Method of reacting CO2 by emulsifying concrete and use in oilwell cementing

Patent metadata

Field	Value
Publication number	US-12552978-B2
Application number	US-202217821438-A
Country	US
Kind code	B2
Filing date	Aug 22, 2022
Priority date	Aug 22, 2022
Publication date	Feb 17, 2026
Grant date	Feb 17, 2026

Abstract

A concrete emulsion comprising a cement, aggregate, water, and carbon dioxide is provided. The carbon dioxide may be liquid or supercritical and is dispersed in the concrete emulsion composition. A method of producing a concrete emulsion composition is also provided. The method includes mixing a cement, aggregate, and water to form a hydrated concrete composition, and emulsifying the hydrated concrete composition with liquid or supercritical CO 2 . An article comprising the concrete emulsion composition is provided. Further, a method of treating a wellbore comprising producing a concrete emulsion composition and pumping the concrete emulsion composition into a wellbore, and a method of manufacturing an article comprising producing a concrete emulsion composition and 3D printing the concrete emulsion composition are also provided.

First claim

What is claimed:

1 . A concrete emulsion composition comprising:
a concrete continuous phase comprising:
a cement,
water, and
aggregate; and
a dispersed carbon dioxide phase, wherein the carbon dioxide is liquid or supercritical and dispersed in the concrete emulsion composition.

2 . The concrete emulsion composition according to claim 1 , wherein the cement is selected from the group consisting of Class G and Class H cement.

3 . The concrete emulsion composition according to claim 1 , wherein the aggregate is sand.

4 . The concrete emulsion composition according to claim 1 , further comprising additives selected from the group consisting of crystalline silica, dispersants, retarders, surfactants, fluid loss control compounds, viscosifiers, weighting agents, CO 2 reactive compounds, accelerators, and combinations thereof.

5 . The concrete emulsion composition according to claim 1 , wherein the cement is present in an amount of 20% to 70% by total weight of the composition.

6 . The concrete emulsion composition according to claim 1 , wherein the aggregate is present in an amount of 20% to 90% by total weight of the composition.

7 . The concrete emulsion composition according to claim 1 , wherein the water is present in an amount of 30% to 80% by total weight of the composition.

8 . The concrete emulsion composition according to claim 1 , wherein the carbon dioxide is present in an amount of 1% to 90% by total weight of the composition.

9 . The concrete emulsion composition according to claim 4 , wherein the crystalline silica is present in an amount of 5% to 70% by weight of concrete.

10 . The concrete emulsion composition according to claim 4 , wherein the dispersants are present in an amount of 0.1% to 5% by weight of concrete.

11 . The concrete emulsion composition according to claim 4 , wherein the retarder is present in an amount of 0.1% to 5% by weight of concrete.

12 . The concrete emulsion composition according to claim 4 , wherein the surfactant is present in an amount of 1% to 10% by weight of concrete.

13 . The concrete emulsion composition according to claim 4 , wherein the fluid loss control compounds are present in an amount of 0.1% to 5% by weight of concrete.

14 . The concrete emulsion composition according to claim 4 , wherein the viscosifier is present in an amount of 0.1% to 5% by weight of concrete.

15 . The concrete emulsion composition according to claim 4 , wherein the weighting agent is present in an amount of 5% to 150% by weight of concrete.

16 . The concrete emulsion composition according to claim 1 , wherein the concrete emulsion composition is cured.

17 . The concrete emulsion composition according to claim 16 , wherein the cured concrete composition has a compressive strength of at least 18 MPa after 8 hours.

18 . A method for producing the concrete emulsion composition according to claim 1 , the method comprising:
mixing a cement, aggregate, and water to form a hydrated concrete composition; and emulsifying the hydrated concrete composition with liquid or supercritical CO 2 .

19 . The method according to claim 18 , wherein the hydrated concrete composition further comprises additives selected from the group consisting of crystalline silica, dispersants, retarders, surfactants, fluid loss control compounds, viscosifiers, weighting agents, CO 2 reactive compounds, and combinations thereof.

20 . The method according to claim 18 , wherein the method is performed at a temperature of 10 to 40° C.

21 . The method according to claim 18 , wherein the method is performed at a pressure of 14 psi to 3000 psi.

22 . An article formed from the concrete emulsion composition according to claim 1 .

23 . The article according to claim 22 , wherein the article is selected from the group consisting of bricks and concrete structures.

24 . A method of treating a wellbore, the method comprising the steps of:
Mixing a cement, aggregate, and water to form a hydrated concrete composition; and emulsifying the hydrated concrete composition with supercritical CO 2 to form the concrete emulsion composition of claim 1 ; and pumping the concrete emulsion composition into the wellbore.

25 . A method of manufacturing an article, the method comprising the steps of:
Mixing a cement, aggregate, and water to form a hydrated concrete composition; and emulsifying the hydrated concrete composition with supercritical CO 2 to form the concrete emulsion composition of claim 1 ; and 3D printing the concrete emulsion composition to produce the article.

Assignees

• Aramco Services Co
• Saudi Arabian Oil Co

Inventors

• Santra Ashok
• Boul Peter

Classifications

• E21B33/13

  Methods or devices for cementing, for plugging holes, crevices or the like · CPC title

• C04B2111/00181

  Mixtures specially adapted for three-dimensional printing (3DP), stereo-lithography or prototyping · CPC title

• C04B2111/00146

  Sprayable or pumpable mixtures · CPC title

• C04B2103/0029

  Type A · CPC title

• C04B40/0236

  Carbon dioxide post-treatment of already hardened material · CPC title