Nano zeolite cement additive and methods of use

Patent metadata

Field	Value
Publication number	US-10150904-B1
Application number	US-201815941350-A
Country	US
Kind code	B1
Filing date	Mar 30, 2018
Priority date	Mar 30, 2018
Publication date	Dec 11, 2018
Grant date	Dec 11, 2018

Abstract

The present invention discusses methods for making a cement composition comprising a nanoparticle zeolite. The addition of the nanoparticle zeolite may provide enhanced compressive and tensile strengths, improved rheology, and a change to the cement microstructure. These effects may improve the cement's use as a cement sheath in drilling operations and under high pressure and high temperature (HPHT) conditions.

First claim

The invention claimed is:

1. A method of making a cured cement material, comprising:
mixing
a hydraulic cement;
water and/or brine in an amount of 40-50% by weight of the hydraulic cement; and
0.5-4 wt % zeolite nanoparticles by weight of the hydraulic cement to form a wet cement slurry; and

curing the wet cement slurry to produce the cured cement material,
wherein the cured cement material comprises zeolite clusters having an average cluster diameter of 1-12 μm,
wherein the zeolite nanoparticles have an average diameter of 40-100 nm,
wherein the cured cement material is porous, with pores having an average diameter of 1-12 μm, and
wherein a subset of the zeolite clusters is located within the pores.

2. The method of claim 1 , wherein the hydraulic cement is selected from the group consisting of an API Class A Portland cement, an API Class G Portland cement, an API Class H Portland cement, and a Saudi Class G hydraulic cement.

3. The method of claim 1 , wherein the zeolite nanoparticles have a silica to alumina mass ratio of 1.2:1-3.0:1.

4. The method of claim 1 , wherein the zeolite nanoparticles comprise 1-6 wt % CaO relative to a total weight of the zeolite nanoparticles.

5. The method of claim 1 , wherein the wet cement slurry reaches a compressive strength of 2,000 psi within a time of curing which is 0.8-3.0 h faster than an essentially identical wet cement slurry that was not formed with zeolite nanoparticles.

6. The method of claim 1 , wherein the wet cement slurry is cured between a casing and a formation of a well bore.

7. The method of claim 1 , wherein the wet cement slurry further comprises silica flour.

8. The method of claim 7 , wherein the wet cement slurry further comprises at least one additive selected from the group consisting of an expanding agent, a dispersant, a fluid loss control agent, a retarder, a defoamer, a density reducing additive, a density enhancing weighting agent, a foaming agent, and a friction reducing agent.

9. The method of claim 8 , wherein the cured cement material has a compressive strength of 5,500-6,800 psi.

10. The method of claim 8 , wherein the wet cement slurry reaches a compressive strength of 2,000 psi within a time of curing which is 1.5-3.5 h faster than an essentially identical wet cement slurry that was not formed with zeolite nanoparticles.

11. The method of claim 1 , wherein the cured cement material has a weight of calcium silicate hydrate that is 20-70% lower than a second weight of calcium silicate hydrate of an essentially identical cured cement material made from a wet cement slurry that does not contain zeolite nanoparticles, relative to the second weight.

12. The method of claim 1 , wherein the cured cement material has a weight of calcium hydroxide that is greater by a factor of 1.5-3.0 than a second weight of calcium hydroxide of an essentially identical cured cement material made from a wet cement slurry that does not contain zeolite nanoparticles.

13. The method of claim 1 , wherein the pores have an average diameter of 3-10 μm.

14. The method of claim 1 , wherein the cured cement material has a hierarchical porosity.

15. The method of claim 1 , wherein the cured cement material has a porosity of 18-24%.

16. The method of claim 1 , wherein the cured cement material has a permeability of 0.0001-0.0010 md.

17. The method of claim 1 , wherein 30-80% of the zeolite clusters, relative to a total number of the zeolite clusters, is located within the pores.

18. The method of claim 1 , wherein the cured cement material further comprises calcium silicate hydrate at a weight percentage of 1-20 wt % relative to a total weight of the cured cement material.

19. The method of claim 1 , wherein the cured cement material further comprises calcium hydroxide at a weight percentage of 35-55 wt % relative to a total weight of the cured cement material.

20. The method of claim 1 , wherein the cured cement material further comprises calcium silicate at a weight percentage of 15-35 wt % relative to a total weight of the cured cement material.

Assignees

• Univ King Fahd Pet & Minerals

Inventors

• Rahman Muhammad Kalimur
• Baig Mirza Talha
• Al-Majed Abdulaziz

Classifications

• C04B14/047

  Zeolites · CPC title

• E21B33/14

  for cementing casings into boreholes · CPC title

• C04B14/043

  Alkaline-earth metal silicates, e.g. wollastonite · CPC title

• C04B22/064

  of the alkaline-earth metals · CPC title

• C04B28/02

  containing hydraulic cements other than calcium sulfates · CPC title