Title of Invention

SETTABLE COMPOSITIONS COMPRISING CEMENT KILN DUST AND ADDITIVE(S) AND METHOD OF USING THEM

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.

Full Text

The present invention relates to cementing operations and, more particularly, to enable compositions comprising water and cement kiln dust "CKD", and associated methods of use. 1 We claim: 1. A method of cementing comprising: providing a settable composition comprising: water; cement kiln dust present in the settable composition in an amount of at least 5% by weight of dry components in the settable composition; and an additive comprising at least one material selected from the group consisting of: shale present in the settable composition in an amount in the range of from 5% to 75% by weight of dry components in the settable composition; zeolite present in the settable composition in an amount in the range of from 5% to 65% by weight of dry components in the settable composition; metakaolin present in the settable composition in an amount in the range of from 10% to 50% by weight of dry components in the settable composition; and combinations thereof; introducing the settable composition into a wellbore; and allowing the settable composition to set to form a hardened mass therein. 2. The method as claimed in claim 1, wherein the water comprises at least one of the following group: freshwater; saltwater; a brine; seawater; and combinations thereof. 3. The method as claimed in claim 1, wherein the settable composition further comprises fly ash. 4. The method as claimed in claim 1, wherein the settable composition further comprises a hydraulic cement. 5. The method as claimed in claim 4, wherein the hydraulic cement is present in the settable composition in an amount in the range of from 5% to 90% by weight of dry components in the settable composition. 2 6. The method as claimed in claim 1, wherein the shale comprises vitrified shale. 7. The method as claimed in claim 1, wherein the zeolite comprises chabazite and clinoptilolite. 8. The method as claimed in claim 1, wherein the settable composition further comprises slag cement in an amoimt in the range of from 5% to 75% by weight of dry components in the settable composition. 9. The method as claimed in claim 8, wherein the slag cement comprises slag and a base. 10. The method as claimed in any one of claims 1 to 5, wherein the settable composition is foamed and fiirther comprises a gas, and a surfactant. 11. The method as claimed in claim 10, wherein the surfactant comprises a foaming and stabilizing surfactant composition. 12. The method as claimed in claim 1, wherein the settable composition fiirther 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. 13. The method as claimed in claim 10, wherein the gas comprises at least one of the following group: air; nitrogen; and combinations thereof 14. The method as claimed in claim 10, when dependent upon claim 3, wherein the fly ash is present in the foamed settable composition in an amount in the range of from 5% to 75% by weight of dry components in the settable composition. 15. The method as claimed in claim 10, wherein the foamed settable composition further comprises a source of calcium ions. 16. The method as claimed in claim 15, wherein the source of calcium ions is a lime. 3 17. The method as claimed in claim 16, wherein the lime is hydrated lime. 18. The method as claimed in claim 11, 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-olefmic sulfonate surfactant and a betaine surfactant; and combinations thereof 19. The method as claimed in claim 11, 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 method as claimed in claim 10, wherein the cement kiln dust is present in the foamed settable composition in an amount in the range of from 5% to 50% by weight of dry components in the settable composition; wherein the foamed settable composition fiirther comprises Portland cement in an amount in the range of from 20% to 90% by weight dry components in the settable composition; 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 0.8% to 5% by volume of the water present in the 4 foamed settable composition. 21. The method as claimed in claim 1, wherein the settable composition is foamed and further comprises a gas, and a surfactant, further comprising: foaming the settable composition with the gas to form the foamed settable composition. Dated this 07*" day of March, 2008 OdujUW*^^^ AISHWXRYAX IN/PA-1685 OF K «& S PARTNERS AGENT FOR THE APPLICANT

Documents:

1974-delnp-2008-Claims-(19-08-2013).pdf

1974-delnp-2008-Claims-(27-12-2012).pdf

1974-delnp-2008-Correspondence Others-(11-11-2013).pdf

1974-delnp-2008-Correspondence Others-(27-12-2012).pdf

1974-delnp-2008-Correspondence Others-(28-05-2008).pdf

1974-delnp-2008-Correspondence Others-(29-06-2012).pdf

1974-delnp-2008-Correspondence-Others-(03-04-2013).pdf

1974-delnp-2008-Correspondence-Others-(19-08-2013).pdf

1974-delnp-2008-Form-18-(28-05-2008).pdf

1974-delnp-2008-GPA-(19-08-2013).pdf

Form-1.pdf

Form-3.pdf

Form-5.pdf