipe string, cement sheath, gravel pack, subterranean, formation, and the like.
A particular challenge in cementing operations is the development of satisfactory mechanical properties in a settable composition within a reasonable time period after placement in the subterranean formation. .During the life of a well, the subterranean cement sheath undergoes numerous strain and stresses as a result of temperature effects, pressure effects, and impact effects. The ability to withstand these strains and stresses is directly related to the mechanical properties of the settable composition after setting. The mechanical properties are often characterized using parameters such as compressive strength, tensile strength, Young's Modulus, Poisson's Ratio, elasticity, and the like. These properties may be modified by the incl usion of additives.
One type of settable composition that has been used heretofore comprises slag cement, which is typically a blend of Portland cement and. slag. Because Portland cement develops compressive strength much more rapidly than slag, the amount of slag is
I typically limited to no more than 40% by weight of the slag cement. Drawbacks to slag cement include the relatively high cost of the Portland cement as compared to the slag, which is a waste material.. Drawbacks to usina hi¾her concentrations of ska. mav include the inability for the settable composition to develop adequate compressive strength in a reasonable time and ensure the long-term struetural integrit of the cement.
Thus, there exists a need for settable compositions that comprise slag with enhanced mechanical features that develop adequate compressive strengt for use in cementing operations.
SUMMARY
An embodiment discloses a method of cementing, the method comprising: providing a slag composition comprising a hydraulic cement consisting essentially of slag, a hydroxyl source, a latex strength enhancer, and water; introducing the slag composition into a subterranean formation; and allowing the slag composition to set.
Another embodiment discloses a method of cementing, the method comprising: preparing a base fluid comprising a latex strength enhancer, a defoaming agent, and a dispersant; preparing a dry blend comprising slag and a hydroxyl source; combining the base fluid and the dry blend to form a slag composition; introducing the slag composition into a subterranean formation; and allowing the slag composition to set.
Yet another embodiment discloses a slag composition, the slag composition comprising: a hydraulic cement consisting essentially of slag: a hydroxyl source; a latex strength enhancer; and water.
The features and advantages of the present invention will be readily apparent to those skilled in the art. While numerous changes may be made b those skilled in the art. such changes are within Ihe spirit of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Embodiments of the present invention disclose slag compositions comprising slag, a hydroxy! source, a latex strength enhancer, and water. One of the many potential advantages of embodiments of the slag compositions i that use of the latex strength enhancer may provide the slag compositions with adequate compressive strengths for use in subterranean applications despite the increased slag content. By way of example, the compressive strength of the slag compositions containing the latex-strength enhancer may be increased, by at least about 25% in one embodiment, at least abou 50% in another embodiment, and at least about 75% in yet another embodiment, as compared to the same slag compositio that does not contain the latex strength enhancer. Accordingly, embodiments of the slag compositions may be used in a variety of subterranean applications where seitable compositions may be used, including, but not limited to, primary and remedial cementing.
In some embodiments, the slag compositions may comprise slag. Slag is generally a by-product in the production of various metals from their corresponding ores. By way of example, the production of cast, iron can produce slag as a granulated, blast furnace byproduct with the slag generally comprising the oxidized impurities found in iron ore. The slag may be included in embodiments of the slag compositions in an amount suitable for a particular application. In some embodiments, the sla may be present in an amount of about 40% to about 100% by weight of cementitious components ("bwoc"), for example, about 40%, about 50%, about 60%, about 70%, about 80%, about 90%, or about 100%, Cementitious components include those components or combinations of components of the slag compositions thai Irydraulicall set, or otherwise harden, to develop compressive strength, including, for example, slag, fly ash, hydraulic cement, and the like, in certain embodiments, the slag may be present in an amount greater than abou 40% bwoc, greater than about 50% bwoc, greater than about 60% bwoc, greater than about 70% bwoc, greater than about 80% bwoc, or greater than about 90% bwoc. hi som embodiments, hydraulic cement included in the slag compositions may consist essentially of the slag.
in some embodiments, the slag compositions may comprise a hydroxyl source. The hydroxy! source is included in the slag compositions for providing hydroxyl groups for activation of the sl ag to provide a settable composition t hat will react with the water to form a hardened mass in accordance with embodiments of the present in vention . Any of a variety of suitable hydroxy! sources may be used that are capable of generating hydroxyl groups (Off) when dissolved in the water. Examples of suitable hydr xyl sources include basic materials, such as sodium hydroxide, sodium bicarbonate, sodium carbonate, lime, and any combination thereof In some embodiments, the hydroxy! source may be present in the slag compositions in an amount in the range of from about 0.1% to about 25% bwoc. In further embodiments, the hydroxyl source may be included in an amount in the range of from about 1% to about 10% bwoc.
in some embodiments, the slag compositions may comprise a latex strength enhancer. Surprisingly, inclusion of the latex strength enhancer in embodiments of the slag compositions of the present invention, provides enhanced compressive strength as compared to slag compositions that do not contain the latex strength enhancer. As will be understood fay those skilled in the art, the latex strength enhancer may comprise any of a variety of rubber materials that are commercially available in latex form. Non-limiting examples of suitable rubber materials are available from Halliburton Energy Services, Duncan, Okia,, under the names Latex 2000'"' cement additive and Latex 3000"" cement additive. Suitable rubber materials include natural rubber (e.g., cis-l ,4-polyisoprene), modified natural rubber, synthetic .rubber, and combinations thereof. Synthetic rubber of various types may be utilized, including ethylene-propylene rubbers, styrene-butadiene rubbers, nitrile rubbers, nitrile butadiene rubbers, butyl rubber, neoprene rubber, polybufadtene rubbers, aerylonitrile-sty ene-butadiene rubber, polyisoprene rubber, AMPS~styrene~butadiene rubber, and any combination thereof. As used herein, the term "AMPS'" refers to 2-acrylamido-2-meihylpropanesulfbnic acid or salts thereof; in certain embodiments, the synthetic rubber ma comprise AMPS in m amount ranging .from about 5% to about 10% by weight, stymie in an amount ranging from about 30% to about 70% by weight, and butadiene in an amount ranging from about 30% to about 70% by weight. Examples of suitable AMPS-styrene-butadiene rubbers are described in more detail in U.S. Patent Nos. 6,488,764 and. 6,184,287, the entire disclosures of which are incorporated herein by reference. Those of ordinary skill in the art will appreciate that other types of synthetic rubbers are also encompassed within the present invention.
In certain embodiments, the late strength enhancer comprises a water-in-oil emulsion that comprises styrene-butadiene rubber. As will be appreciated, the aqueous phase of the emulsion comprises an aqueous colloidal dispersion of the styrene-butadiene copolymer. Moreover, in addition to the dispersed styrene-butadiene copolymer, the emulsion may comprise water in the range of from about 40% to about 70% by weight of the emulsion and small quantities of an emulsifier, polymerization catalysts, chain modifying agents, and the like. As will be appreciated, styrene-butadiene latex, is often produced as a terpolymer emulsion that may include a third, monomer to assist in stabilizing the emulsion. Non-ionic groups which exhibit stearic effects and which contain long ethoxylate or hydrocarbon tails a!so may be present,
in accordance with embodiments of the present invention, the weight ratio of the styrene to the butadiene in the emulsion may range from about 10:90 to about 90: iO. In some embodiments, the weight ratio of the styrene to the butadiene in the emulsion may range from about 20:80 to about 80:20. An example of suitable styrene-butadiene latex has a styTene-to-biitadiene weight ratio of about 25:75 and comprises water in. an amount of about 50% by weight of the emulsion. Another example of suitable styrene-butadiene latex has a styrene-to-butadiene weight ratio of about 30:70.
The latex strength enhancer may generally be provided in embodiments of the slag compositions in an amount sufficient for the desired application. In some embodiments, the late strength enhancer may be included in the slag compositions in an amount in the range of from about 1 % to about 45% bwoc. In further embodiments, the latex strength enhancer may be included, in the slag compositions in an amount in the range of from about 5% to about 20% bwoc, it should be understood that the concentrations of the latex strength enhancer are pro vided based on the amount of aqueous latex that may be used.
In some embodiments, the slag compositions may further comprise hydraulic cement A variety of hydraulic cements may be utilized in accordance with the present invention, including, but not limited to, those comprising calcium, aluminum, silicon, oxygen, iron, and/or sulfur, which set and harden b reaction with water. Suitable hydraulic cements include, but are not limited to, Portland cements, pozzolana cements, gypsum cements, high alumina content cements, silica cements, and. any combination thereof In certain embodiments, the hydraulic cement may comprise a Portland cement. In some embodiments, the Portland cements that are suited, for use in the present invention are classified as Classes A, C, II, and G cements according to American Petroleum Institute, API Specification for Materials and Testing for Well Cements, API Specification 10, Fifth Ed., July 1 , 1990. In addition, in some embodiments, cements suitable for use in the present invention may include cements classified as ASTM Type I, l or HI.
Where present, the hydraulic cement generally may be included in the slag compositions in an amount sufficient to provide the desired compressive strength, density, and/or cost. In some embodiments, the hydraulic cement ma be present in the slag compositions of the present invention in an amount in the range of 0.1 % to about 60% bwoc, for example, about 10%, about 20%, about 30%, about 40%, about 50%, or about 60%. In some embodiments, the hydraulic cement may he included in an amount that does not exceed about 60% bwoc, does not exceed about 50% bwoc, does not exceed about 40% bwoc, does not exceed about 30% bwoc, does not exceed about 20% bwoc. does, not exceed about 20% bwoc, or does not exceed about 10% bwoc.
In some embodiments, the slag compositions may further comprise a defoaming agent. Where present, the defoaming agent should act, among other things, to prevent foaming during mixing of the slag composition. Because the latex strength enhancer can include emulsifiers and latex stabilizers which can also functio as foaming agents, an unstable foam can be formed when the slag is mixed with the latex strength enhancer and water. In general, the defoaming agen should prevent the formation of the unstable foam. The defoaming agent can comprise any of a number of different compounds suitable for such capabilities, such as poiyols, silicon defoamers, alkyl polyaerylates, ethylene oxide/propylene oxide compounds, aeetylem'e diols, and any combination thereo Norn limiting examples of suitable defoaming agents include those available from Halliburton. Energy Services under the names D-A1R 3000" foamer, D-AIR 4000L ' foamer, and D~ AIR 5000''* foamer. The deioaming agent may generally be provided in embodiments of the slag compositions in an amount sufficient for the desired application. In some embodiments, the defoaming agent may be presen in the slag compositions in an amount in the range of from about 0.1% to about 5% bwoc. hi further embodiments, the defoaming additive may be included in an amount in the range of from about 0.1% to about 2% bwoc.
in some embodiments, the slag compositions may further comprise a dispersant. Where present, the. dispersant should act, among other things, to control the rheology of the slag composition. While a variety of dispersants known to those skilled in the art may¬ be used in accordance with the present invention, examples of suitable dispersaats include naphthalene sulfonic acid condensate with formaldehyde; acetone, formaldehyde, and sulfite condensate; melamme sulfonate condensed with formaldehyde; any combination thereof. Where used, the dispersant should be present in embodiments of the slag compositions of the present invention in an amount sufficient to prevent gelation of the slag composition and/or improve rheologieal properties. In some embodiments, the dispersant may be present in the slag compositions in an amount in the range of from about 0.1% to about. 5% bwoc. The water used in. embodiments of the slag compositions of the present invention may include- for example, freshwater, saltwater (e.g., water containing one or more salts dissolved therein), brine (e.g., saturated saltwater produced -from subterranean formations), seawaten or any combination thereof. Generally, the water may be from any source, provided, for example, tit at it does not contain an excess of compounds thai may undesirably affect other components in the slag composition. In some embodiments, the water may be included in an amount sufficient to form a pumpable slurry, in some embodiments, the water may be included in the slag compositions of the present invention in an amount of about 40% to. about 200% by dry weight of ceraentilious components ( bwoc"). In some embodiments, the water may be included in an amount of about 40% to about 150% bwoc.
Other additives suitable for use in subterranean cementing operations may also be added, to embodiments of the slag compositions, in accordance with embodiments of the present invention. Examples of such additives Include, but are not limited to, strength- retrogression additives, set accelerators, set retarders, weighting agents, lightweight additives, gas-generating additives, mechanical property enhancing additives, lost- circulation materials, fihration-control additives, fluid lass control additives, foaming additives, thixotropic additives, and any combination thereof. Specific examples of these, and other, additives include crystalline silica, amorphous silica, fumed silica, salts, fibers, hydratable clays, calcined shale, vitrified shale, microspheres, fly ash, diafomaceous earth, metakaoHn, ground perlite, rice husk ash, natural po«zolan, zeolite, cement kiln dust, resins, any combination thereof and the like. A person having ordinar skill in the art, with the benefit of this disclosure, wil l readily be able to determine the type and amount of additive useful for -a particular application and desired result.
Those of ordinary skill .in the art will appreciate that embodiments of the slag compositions generally should have a density suitable for a particular application. By way of example, embodiments of the slag compositions 'may have a density of about 12 pounds per gallon ("lb/gal") to about 20 lb/gal. In certain embodiments, the slag compositions may have a density of about 14 lb/gal to abou 17 lb/gal. In certain embodiments, the slag composition may be a heavyweight composition having a density of at least about 14 lb/gal. Those of ordinary skill in the art, with the benefit of this disclosure, wi ll recognize the appropriate density for a particular application,
in some embodiments, the slag compositions may be prepared by combining the slag with water. The latex strength enhancer and other additives may be combined with the water before it is added to the slag. For example, a base fluid may be prepared that comprises the latex strength enhancer- the defoaming additive, the dispersant, and the water, wherein the base fluid is then combined with the shut In some embodiments, the slag may be dr blended with other additives, such as the hydroxy! source andfar the hydraulic cement, to form a dry blend, wherein the dry blend may then be combined with the water or base fluid. Other suitable techniques ma be used for preparation of the slag compositions as will be appreciated by those of ordinary skill, in the art in accordance with embodiments of the present invention.
As will be appreciated by those of ordinary skill in the art, embodiments of the slag compositions may be used in a. variety of subterranean applications, including primary and remedial cementing. Embodiments ma include providing a slag composition and allowing the slag composition to set. Embodiments of the slag compositions may comprise, for example, slag, a hydroxy! source, a latex strength enhancer, and water. Embodiments of the slag compositions may further comprise one or more of a hydraulic cement, a defoaming additive, or a dispersant. as well as a variety of other additives suitable for use in subterranean cementing applications as will be apparent to those of ordinary skill in the art.
In primary cementing embodiments, for example, a slag composition may be introduced into a subterranean formation between a conduit (e.g., pipe string, liner, etc.} and a well bore wall. The slag composition may be allowed to set to form an annular sheath of hardened cement in the space between the well bore wall and the conduit Among other things, the sheath, farmed by the slag composition may form a barrier, preventing the migration of fluids in the well bore. The sheath formed by the slag composition also may, for example, support the conduit in the well bore.
In remedial cementing embodiments, a slag composition may be used, for example, in squeeze-cementing operations or in the placement of plugs. By way of example, the slag composition, may be placed in a well bore to plug a void or crack hi the formation, in a gravel pack, in the conduit, in the cement sheath, and/or a mieroaraiuius between the cement sheath and the conduit. In another embodiment, the slag composition may be placed into a well bore to form a plug in the well bore with the plug, for example, sealing the well, bore,
To facilitate a better understanding of the present invention, the following examples of some of the preferred embodiments are given. In no wa should such examples he read to limit, or to define, the scope of the invention. EXAMPLE I
The following series of tests were performed to evaluate the mechanical properties of slag compositions. Five different slag compositions, designated Samples 1-5, were prepared using the indicated amounts of water, slag, lime, a latex strength enhancer, a late stabilizer, and a cement dispersant. The amounts of these components are indicated In the table below with percent by weight of cement ("% bwoc") indicating the percent of the component by weight of slag and gallon per sack ("gal'sk") indicating the gallons of the respective component per 94-pound sack of slag. The slag compositions had a density of 1 ,5 lb/gal. The latex strength enhancer used was either Latex™ 2000 cement additive or Latex™ 3000 cement additive as indicated, i Table 1 below. Sample 1 was a comparative composition that did not include the latex strength enhancer. The latex stabilizer was Stabilizer 434D™ surfactant, from Halliburton Energy Services, inc., Duncan, Oklahoma, The dispersant used was CFR-3L™ cement friction reducer, from Halliburton Energy Services, inc., Duncan, Oklahoma, The slag compositions were subjected to 24-hour compressive strength tests at 340°P in accordance with API Specification 1.0,
TABLE 1
Figure imgf000011_0001
Based on the results of these tests, inclusion of latex strength enhancer in the slag compositions had a significant impact on compressive strength developmen For example, increases in compressive strength of least about. 50% (Sample 2) and up to about 95% (Sample 3) were obtained by including 2 gal/sk of the latex strength enhancer in the slag composi lion . EXAMPLE 2
The following series of tests were performed to evaluate the effect of including a latex strength enhancer on the thickening times of slag compositions. Three different slag compositions, designated Samples 6-Ss were prepared using the indicated amounts of water, slag, lime, a latex strength enhancer, and a cement set retarder. The amounts of these components are indicated in the table below with % bwoc indicating the percent of the component by weight of slag and. gal/sfc indicating the gallons of the respective component per 94-pound sack of slag. The slag compositions had a density of 14.5 lb/gal. The latex strength enhancer used was Latex™ 3000 cement additive. The cement set retarder used was HK! ~5 retarder, from Halliburton Energy Services, Inc., Duncan, Oklahoma. The slag compositions were tested to determine their thickening times at I40°F, which is the time required for the compositions to reach 70 Bearden units of consistency.
TABLE 2
Figure imgf000012_0001
Therefore, the present invention is well adapted to attain the ends and advantages mentioned as well as those thai are inherent therein. The particular embodiments disclosed above are illustrative only, as the present invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, the invention covers all combinations of all those embodiments, furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present invention. While compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps, the compositions and methods can also "consist essentially of or "consist of the various components and steps. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. Jn particular, every range of values (of the form, "about a to about V or, equivalent!}', "from, approximatel a to by' or, equivaieni!y, "'from approximately a~ b") disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values, Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitl and clearly defined by the patentee.

Claims

What is claimed is;
1. A method of cementing comprising;
providing a slag composition comprising;
a hydraulic cement consisting essentially of slag;
a hydroxy! source;
a latex strength enhancer; and
water;
introducing the slag composition into a subterranean formation; and allowing the slag composition to se
2. The method of claim 1, wherein the slag composition has a density of about 12 pounds per gallon to about 2(5 pounds per gallon.
3. The method of claim. 1, wherein the hydroxy! source comprises a basic material selected from the group consisting of sodium hydroxide, sodium bicarbonate, sodium carbonate, lime, and any combination thereof.
4. The method of claim 1, wherein hydroxy! source is present in an amount of about 0.1% t about 25% by weight of ee .entitious components in the slag composition,
5. The method of claim 1, wherein the latex strength enhancer comprises a rubber material selected from group consisting of ethylene-propylene rubber, styrene- butadiene rubber, nitrile rubber, nitrile butadiene rubber, butyl rubber, neoprene rubber, polybutadiene rubber, acrylomtrile-styrene-butadiene rubber, polyisoprene rubber, AMPS- styrene-butadiene rubber, and any combination thereof.
6. The method of claim 1 , wherein the latex strength enhancer comprises siyrene-bntadiene rubber,
7. Hie method of claim 1 , wherein the latex strength enhancer comprises AMPS-styrene-butadieiie rubber.
8. The method of claim 1 , wherein the latex strength enhancer is present in an amoun of abo t 1% to about 45% by weight of cementitious components in the slag composition,
9. The method of claim i , wherein the slag composition further comprises an additive selected from the group consisting of a dispersanf a defoaming agent, a strength- retrogression additive, a set accelerator, a set retarder, a weighting agent, a lightweight additive, a gas-generating additive, a mechanical property enhancing additive, a lost- circulation material, a filtration-control additive, a fluid loss control additive, a foaming additive, a thixotropic additive, and any combination thereof.
10. The method of claim 1 , wherein the slag composition further comprises an additive selected from, the group consisting of crystalline silica, amorphous silica, fumed silica, salt, a fiber, a hydraiahle clay, calcined shale, vitrified shale, a microsphere, diatomaceous earth, metakaoKn, ground perlite, rice husk ash, zeolite, a resin, and any combination thereof
1 S . The method of claim 1, wherein the slag composition further comprises a defoaming agent and. a dispersant, wherein the hydroxy! source is present in an. amount of about 1% to about 1.0% by weight of cementitious materials in the slag composition and comprises lime, wherein the latex strength enhancer is present in an amount of about 5% to about 20% by weight of ceme titious materials in the slag composition and comprises AMPS-styrene-butadiene rubber, and wherein the slag composition has a density of about 14 pounds per gallon to about 17 pounds per gallon.
12. The method of claim 1, wherein, introducing the slag composition into a subterranean formation comprises introducing the slag composition, into a space between a conduit and a well bore wall.
13. The method of claim 1, wherein the latex strength enhancer increases the 24-hour compressive strength of the slag composition at 140°F in an amount of at least about 25%.
14. A method of cementing comprising:
preparing a base fluid comprising a latex strength, enhancer, a defoaming agent, and a dispersant;
preparing a dry blend comprising slag and a hydroxy! source; combining the base fluid and the dry blend to form a slag composition; introducing the slag composition into a subterranean formation; and allowing the slag composition to set.
15. The method of claim 14, wherein the hydroxy! source comprises a basic material, selected from the group consisting of sodium, hydroxide, sodium bicarbonate, sodium carbonate, lime, and any combination thereof,
1.6. The method of claim 14, wherein hydroxy! source is present in the slag composition in an amount of about 0.1% to about 25% by weight of cementitious components in the slag composition.
17. The method of claim 14, wherein the latex strength enhancer comprises a rubber material selected from group consisting of ethylene-propylene rubber, styrene- butadiene rubber, nitri.Se rubber, nitrile butadiene rubber, butyl rubber, neoprene rubber, poiybutadiene rubber, aer>4onitrile-styrene-buiacliene rubber, pol ytsoprene rubber, AMPS- siyrene-bntadiene rubber, and any combination thereof,
18. The method of claim 14, wherein the latex strength enhancer is present in the slag composition an amount of about 1% to about 45% b weight of cementitious components in the slag composition,
19. The method of claim 14, wherein the slag is present in the slag composition in an amount of at least about 40% by weight of cemen.titi.ous components in the slag composition.
20. 'The method of claim 14, wherein the slag composition further comprises an additive selected from the group consisting of a strength-retrogression additive, a se accelerator, a set reiarder, a weighting agent, a lightweight additive, a gas-generating additive, a mechanical property enhancing additive, a lost-circulation material, a filtration- control additive, a fluid loss control additive, a foaming additive, a thkotropic additive, and any combination thereof.
21. The method of claim 1.4, wherein the slag composition further comprises an additive selected, from the group consisting of crystalline silica, amorphous silica, fumed silica, a salt, fiber, a hydratabie clay, calcined shale, vitrified shale, a microsphere, fly ash, diatoraaceous earth, metakaohn, ground perlite, rice husk ash, natural pozzolan, zeolite, cement kiln dust, a resin, and any combination thereof
22. The method of claim 14, wherein the hydroxy! source is present in the slag composition in art amount of about 1% to about 10% by weight of cementitious materials in the slag composition and comprises lime, wherein the latex strength enhancer is present in the slag composition in. an amount of about 5% to about 20% by weight of cementitious material in the slag composition and. comprises AMPS~styrene~but.ad.iene rubber, wherein the slag is present in the slag composition in an amount of at least about 40% by weight of cementitious components in the slag composition, and wherein the slag composition has a density of about 14 pounds per gallon to about 17 pounds per gallon.
23. The method of claim 14, wherein the dr blend further comprises a hydraulic cement
24. The method of claim 14, wherein introducing the slag composition into a subterranean formation comprises introducing the slag composition into a space be ween a conduit and a well bore wall,
25. A slag composition comprising:
a hydraulic cement consisting essentially of slag;
a hydroxy! source;
a latex strength enhancer; and
water.
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