US20110048697A1 - Sonically activating settable compositions - Google Patents
Sonically activating settable compositions Download PDFInfo
- Publication number
- US20110048697A1 US20110048697A1 US12/547,286 US54728609A US2011048697A1 US 20110048697 A1 US20110048697 A1 US 20110048697A1 US 54728609 A US54728609 A US 54728609A US 2011048697 A1 US2011048697 A1 US 2011048697A1
- Authority
- US
- United States
- Prior art keywords
- composition
- cement
- settable
- activator
- cement slurry
- 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.)
- Abandoned
Links
- 239000000203 mixture Substances 0.000 title claims abstract description 76
- 230000003213 activating effect Effects 0.000 title abstract description 10
- 239000004568 cement Substances 0.000 claims abstract description 202
- 239000012190 activator Substances 0.000 claims abstract description 64
- 230000004044 response Effects 0.000 claims abstract description 20
- 239000012530 fluid Substances 0.000 claims description 20
- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical group [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 claims description 14
- 239000001110 calcium chloride Substances 0.000 claims description 14
- 229910001628 calcium chloride Inorganic materials 0.000 claims description 14
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims description 12
- 150000003839 salts Chemical class 0.000 claims description 10
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 claims description 8
- 229920000642 polymer Polymers 0.000 claims description 8
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 7
- 239000005977 Ethylene Substances 0.000 claims description 7
- 239000004793 Polystyrene Substances 0.000 claims description 7
- 150000004645 aluminates Chemical class 0.000 claims description 7
- -1 amine compounds Chemical class 0.000 claims description 7
- 229920001577 copolymer Polymers 0.000 claims description 7
- 229920002223 polystyrene Polymers 0.000 claims description 7
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 claims description 6
- 239000000654 additive Substances 0.000 claims description 6
- ZCCIPPOKBCJFDN-UHFFFAOYSA-N calcium nitrate Chemical compound [Ca+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O ZCCIPPOKBCJFDN-UHFFFAOYSA-N 0.000 claims description 6
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 5
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 5
- 235000019422 polyvinyl alcohol Nutrition 0.000 claims description 5
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 claims description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 4
- 230000000996 additive effect Effects 0.000 claims description 4
- 239000011396 hydraulic cement Substances 0.000 claims description 4
- 239000003112 inhibitor Substances 0.000 claims description 4
- 229920003229 poly(methyl methacrylate) Polymers 0.000 claims description 4
- 239000004926 polymethyl methacrylate Substances 0.000 claims description 4
- 229910000029 sodium carbonate Inorganic materials 0.000 claims description 4
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 3
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 claims description 3
- 229920000954 Polyglycolide Polymers 0.000 claims description 3
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
- ANBBXQWFNXMHLD-UHFFFAOYSA-N aluminum;sodium;oxygen(2-) Chemical compound [O-2].[O-2].[Na+].[Al+3] ANBBXQWFNXMHLD-UHFFFAOYSA-N 0.000 claims description 3
- 150000001412 amines Chemical class 0.000 claims description 3
- 239000011575 calcium Substances 0.000 claims description 3
- 229910052791 calcium Inorganic materials 0.000 claims description 3
- 239000002019 doping agent Substances 0.000 claims description 3
- RAFRTSDUWORDLA-UHFFFAOYSA-N phenyl 3-chloropropanoate Chemical compound ClCCC(=O)OC1=CC=CC=C1 RAFRTSDUWORDLA-UHFFFAOYSA-N 0.000 claims description 3
- 229920000747 poly(lactic acid) Polymers 0.000 claims description 3
- 239000004633 polyglycolic acid Substances 0.000 claims description 3
- 239000004626 polylactic acid Substances 0.000 claims description 3
- 238000006116 polymerization reaction Methods 0.000 claims description 3
- 229920002635 polyurethane Polymers 0.000 claims description 3
- 239000004814 polyurethane Substances 0.000 claims description 3
- 229920002689 polyvinyl acetate Polymers 0.000 claims description 3
- 239000011118 polyvinyl acetate Substances 0.000 claims description 3
- 239000011734 sodium Substances 0.000 claims description 3
- 229910052708 sodium Inorganic materials 0.000 claims description 3
- 239000011780 sodium chloride Substances 0.000 claims description 3
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 3
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 2
- 229920001730 Moisture cure polyurethane Polymers 0.000 claims description 2
- 239000011398 Portland cement Substances 0.000 claims description 2
- 239000004115 Sodium Silicate Substances 0.000 claims description 2
- GSEJCLTVZPLZKY-UHFFFAOYSA-N Triethanolamine Chemical compound OCCN(CCO)CCO GSEJCLTVZPLZKY-UHFFFAOYSA-N 0.000 claims description 2
- SLINHMUFWFWBMU-UHFFFAOYSA-N Triisopropanolamine Chemical compound CC(O)CN(CC(C)O)CC(C)O SLINHMUFWFWBMU-UHFFFAOYSA-N 0.000 claims description 2
- 230000007423 decrease Effects 0.000 claims description 2
- ZBCBWPMODOFKDW-UHFFFAOYSA-N diethanolamine Chemical compound OCCNCCO ZBCBWPMODOFKDW-UHFFFAOYSA-N 0.000 claims description 2
- 229940043237 diethanolamine Drugs 0.000 claims description 2
- 239000010440 gypsum Substances 0.000 claims description 2
- 229910052602 gypsum Inorganic materials 0.000 claims description 2
- 239000011777 magnesium Substances 0.000 claims description 2
- 229910052749 magnesium Inorganic materials 0.000 claims description 2
- 229910001629 magnesium chloride Inorganic materials 0.000 claims description 2
- 239000000178 monomer Substances 0.000 claims description 2
- 239000000377 silicon dioxide Substances 0.000 claims description 2
- 229910001388 sodium aluminate Inorganic materials 0.000 claims description 2
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 2
- 229960004418 trolamine Drugs 0.000 claims description 2
- 239000011342 resin composition Substances 0.000 claims 1
- 239000002002 slurry Substances 0.000 abstract description 173
- 238000000034 method Methods 0.000 abstract description 28
- 230000015572 biosynthetic process Effects 0.000 abstract description 8
- 239000002775 capsule Substances 0.000 description 78
- 238000002604 ultrasonography Methods 0.000 description 32
- 238000004519 manufacturing process Methods 0.000 description 14
- 230000008569 process Effects 0.000 description 12
- 239000002585 base Substances 0.000 description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 9
- 150000001875 compounds Chemical class 0.000 description 7
- 238000005755 formation reaction Methods 0.000 description 7
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 6
- 230000007246 mechanism Effects 0.000 description 6
- 239000003921 oil Substances 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- 239000007789 gas Substances 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 239000012528 membrane Substances 0.000 description 5
- KCXVZYZYPLLWCC-UHFFFAOYSA-N EDTA Chemical compound OC(=O)CN(CC(O)=O)CCN(CC(O)=O)CC(O)=O KCXVZYZYPLLWCC-UHFFFAOYSA-N 0.000 description 4
- 239000000839 emulsion Substances 0.000 description 4
- 230000036571 hydration Effects 0.000 description 4
- 238000006703 hydration reaction Methods 0.000 description 4
- 239000003094 microcapsule Substances 0.000 description 4
- 150000003007 phosphonic acid derivatives Chemical class 0.000 description 4
- 238000005086 pumping Methods 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- 230000004913 activation Effects 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 229940042400 direct acting antivirals phosphonic acid derivative Drugs 0.000 description 3
- 238000005553 drilling Methods 0.000 description 3
- 238000002474 experimental method Methods 0.000 description 3
- 230000002209 hydrophobic effect Effects 0.000 description 3
- 230000000977 initiatory effect Effects 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 150000007524 organic acids Chemical class 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 229920006395 saturated elastomer Polymers 0.000 description 3
- 239000004094 surface-active agent Substances 0.000 description 3
- ZORQXIQZAOLNGE-UHFFFAOYSA-N 1,1-difluorocyclohexane Chemical compound FC1(F)CCCCC1 ZORQXIQZAOLNGE-UHFFFAOYSA-N 0.000 description 2
- 239000010755 BS 2869 Class G Substances 0.000 description 2
- RGHNJXZEOKUKBD-SQOUGZDYSA-N D-gluconic acid Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)[C@@H](O)C(O)=O RGHNJXZEOKUKBD-SQOUGZDYSA-N 0.000 description 2
- SRBFZHDQGSBBOR-IOVATXLUSA-N D-xylopyranose Chemical compound O[C@@H]1COC(O)[C@H](O)[C@H]1O SRBFZHDQGSBBOR-IOVATXLUSA-N 0.000 description 2
- 229910019142 PO4 Inorganic materials 0.000 description 2
- 229910000318 alkali metal phosphate Inorganic materials 0.000 description 2
- 150000001642 boronic acid derivatives Chemical class 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 230000003111 delayed effect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000004945 emulsification Methods 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 235000005985 organic acids Nutrition 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- PYUBPZNJWXUSID-UHFFFAOYSA-N pentadecapotassium;pentaborate Chemical compound [K+].[K+].[K+].[K+].[K+].[K+].[K+].[K+].[K+].[K+].[K+].[K+].[K+].[K+].[K+].[O-]B([O-])[O-].[O-]B([O-])[O-].[O-]B([O-])[O-].[O-]B([O-])[O-].[O-]B([O-])[O-] PYUBPZNJWXUSID-UHFFFAOYSA-N 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 2
- 239000010452 phosphate Substances 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- BWHMMNNQKKPAPP-UHFFFAOYSA-L potassium carbonate Chemical compound [K+].[K+].[O-]C([O-])=O BWHMMNNQKKPAPP-UHFFFAOYSA-L 0.000 description 2
- 239000001593 sorbitan monooleate Substances 0.000 description 2
- 235000011069 sorbitan monooleate Nutrition 0.000 description 2
- 229940035049 sorbitan monooleate Drugs 0.000 description 2
- 239000010754 BS 2869 Class F Substances 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- RGHNJXZEOKUKBD-UHFFFAOYSA-N D-gluconic acid Natural products OCC(O)C(O)C(O)C(O)C(O)=O RGHNJXZEOKUKBD-UHFFFAOYSA-N 0.000 description 1
- FEWJPZIEWOKRBE-JCYAYHJZSA-N Dextrotartaric acid Chemical compound OC(=O)[C@H](O)[C@@H](O)C(O)=O FEWJPZIEWOKRBE-JCYAYHJZSA-N 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical class [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 1
- 229910021578 Iron(III) chloride Inorganic materials 0.000 description 1
- 229920001732 Lignosulfonate Polymers 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- ABLZXFCXXLZCGV-UHFFFAOYSA-N Phosphorous acid Chemical compound OP(O)=O ABLZXFCXXLZCGV-UHFFFAOYSA-N 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical class [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 229920002125 Sokalan® Chemical class 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- FEWJPZIEWOKRBE-UHFFFAOYSA-N Tartaric acid Natural products [H+].[H+].[O-]C(=O)C(O)C(O)C([O-])=O FEWJPZIEWOKRBE-UHFFFAOYSA-N 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 239000003570 air Substances 0.000 description 1
- PYMYPHUHKUWMLA-UHFFFAOYSA-N arabinose Natural products OCC(O)C(O)C(O)C=O PYMYPHUHKUWMLA-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- SRBFZHDQGSBBOR-UHFFFAOYSA-N beta-D-Pyranose-Lyxose Natural products OC1COC(O)C(O)C1O SRBFZHDQGSBBOR-UHFFFAOYSA-N 0.000 description 1
- 238000009530 blood pressure measurement Methods 0.000 description 1
- 229910021538 borax Inorganic materials 0.000 description 1
- 239000012267 brine Substances 0.000 description 1
- VSGNNIFQASZAOI-UHFFFAOYSA-L calcium acetate Chemical compound [Ca+2].CC([O-])=O.CC([O-])=O VSGNNIFQASZAOI-UHFFFAOYSA-L 0.000 description 1
- 239000001639 calcium acetate Substances 0.000 description 1
- 235000011092 calcium acetate Nutrition 0.000 description 1
- 229960005147 calcium acetate Drugs 0.000 description 1
- 159000000007 calcium salts Chemical class 0.000 description 1
- YMIFCOGYMQTQBP-UHFFFAOYSA-L calcium;dichloride;hydrate Chemical compound O.[Cl-].[Cl-].[Ca+2] YMIFCOGYMQTQBP-UHFFFAOYSA-L 0.000 description 1
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- BVKZGUZCCUSVTD-UHFFFAOYSA-N carbonic acid Chemical class OC(O)=O BVKZGUZCCUSVTD-UHFFFAOYSA-N 0.000 description 1
- 125000002843 carboxylic acid group Chemical group 0.000 description 1
- 235000010980 cellulose Nutrition 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 230000009849 deactivation Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- HOOWDPSAHIOHCC-UHFFFAOYSA-N dialuminum tricalcium oxygen(2-) Chemical compound [O--].[O--].[O--].[O--].[O--].[O--].[Al+3].[Al+3].[Ca++].[Ca++].[Ca++] HOOWDPSAHIOHCC-UHFFFAOYSA-N 0.000 description 1
- UQGFMSUEHSUPRD-UHFFFAOYSA-N disodium;3,7-dioxido-2,4,6,8,9-pentaoxa-1,3,5,7-tetraborabicyclo[3.3.1]nonane Chemical compound [Na+].[Na+].O1B([O-])OB2OB([O-])OB1O2 UQGFMSUEHSUPRD-UHFFFAOYSA-N 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 239000010881 fly ash Substances 0.000 description 1
- 239000013505 freshwater Substances 0.000 description 1
- 238000001879 gelation Methods 0.000 description 1
- 239000000174 gluconic acid Substances 0.000 description 1
- 235000012208 gluconic acid Nutrition 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- RBTARNINKXHZNM-UHFFFAOYSA-K iron trichloride Chemical compound Cl[Fe](Cl)Cl RBTARNINKXHZNM-UHFFFAOYSA-K 0.000 description 1
- RUTXIHLAWFEWGM-UHFFFAOYSA-H iron(3+) sulfate Chemical compound [Fe+3].[Fe+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O RUTXIHLAWFEWGM-UHFFFAOYSA-H 0.000 description 1
- 229910000360 iron(III) sulfate Inorganic materials 0.000 description 1
- 159000000003 magnesium salts Chemical class 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000002480 mineral oil Substances 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 238000006386 neutralization reaction Methods 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 239000004584 polyacrylic acid Chemical class 0.000 description 1
- 229920005597 polymer membrane Polymers 0.000 description 1
- 239000011591 potassium Chemical class 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 229910000027 potassium carbonate Inorganic materials 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 150000003254 radicals Chemical class 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- 239000013535 sea water Substances 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 235000019830 sodium polyphosphate Nutrition 0.000 description 1
- 159000000000 sodium salts Chemical class 0.000 description 1
- 235000010339 sodium tetraborate Nutrition 0.000 description 1
- 239000004328 sodium tetraborate Substances 0.000 description 1
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000000527 sonication Methods 0.000 description 1
- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 239000001648 tannin Substances 0.000 description 1
- 229920001864 tannin Polymers 0.000 description 1
- 235000018553 tannin Nutrition 0.000 description 1
- 239000011975 tartaric acid Substances 0.000 description 1
- 235000002906 tartaric acid Nutrition 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/13—Methods or devices for cementing, for plugging holes, crevices, or the like
- E21B33/14—Methods or devices for cementing, for plugging holes, crevices, or the like for cementing casings into boreholes
-
- 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
- C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
- C04B20/10—Coating or impregnating
- C04B20/1018—Coating or impregnating with organic materials
- C04B20/1029—Macromolecular compounds
- C04B20/1033—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
-
- 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
- C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
- C04B40/06—Inhibiting the setting, e.g. mortars of the deferred action type containing water in breakable containers ; Inhibiting the action of active ingredients
- C04B40/0658—Retarder inhibited mortars activated by the addition of accelerators or retarder-neutralising agents
-
- 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
Definitions
- This invention relates to cementing operations and, more particularly, to sonically activating settable compositions.
- Some wellbores for example, those of some oil and gas wells, are lined with a casing.
- the casing stabilizes the sides of the wellbore.
- cement is introduced down the wellbore and into an annular space between the casing and the surrounding earth. The cement secures the casing in the wellbore, and prevents fluids from flowing vertically in the annulus between the casing and the surrounding earth.
- Different cement formulations are designed for a variety of wellbore conditions, which may be above ambient temperature and pressure. In designing a cement formulation, a number of potential mixtures may be evaluated to determine their mechanical properties under various conditions.
- a composition for treating a subterranean formation includes a settable composition and an activator.
- the activator is released in response to a sonic signal to initiate setting of the settable composition.
- FIG. 1 is an example well system for producing fluids from a production zone
- FIGS. 2A and 2B are example cementing process in the well system of FIG. 1 ;
- FIGS. 3A and 3B illustrate an example activation device for activating cement slurry in a wellbore
- FIGS. 4A and 4B illustrate example processes for releasing activators in cement slurries
- FIG. 5 is a flow chart illustrating an example method for activating deposited cement slurry
- FIG. 6 is a flow chart illustrating an example method for fabricating capsules
- FIGS. 7A-F illustrate example capsules for activating a cement slurry in the system of FIG. 1 ;
- FIG. 8 is another example well system for producing fluids from a production zone.
- FIGS. 9A-H illustrate example graphs demonstrating affects of sonic signals on cement slurries.
- the present disclosure is directed to one or more well systems having an on-command cement delivery system that selectively controls setting of a cement slurry.
- the described systems may use sonic irradiation (e.g., ultrasound, terahertz), such as in the range from about 20 Hz to 2 MHz, to release activators to initiate or accelerate the cement setting (see FIG. 1 ) and/or may use ultrasound to directly activate or accelerate cement slurries (see FIG. 8 ).
- the described systems may include a cement slurry and capsules that release activators into the cement slurry in response to ultrasound.
- An activator typically includes any chemicals that activate and/or accelerate the setting process for a cement slurry in the described systems.
- an activator may also retard or otherwise affect the setting or properties of the cement slurry.
- the described systems may include one or more of the following activators: sodium hydroxide, sodium carbonate, calcium chloride, calcium nitrite, calcium nitrate, and/or others.
- the capsules may include elements that substantially enclose one or more activators and that release the activator in response to at least sonic signals.
- the sonic signal may break or otherwise form an opening in the encapsulating element to release the one or more activators.
- the described systems may directly activate the cement slurry using one or more different mechanisms responsive to sonic signals.
- the one or more different mechanisms may include modifying chemical properties, releasing chemicals, modifying physical properties (e.g., particle size), updating operating conditions (e.g., pressure, temperature), and/or other mechanisms responsive to sonic signals.
- described systems may use sonic signals to directly minimize or otherwise reduce the effect of hydrophobic surfactants to, for example, enable the surfactants to enter into suspension and/or partially hydrate.
- the described systems may directly activate cement slurries using sonic signals independent of introducing or adding chemicals to the cement slurry.
- the systems may include free-radical dopants in cement slurries that release autocatalytic free radicals in response to at least ultrasonic signals.
- the sonic signals may trigger or otherwise activate a polymerization process in the cement slurry to provide in-situ polymerization.
- the described systems include a cement slurry in an annulus formed between a casing and a wellbore, and when the cement is set, the cement secures the casing in place. By selectively controlling the setting of a cement slurry, the described systems allow cement properties to be tailored once the cement slurry has been pumped down the borehole.
- the system 100 is a cross-sectional well system 100 that initiates or accelerates the setting of cement slurring using encapsulated activators.
- the well system 100 includes a production zone 102 , a non-production zone 104 , a wellbore 106 , a cement slurry 108 , and capsules 110 .
- the production zone 102 may be a subterranean formation including resources (e.g., oil, gas, water).
- the non-production zone 104 may be one or more formations that are isolated from the wellbore 106 using the cement slurry 108 .
- the zone 104 may include contaminants that, if mixed with the resources, may result in requiring additional processing of the resources and/or make production economically unviable.
- the cement slurry 108 may be pumped or selectively positioned in the wellbore 106 , and the setting of the cement slurry 108 may be activated or accelerated using the capsules 110 .
- the capsules 110 may release activators in response to ultrasound initiated by, for example, a user of the system 100 . By controlling the setting, a user may configure the system 100 without substantial interference from the setting of the cement slurry 108 .
- the wellbore 106 extends from a surface 112 to the production zone 102 .
- the wellbore 106 may include a rig 114 that is disposed proximate to the surface 112 .
- the rig 114 may be coupled to a casing 116 that extends the entire length of the wellbore or a substantial portion of the length of the wellbore 106 from about the surface 112 towards the production zones 102 (e.g., hydrocarbon-containing reservoir).
- the casing 116 can extend past the production zone 102 .
- the casing 116 may extend to proximate a terminus 118 of the wellbore 106 .
- the well 106 may be completed with the casing 116 extending to a predetermined depth proximate to the production zone 102 .
- the wellbore 106 initially extends in a substantially vertical direction toward the production zone 102 .
- the wellbore 106 may include other portions that are horizontal, slanted or otherwise deviated from vertical.
- the rig 114 may be centered over a subterranean oil or gas formation 102 located below the earth's surface 112 .
- the rig 114 includes a work deck 124 that supports a derrick 126 .
- the derrick 126 supports a hoisting apparatus 128 for raising and lowering pipe strings such as casing 116 .
- Pump 130 is capable of pumping a variety of wellbore compositions (e.g., drilling fluid, cement) into the well and includes a pressure measurement device that provides a pressure reading at the pump discharge.
- the wellbore 106 has been drilled through the various earth strata, including formation 102 .
- the casing 116 Upon completion of wellbore drilling, the casing 116 is often placed in the wellbore 106 to facilitate the production of oil and gas from the formation 102 .
- the casing 116 is a string of pipes that extends down wellbore 106 , through which oil and gas will eventually be extracted.
- a cement or casing shoe 132 is typically attached to the end of the casing string when the casing string is run into the wellbore. The casing shoe 132 guides the casing 116 toward the center of the hole and may minimize or otherwise decrease problems associated with hitting rock ledges or washouts in the wellbore 106 as the casing string is lowered into the well.
- the casing shoe 132 may be a guide shoe or a float shoe, and typically comprises a tapered, often bullet-nosed piece of equipment found on the bottom of the casing string 116 .
- the casing shoe 132 may be a float shoe fitted with an open bottom and a valve that serves to prevent reverse flow, or U-tubing, of cement slurry 108 from annulus 122 into casing 116 after the cement slurry 108 has been placed into the annulus 122 .
- the region between casing 116 and the wall of wellbore 106 is known as the casing annulus 122 .
- casing 116 is usually “cemented” in wellbore 106 , which is referred to as “primary cementing.”
- the cement slurry 108 may be injected into the wellbore 106 through one or more ports 134 in the casing shoe 132 .
- the cement slurry 108 may flow through a hose 136 into the casing 116 .
- the casing 116 may be supported by a liner hanger 138 near the bottom of a previous casing 120 .
- the system 100 may activate the setting of the cement slurry 108 using the capsules 110 during, for example, conventional primary cementing operation.
- the capsules 110 may be mixed into the cement slurry 108 prior to entering the casing 116 , and the cement slurry 108 may then be pumped down the inside of the casing 116 .
- the capsules 110 may be mixed in the cement slurry 108 at a density in the range of 4-24 pound per gallon (ppg). As the slurry 108 reaches the bottom of casing 116 , it flows out of casing 116 and into casing annulus 122 between casing 116 and the wall of wellbore 106 .
- plugs may be pumped by a wellbore servicing fluid (e.g., drilling mud) through casing 116 behind the cement slurry 108 .
- the wiper contacts the inside surface of casing 116 and pushes any remaining slurry 108 out of casing 116 .
- an ultrasonic signal may be transmitted before, during, and/or after the pumping is complete to activate the capsules 110 .
- the capsules 110 may release activators that initiate and/or accelerate the setting of the cement slurry 108 in the annulus 122 .
- the casing 116 may be affixed to the adjacent ground material with set cement 202 as illustrated in FIGS. 2A and 2B .
- the casing 116 comprises a metal. After setting, the casing 116 may be configured to carry a fluid, such as air, water, natural gas, or to carry an electrical line, tubular string, or other elements.
- a settable slurry 108 including capsules 110 may be pumped into annulus 122 by a pump truck (not illustrated). While the following discussion will center on the settable slurry 108 comprising a cement slurry 108 , the settable slurry 108 may include other compounds such as resin systems, settable muds, conformance fluids, lost circulation, and/or other settable compositions. Example cement slurries 108 are discussed in more detail below.
- the capsules 110 may release activators to activate or otherwise increase the setting rate of the cement slurry 108 in response to at least ultrasound. In other words, the released activators may activate the cement slurry 108 to set cement in the annulus 122 .
- the capsules 110 may release an activator that initiates or accelerates the setting of the cement slurry 108 .
- the cement slurry 108 may remain in a substantially slurry state for a specified period of time, and the capsules 110 may activate the cement slurry in response to ultrasound.
- ultrasound may crack, break or otherwise form one or more holes in the capsules 110 to release the activators.
- the ultrasound may generate heat that melts one or more holes in the capsules 110 .
- the capsules 110 enclose the activators with, for example, a membrane such as a polymer (e.g., polystyrene, ethylene/vinyl acetate copolymer, polymethylmethacrylate, polyurethanes, polylactic acid, polyglycolic acid, polyvinylalcohol, polyvinylacetate, hydrolyzed ethylene/vinyl acetate, or copolymers thereof).
- a membrane such as a polymer (e.g., polystyrene, ethylene/vinyl acetate copolymer, polymethylmethacrylate, polyurethanes, polylactic acid, polyglycolic acid, polyvinylalcohol, polyvinylacetate, hydrolyzed ethylene/vinyl acetate, or copolymers thereof).
- the capsule 110 may include other materials responsive to ultrasound.
- the capsule 110 may include a polymer membrane that ultrasonically degrades to release the enclosed activators.
- an ultrasonic signal may
- At least one dimension of the capsules 110 may be microscopic such as in range from 10 nanometers (nm) to 15,000 nm.
- the dimensions of the capsules 110 may be on a scale of a few tens to about one thousand nanometers and may have one or more external shapes including spherical, cubic, oval and/or rod shapes.
- the capsules 110 can be shells with diameters in the range from about 10 nm to about 1,000 nm. In other implementations, the capsules 110 can include a diameter in a range from about 15 micrometers to about 10,000 micrometers.
- the capsules 110 may be made of metal (e.g., gold) and/or of non-metallic material (e.g., carbon). In some implementations, the capsules 110 may be coated with materials to enhance their tendency to disperse in the cement slurry 108 . The capsules 110 may be dispersed in the cement slurry at a concentration of 10 5 to 10 9 capsules/cm 3 .
- the capsules 110 are a shell selected from the group consisting of a polystyrene, ethylene/vinyl acetate copolymer, and polymethylmethacrylate, polyurethanes, polylactic acid, polyglycolic acid, polyvinylalcohol, polyvinylacetate, hydrolyzed ethylene/vinyl acetate, and copolymers thereof.
- the release activator may include sodium hydroxide, sodium carbonate, amine compounds, salts comprising calcium, sodium, magnesium, aluminum, and/or a mixture thereof.
- the capsule 110 may release a calcium salt such as calcium chloride.
- the capsule 110 may release a sodium salt such as sodium chloride, sodium aluminate, and/or sodium silicate.
- the capsule 110 may release a magnesium salt such as magnesium chloride.
- the capsule 110 may release amine compounds such as triethanol amine, tripropanol amine, tri-isopropanol amine, and/or diethanol amine.
- the capsule 110 may release the activator in a sufficient amount to set the cement slurry 108 within about 1 minute to about 24 hours.
- the concentration may be in the range of from about 3% to about 30% by weight of the cement in the cement slurry 108 .
- the concentration may be in the range of from about 0.5% to about 5% by weight of the cement in the cement slurry 108 .
- the release activator may include amine accelerators for a epoxy/novalac resins.
- the capsule 110 may “flash-set” the cement slurry 108 .
- flash-set will be understood to mean the initiation of setting of the cement slurry 108 within about 1 minute to about 15 minutes after contacting the released activator.
- the previously identified activators may flash set the cement slurry 108 .
- Flash-set activators may include sodium hydroxide, sodium carbonate, potassium carbonate, bicarbonate salts of sodium or potassium, sodium silicate salts, sodium aluminate salts, ferrous and ferric salts (e.g., ferric chloride and ferric sulfate), polyacrylic acid salts, and/or others.
- the following activators can flash-set the cement slurry 108 based on these activators exceeding a specified concentration: calcium nitrate, calcium acetate, calcium chloride, and/or calcium nitrite.
- the capsule 110 may release a solid activator.
- the cement slurry 108 may comprise a “delayed set” cement compositions that remain in a slurry state (e.g., resistant to setting or gelation) for an extended period of time.
- a delay-set cement slurry 108 may include a cement, a base fluid, and a set retarder.
- activation may change the state of the cement slurry from delay set to neutral, to accelerated, or to less delayed.
- the cement slurry 108 may include other additives.
- the delayed-set cement slurry 108 typically remains in a slurry state for in range of about 6 hours to about 4 days under downhole or other conditions.
- the cement slurry 108 may include components that result in a slurry state for a greater, or shorter, amount of time.
- the cement slurry 108 may be mixed or otherwise made well ahead of positioning the slurry 108 in the annulus 122 .
- the delayed-set cement slurry 108 can, in some implementations, include a cement, a base fluid, and a set retarder.
- the delayed-set cement slurry 108 may be set at a desired time, such as after placement, by activating the capsules 110 to release one or more activators.
- delayed-set cement slurry 108 may include a hydraulic cement.
- hydraulic cements typically include calcium, aluminum, silicon, oxygen, and/or sulfur and may set and harden by reaction with water.
- Hydraulic cements include, but are not limited to, Portland cements, pozzolanic cements, high aluminate cements, gypsum cements, silica cements, high alkalinity cements, and/or Sorel cements.
- the delayed-set cement slurry 108 may include cements based on shale or blast furnace slag.
- the shale may include vitrified shale, raw shale (e.g., unfired shale), and/or a mixture of raw shale and vitrified shale.
- the settable composition 108 includes a polymer additive comprising at least one of a monomer, a pre-polymer, an oligomer, or a short chain polymer that polymerizes in response to the sonic signal
- the delayed-set cement slurry 108 may include one or more base fluids such as, for example, an aqueous-based base fluid, a nonaqueous-based base fluid, or mixtures thereof.
- Aqueous-based may include water from any source that does not contain an excess of compounds (e.g., dissolved organics, such as tannins) that may adversely affect other compounds in the cement slurry 108 .
- the delayed-set cement slurry 108 may include fresh water, salt water (e.g., water containing one or more salts), brine (e.g., saturated salt water), and/or seawater.
- Nonaqueous-based may include one or more organic liquids such as, for example, mineral oils, synthetic oils, esters, and/or others.
- any organic liquid in which a water solution of salts can be emulsified may be suitable for use as a base fluid in the delayed-set cement slurry 108 .
- the base fluid exceeds a concentration sufficient to form a pumpable slurry.
- the base fluid may be water in an amount in the range of from about 25% to about 150% by weight of cement (“bwoc”) such as one or more of the following ranges: about 30% to about 75% bwoc; about 35% to about 50% bwoc; about 38% to about 46% bwoc; and/or others.
- the cement slurry 108 may include one or more different types of set retarders such as, for example, phosphonic acid, phosphonic acid derivatives, lignosulfonates, salts, organic acids, carboxymethylated hydroxyethylated celluloses, synthetic co- or ter-polymers comprising sulfonate and carboxylic acid groups, and/or borate compounds.
- set retarders used in the present invention are phosphonic acid derivatives. Examples of set retarders may include phosphonic acid derivatives commercially available from, for example, Solutia Corporation of St. Louis, Mo.
- Example borate compounds may include sodium tetraborate, potassium pentaborate, and/or others.
- a commercially available example of a suitable set retarder comprising potassium pentaborate is available from Halliburton Energy Services, Inc. under the trade name “Component R.”
- Example organic acids may include gluconic acid, tartaric acid, and/or others.
- An example of a suitable organic acid may be commercially available from Halliburton Energy Services, Inc. under the trade name “HR® 25.”
- Other examples of set retarders may be commercially available from Halliburton Energy Services, Inc.
- the set retarder in the delayed-set cement slurry 108 may be in an amount sufficient to delay the setting in a subterranean formation for a specified time.
- the amount of the set retarder included in the cement slurry 108 may be in one or more of the following ranges: about 0.1% to about 10% bwoc; about 0.5% to about 4% bwoc; and/or others.
- the cement slurry 108 may not include a set retarder.
- the system slurry 108 may include high aluminate cements and/or phosphate cements independent of a set retarder.
- the activators may initiate setting of the slurry 108 .
- these activators may include alkali metal phosphate salts.
- High aluminate cement may comprise calcium aluminate in an amount in the range of from about 15% to about 45% by weight of the high aluminate cement, Class F fly ash in an amount in the range of from about 25% to about 45% by weight of the high aluminate cement, and sodium polyphosphate in an amount in the range of from about 5% to about 15% by weight of the high aluminate cement.
- a reactive component of the cement composition e.g., the alkali metal phosphate salt
- the alkali metal phosphate salt may be used as an activator.
- FIGS. 2A and 2B illustrate a cross sectional view of the well system 100 including activated set cement 202 in at least a portion of the annulus 122 .
- the capsules 110 released activators in at least a portion of the cement slurry 108 to form the set cement 202 .
- the cement slurry flowed into the annulus 122 through the casing 116 , and in response to at least a signal, the capsules 110 in the slurry 108 released an activator.
- substantially all capsules 110 in the annulus 122 released activators to form the set cement 202 along substantially the entire length of the annulus 122 .
- the cement slurry 108 flowed into the annulus 122 through the casing 116 , and in response to at least an ultrasonic signal, the capsules 110 in the slurry 108 released activators within a specified location 204 .
- the region or location 204 is located proximate the zone 102 .
- the capsules 110 proximate the zone 102 may release activators and form the set cement 202 located in the region 204 .
- the ultrasonic signal may be localized to the region identified by 204 , and in response to at least the localized signal, the set cement 204 forms.
- an initial amount of the cement slurry 108 may be exposed to an ultrasonic signal such that the setting period may be substantially equal to a period of time for the setting cement slurry 108 to flow to the location 204 .
- the cement slurry 108 may be exposed to the ultrasonic signal as the slurry 108 including the capsules 110 enters the casing 116 .
- fluid flow through the annulus 122 may become more restricted and may eventually cease.
- the cement slurry 108 may be substantially prevented from flowing onto the surface 112 through the annulus 122 .
- the remainder of the cement slurry 108 may set in the annulus 122 behind the leading edge as illustrated in FIG. 2A or the cement slurry 108 may set at a later time as illustrated in FIG. 2B . In the later, the remaining cement slurry 108 may be exposed to ultrasonic signals at a later time to initiate or accelerate the setting processes.
- FIGS. 3A and 3B illustrates an example capsule 110 of FIG. 1 in accordance with some implementations of the present disclosure.
- the capsule 110 is spherical but may be other shapes as discussed above.
- the capsule 110 is a shell 302 encapsulating one or more activators 304 as illustrated in FIG. 3B .
- the capsule 110 releases one or more stored activators 304 in response to at least an ultrasonic signal.
- the capsule 110 may crack or otherwise form one or more holes in response to at least the ultrasonic signal.
- the illustrated capsule 110 is for example purposes only, and the capsule 110 may include some, none, or all of the illustrated elements without departing from the scope of this disclosure.
- FIGS. 4A and 4B illustrate example implementations of the capsules 110 releasing one or more activators.
- the capsules 110 may release activators by heating one or more portions to form at least one opening, destroying or otherwise removing one or more portions, and/or other processes.
- the following implementations are for illustration purposes only, and the capsules 110 may release activators using some, all or none of these processes.
- the capsule 110 forms an opening through heat formed from ultrasonic signals.
- the ultrasonic signals may directly heat the membrane of the capsule 110 and/or heat the surrounding cement slurry 108 to a temperature above the melting point.
- the capsule 110 may be a gold shell that when vibrated at its natural frequency melts at least a portion of the shell to release the enclosed activators. In these instances, the generated heat may melt or otherwise deform the shell to form an opening.
- the capsule 110 may be other materials such as a polymer.
- the capsule 110 forms cracks, breaks, or openings in response ultrasonic signals.
- the ultrasonic signal may crack or otherwise destroy portions of the capsule 110 .
- the ultrasound may form defects in the membrane of the capsule and, as a result, form one or more openings as illustrated.
- FIGS. 5 and 6 are flow diagrams illustrating example methods 500 and 600 for implementing and manufacturing devices including one or more activators.
- the illustrated methods are described with respect to well system 100 of FIG. 1 , but these methods could be used by any other system.
- well system 100 may use any other techniques for performing these tasks. Thus, many of the steps in these flowcharts may take place simultaneously and/or in different order than as shown.
- the well system 100 may also use methods with additional steps, fewer steps, and/or different steps, so long as the methods remain appropriate.
- method 500 begins at step 502 where capsules are selected based, at least in part, on one or more parameters.
- the capsules 110 and the enclosed activators may be based, at least in part, on components of the cement slurry 108 .
- the capsules 110 may be selected based on downhole conditions (e.g., temperature).
- the selected capsules are mixed with a cement slurry.
- the capsules 110 may be mixed with the cement slurry 108 as the truck 130 pumps the slurry into the annulus 122 .
- the capsules 110 may be mixed with dry cement prior to generating the cement slurry 108 .
- the cement slurry including the capsules are pumped downhole.
- the cement slurry 108 including the capsules 110 may be pumped into the annulus 122 at a specified rate.
- One or more ultrasonic signals are transmitted to the at least a portion of the downhole cement slurry at step 508 .
- the transmitter may be lowered into the casing to transmit signals at a portion of the cement slurry 108 .
- the transmitted signals may activate the capsules 110 proximate the shoe 132 to set that portion of the cement slurry 108 as illustrated in FIG. 2B .
- the casing 116 may be moved (e.g., up/down) to assist in distributing the activators as desired.
- the method 600 begins at step 602 where a first emulsification step is performed.
- a polystyrene dissolved in CH 2 Cl 2 where saturated aqueous CaCl 2 may be emulsified using WS-36 (Sorbitan Monooleate).
- the first emulsification may then again be emulsified in a second step.
- the first emulsion may then be subsequently emulsified into a large volume (e.g., 10 ⁇ excess) of a 2% polyvinylalcohol solution.
- FIGS. 7A-F illustrate an example implementation of the capsules 110 in accordance with some implementations of the present disclosure.
- the capsules 110 encapsulate activators, and power ultrasound may break the capsules to release the activators on command.
- the illustrated capsules 110 are polystyrene microcapsules encapsulating aqueous CaCl 2 .
- the capsules 110 may be formed from other materials such as ethylene/vinyl acetate copolymer, polymethylmethacrylate, and/or others. In some instances, these types of capsules 110 may be created using a double emulsion technique.
- the technique may include a polystyrene dissolved in CH 2 Cl 2 where saturated aqueous CaCl 2 was emulsified using WS-36 (Sorbitan Monooleate).
- this emulsion may then be subsequently emulsified into a large volume (e.g., 10 ⁇ excess) of a 2% polyvinylalcohol solution.
- the double emulsion was stirred and heated to about 30° C. to drive off CH 2 Cl 2 and concentrate the polystyrene ultimately forming liquid filled microcapsules.
- four different cement slurries were tested and the results are graphed in FIGS. 7C-F .
- a retarded slurry, a retarded slurry with CaCl 2 , a retarded slurry with the microcapsules, and a retarded slurry with the microcapsules treated with sonication were evaluated.
- a 20 kHz ultrasonic horn was used for ten minutes at 50% power to treat the sonicated sample.
- the composition and results are listed in Tables 1-3 below.
- the illustrated parameters including operating conditions are for illustration purposes only.
- the system 100 may use some, all or none of the values without departing from the scope of this disclosure.
- FIG. 8 is another example system 100 that directly activates the cement slurry 108 using ultrasonic signals.
- ultrasonic transducers 802 a and 802 b may be affixed to the exterior of the casing 116 and emit ultrasound to sonically activate the cement slurry.
- the system 100 may set cement on-demand.
- the system 100 may set the cement slurry 108 in a period of the range from 1 hour to 1 day.
- the sonic transducers 802 may directly activate the cement slurry 108 using one or more different mechanisms responsive to sonic signals.
- the one or more different mechanisms may include modifying chemical properties, releasing chemicals, modifying physical properties (e.g., particle size), updating operating conditions (e.g., pressure, temperature), and/or other mechanisms responsive to sonic signals.
- the sonic transducers 802 may reduce the particulate size in the cement slurry 108 and, as a result, may increase the surface area. By increasing the surface area, the setting process may be initiated, accelerated, or otherwise activated.
- the sonic signals may increase the pressure and/or temperature and, as a result, may initiate, accelerate, or otherwise activate the setting process.
- the ultrasonic transducers 802 may activate accelerators in the cement slurry 108 and/or deactivate cement retarders in the cement slurry 108 to set the cement on demand.
- the ultrasonic transducers 802 may generate ultrasonic or acoustic waves to initiate the setting process of the cement slurry 108 through, for example, the selective activation of accelerators in the cement slurry 108 such as CaCl 2 and/or the deactivation of cement retarders in the cement slurry 108 such as xylose.
- cement hydration inhibitors in relatively low concentration can work to alter the surface energy of the tricalcium aluminate, silicate and/or other compounds in the cement slurry 108 , which can make the compounds more hydrophobic.
- the transducers 802 may ultrasonically agitate the cement slurry 108 to reduce the effect of hydrophobic surfactants, which may enable the compounds to enter into solution and/or partially hydrate.
- the transducers 802 may generate ultrasonic signals having a frequency that substantially matches the resonant conditions for inhibitor neutralization.
- the system 100 may execute frequency tuning to substantially optimize frequency and power combinations for a given geometry and inhibitor chemistry. In these instances, a user of the system 100 may remotely control the initiation of cement hydration.
- the system 100 may initiate an autocatalytic process.
- the transducers 802 may generate ultrasonic signals that sets off an autocatalytic free-radical release that propagates through the cement slurry 108 .
- this process may initiate from a single point.
- the cement slurry 108 may include additives (e.g., free-radical dopants) that release free-radical species through out the slurry 108 in response to at least ultrasonic initiation or hydration.
- FIGS. 9A-H illustrate example graphs demonstrating affects of sonic signals on cement slurries.
- measurements were made on cement slurries that were sonically activated in comparison to cement slurries not sonically activated.
- ultrasound was used to accelerated the set of retarded cement slurries.
- the cement slurries were retarded using one of the following three retarders: EDTA; a combination of FDP-C742A and EDTA; and a combination of FDP-C742A and Component R.
- the cement slurries pumped between 6.5 hours to 80 hours. After exposure to 20 kHz of ultrasound, the pump times for these slurries may be reduced 40-50%.
- the graph 910 plots data for cement slurry comprising 16.4 PPG (Class H cement, neat) operating at 120° F. and 3600 PSI in 30 minutes.
- the cement slurry was not exposed to ultrasound.
- the graph 910 includes a peak 912 indicating the pump time to be 2 hours and 23 minutes.
- the graph 920 plots data for the same cement slurry as graph 910 including exposure to 20 kHz ultrasound for seven minutes. In this experiment, the ultrasound was shut off after 5 minutes to due to an increase in the cement-slurry temperature. The cement slurry was exposed to an additional 2 minutes of the ultrasound once cooled.
- the graph 920 includes a peak 922 indicating the pump time to be 2 hours.
- the graph 930 plots data for cement slurry comprising 16.4 PPG (Class H cement, 1% EDTA) operating at 120° F. and 3600 PSI in 30 minutes.
- the cement slurry was not exposed to ultrasound.
- the graph 930 includes a peak 932 indicating the pump time to be 7 hours and 45 minutes.
- the graph 940 plots data for the same cement slurry as graph 930 including exposure to 20 kHz ultrasound for 7 minutes (5 minutes on, 2 minutes off, 2 minutes on). In this experiment, the ultrasound was shut off after 5 minutes due to an increase in the cement-slurry temperature.
- the cement slurry was exposed to an additional 2 minutes of the ultrasound once cooled.
- the pump time was 4 hours 15 minutes.
- the graph 950 plots data for cement slurry comprising 16.4 PPG (Class G cement w/35% SSA-1; 10.4 SSA-1; 1% CFR-3; 0.8% Halad-200; 0.4 gal/sk Gascon 469; 1.8% FDP-C742A; 1.8% EDTA; 0.3 gal/sk NF-6) with the % in bwoc.
- the operating conditions were 400° F. and 13100 PSI in 90 minutes.
- the cement slurry was not exposed to ultrasound.
- the pump time was 6 hours and 46 minutes.
- the graph 960 plots data for the same cement slurry as graph 950 including exposure to 20 kHz ultrasound for 15 minutes (10 minutes on, 1 minutes off, 5 minutes on).
- the ultrasound was shut off after 10 minutes due to an increase in the cement-slurry temperature.
- the cement slurry was exposed to an additional 5 minutes of the ultrasound once cooled.
- the pump time was 3 hours 15 minutes.
- the graph 970 plots data for cement slurry comprising 16.4 PPG (Class G cement w/35% SSA-1; 10.4 SSA-1; 1% CFR-3; 0.8% Halad-200; 0.4 gal/sk Gascon 469; 1.8% FDP-C742A; 0.8% Compound R; 0.3 gal/sk NF-6) with the % in bwoc.
- the operating conditions were 422° F. and 13100 PSI in 90 minutes.
- the cement slurry was not exposed to ultrasound.
- the pump time was 79 hours.
- the graph 980 plots data for the same cement slurry as graph 970 including exposure to 20 kHz ultrasound for 15 minutes (5 minutes intervals). The pump time was 50 hours.
- 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.
Abstract
Description
- This invention relates to cementing operations and, more particularly, to sonically activating settable compositions.
- Some wellbores, for example, those of some oil and gas wells, are lined with a casing. The casing stabilizes the sides of the wellbore. In a cementing operation, cement is introduced down the wellbore and into an annular space between the casing and the surrounding earth. The cement secures the casing in the wellbore, and prevents fluids from flowing vertically in the annulus between the casing and the surrounding earth. Different cement formulations are designed for a variety of wellbore conditions, which may be above ambient temperature and pressure. In designing a cement formulation, a number of potential mixtures may be evaluated to determine their mechanical properties under various conditions.
- The present disclosure is directed to a system and method for sonically activating cement slurries. In some implementations, a composition for treating a subterranean formation includes a settable composition and an activator. The activator is released in response to a sonic signal to initiate setting of the settable composition.
- The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
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FIG. 1 is an example well system for producing fluids from a production zone; -
FIGS. 2A and 2B are example cementing process in the well system ofFIG. 1 ; -
FIGS. 3A and 3B illustrate an example activation device for activating cement slurry in a wellbore; -
FIGS. 4A and 4B illustrate example processes for releasing activators in cement slurries; -
FIG. 5 is a flow chart illustrating an example method for activating deposited cement slurry; -
FIG. 6 is a flow chart illustrating an example method for fabricating capsules; -
FIGS. 7A-F illustrate example capsules for activating a cement slurry in the system ofFIG. 1 ; -
FIG. 8 is another example well system for producing fluids from a production zone; and -
FIGS. 9A-H illustrate example graphs demonstrating affects of sonic signals on cement slurries. - Like reference symbols in the various drawings indicate like elements.
- The present disclosure is directed to one or more well systems having an on-command cement delivery system that selectively controls setting of a cement slurry. For example, the described systems may use sonic irradiation (e.g., ultrasound, terahertz), such as in the range from about 20 Hz to 2 MHz, to release activators to initiate or accelerate the cement setting (see
FIG. 1 ) and/or may use ultrasound to directly activate or accelerate cement slurries (seeFIG. 8 ). In some instances, the described systems may include a cement slurry and capsules that release activators into the cement slurry in response to ultrasound. An activator typically includes any chemicals that activate and/or accelerate the setting process for a cement slurry in the described systems. An activator may also retard or otherwise affect the setting or properties of the cement slurry. For example, the described systems may include one or more of the following activators: sodium hydroxide, sodium carbonate, calcium chloride, calcium nitrite, calcium nitrate, and/or others. In some implementations, the capsules may include elements that substantially enclose one or more activators and that release the activator in response to at least sonic signals. For example, the sonic signal may break or otherwise form an opening in the encapsulating element to release the one or more activators. - In regards to directly activating cement slurries, the described systems may directly activate the cement slurry using one or more different mechanisms responsive to sonic signals. The one or more different mechanisms may include modifying chemical properties, releasing chemicals, modifying physical properties (e.g., particle size), updating operating conditions (e.g., pressure, temperature), and/or other mechanisms responsive to sonic signals. For example, described systems may use sonic signals to directly minimize or otherwise reduce the effect of hydrophobic surfactants to, for example, enable the surfactants to enter into suspension and/or partially hydrate. In these instances, the described systems may directly activate cement slurries using sonic signals independent of introducing or adding chemicals to the cement slurry. In addition, the systems may include free-radical dopants in cement slurries that release autocatalytic free radicals in response to at least ultrasonic signals. Alternatively or in combination, the sonic signals may trigger or otherwise activate a polymerization process in the cement slurry to provide in-situ polymerization. In general, the described systems include a cement slurry in an annulus formed between a casing and a wellbore, and when the cement is set, the cement secures the casing in place. By selectively controlling the setting of a cement slurry, the described systems allow cement properties to be tailored once the cement slurry has been pumped down the borehole.
- Referring to
FIG. 1 , thesystem 100 is across-sectional well system 100 that initiates or accelerates the setting of cement slurring using encapsulated activators. In the illustrated implementation, thewell system 100 includes aproduction zone 102, anon-production zone 104, awellbore 106, acement slurry 108, andcapsules 110. Theproduction zone 102 may be a subterranean formation including resources (e.g., oil, gas, water). Thenon-production zone 104 may be one or more formations that are isolated from thewellbore 106 using thecement slurry 108. For example, thezone 104 may include contaminants that, if mixed with the resources, may result in requiring additional processing of the resources and/or make production economically unviable. Thecement slurry 108 may be pumped or selectively positioned in thewellbore 106, and the setting of thecement slurry 108 may be activated or accelerated using thecapsules 110. In some implementations, thecapsules 110 may release activators in response to ultrasound initiated by, for example, a user of thesystem 100. By controlling the setting, a user may configure thesystem 100 without substantial interference from the setting of thecement slurry 108. - Turning to a more detailed description of the elements of
system 100, thewellbore 106 extends from asurface 112 to theproduction zone 102. Thewellbore 106 may include arig 114 that is disposed proximate to thesurface 112. Therig 114 may be coupled to acasing 116 that extends the entire length of the wellbore or a substantial portion of the length of thewellbore 106 from about thesurface 112 towards the production zones 102 (e.g., hydrocarbon-containing reservoir). In some implementations, thecasing 116 can extend past theproduction zone 102. Thecasing 116 may extend to proximate aterminus 118 of thewellbore 106. In some implementations, thewell 106 may be completed with thecasing 116 extending to a predetermined depth proximate to theproduction zone 102. In short, thewellbore 106 initially extends in a substantially vertical direction toward theproduction zone 102. In some implementations, thewellbore 106 may include other portions that are horizontal, slanted or otherwise deviated from vertical. - The
rig 114 may be centered over a subterranean oil orgas formation 102 located below the earth'ssurface 112. Therig 114 includes awork deck 124 that supports aderrick 126. Thederrick 126 supports ahoisting apparatus 128 for raising and lowering pipe strings such ascasing 116.Pump 130 is capable of pumping a variety of wellbore compositions (e.g., drilling fluid, cement) into the well and includes a pressure measurement device that provides a pressure reading at the pump discharge. Thewellbore 106 has been drilled through the various earth strata, includingformation 102. Upon completion of wellbore drilling, thecasing 116 is often placed in thewellbore 106 to facilitate the production of oil and gas from theformation 102. Thecasing 116 is a string of pipes that extends downwellbore 106, through which oil and gas will eventually be extracted. A cement orcasing shoe 132 is typically attached to the end of the casing string when the casing string is run into the wellbore. Thecasing shoe 132 guides thecasing 116 toward the center of the hole and may minimize or otherwise decrease problems associated with hitting rock ledges or washouts in thewellbore 106 as the casing string is lowered into the well. Thecasing shoe 132 may be a guide shoe or a float shoe, and typically comprises a tapered, often bullet-nosed piece of equipment found on the bottom of thecasing string 116. Thecasing shoe 132 may be a float shoe fitted with an open bottom and a valve that serves to prevent reverse flow, or U-tubing, ofcement slurry 108 fromannulus 122 intocasing 116 after thecement slurry 108 has been placed into theannulus 122. The region betweencasing 116 and the wall ofwellbore 106 is known as thecasing annulus 122. To fill upcasing annulus 122 andsecure casing 116 in place, casing 116 is usually “cemented” inwellbore 106, which is referred to as “primary cementing.” In some implementations, thecement slurry 108 may be injected into thewellbore 106 through one ormore ports 134 in thecasing shoe 132. Thecement slurry 108 may flow through ahose 136 into thecasing 116. In some instances where thecasing 116 does not extend the entire length of thewellbore 106 to thesurface 112, thecasing 116 may be supported by aliner hanger 138 near the bottom of aprevious casing 120. - In some implementations, the
system 100 may activate the setting of thecement slurry 108 using thecapsules 110 during, for example, conventional primary cementing operation. In conventional primary cementing implementations, thecapsules 110 may be mixed into thecement slurry 108 prior to entering thecasing 116, and thecement slurry 108 may then be pumped down the inside of thecasing 116. For example, thecapsules 110 may be mixed in thecement slurry 108 at a density in the range of 4-24 pound per gallon (ppg). As theslurry 108 reaches the bottom ofcasing 116, it flows out ofcasing 116 and intocasing annulus 122 betweencasing 116 and the wall ofwellbore 106. As cement slurry flows upannulus 122, it displaces any fluid in the wellbore. To ensure no cement remains insidecasing 116, devices called “wiper plugs” may be pumped by a wellbore servicing fluid (e.g., drilling mud) throughcasing 116 behind thecement slurry 108. The wiper contacts the inside surface ofcasing 116 and pushes any remainingslurry 108 out ofcasing 116. When cement slurry reaches the earth'ssurface 112, andannulus 122 is filled withslurry 108, pumping is terminated. In connection with pumping thecement slurry 108 into the annulus, an ultrasonic signal may be transmitted before, during, and/or after the pumping is complete to activate thecapsules 110. In response to at least the signal, thecapsules 110 may release activators that initiate and/or accelerate the setting of thecement slurry 108 in theannulus 122. Some or all of thecasing 116 may be affixed to the adjacent ground material withset cement 202 as illustrated inFIGS. 2A and 2B . In some implementations, thecasing 116 comprises a metal. After setting, thecasing 116 may be configured to carry a fluid, such as air, water, natural gas, or to carry an electrical line, tubular string, or other elements. - After positioning the
casing 116, asettable slurry 108 includingcapsules 110 may be pumped intoannulus 122 by a pump truck (not illustrated). While the following discussion will center on thesettable slurry 108 comprising acement slurry 108, thesettable slurry 108 may include other compounds such as resin systems, settable muds, conformance fluids, lost circulation, and/or other settable compositions.Example cement slurries 108 are discussed in more detail below. In connecting with depositing or otherwise positioning thecement slurry 108 in theannulus 122, thecapsules 110 may release activators to activate or otherwise increase the setting rate of thecement slurry 108 in response to at least ultrasound. In other words, the released activators may activate thecement slurry 108 to set cement in theannulus 122. - In some implementations, the
capsules 110 may release an activator that initiates or accelerates the setting of thecement slurry 108. For example, thecement slurry 108 may remain in a substantially slurry state for a specified period of time, and thecapsules 110 may activate the cement slurry in response to ultrasound. In some instances, ultrasound may crack, break or otherwise form one or more holes in thecapsules 110 to release the activators. In some instances, the ultrasound may generate heat that melts one or more holes in thecapsules 110. Thecapsules 110 enclose the activators with, for example, a membrane such as a polymer (e.g., polystyrene, ethylene/vinyl acetate copolymer, polymethylmethacrylate, polyurethanes, polylactic acid, polyglycolic acid, polyvinylalcohol, polyvinylacetate, hydrolyzed ethylene/vinyl acetate, or copolymers thereof). Thecapsule 110 may include other materials responsive to ultrasound. In these implementations, thecapsule 110 may include a polymer membrane that ultrasonically degrades to release the enclosed activators. In some examples, an ultrasonic signal may structurally change the membrane to release the activators such as, for example, opening a preformed slit in thecapsules 110. In some implementations, at least one dimension of thecapsules 110 may be microscopic such as in range from 10 nanometers (nm) to 15,000 nm. For example, the dimensions of thecapsules 110 may be on a scale of a few tens to about one thousand nanometers and may have one or more external shapes including spherical, cubic, oval and/or rod shapes. In some implementations, thecapsules 110 can be shells with diameters in the range from about 10 nm to about 1,000 nm. In other implementations, thecapsules 110 can include a diameter in a range from about 15 micrometers to about 10,000 micrometers. Alternatively or in combination, thecapsules 110 may be made of metal (e.g., gold) and/or of non-metallic material (e.g., carbon). In some implementations, thecapsules 110 may be coated with materials to enhance their tendency to disperse in thecement slurry 108. Thecapsules 110 may be dispersed in the cement slurry at a concentration of 105 to 109 capsules/cm3. In some implementations, thecapsules 110 are a shell selected from the group consisting of a polystyrene, ethylene/vinyl acetate copolymer, and polymethylmethacrylate, polyurethanes, polylactic acid, polyglycolic acid, polyvinylalcohol, polyvinylacetate, hydrolyzed ethylene/vinyl acetate, and copolymers thereof. - The release activator may include sodium hydroxide, sodium carbonate, amine compounds, salts comprising calcium, sodium, magnesium, aluminum, and/or a mixture thereof. The
capsule 110 may release a calcium salt such as calcium chloride. In some implementations, thecapsule 110 may release a sodium salt such as sodium chloride, sodium aluminate, and/or sodium silicate. Thecapsule 110 may release a magnesium salt such as magnesium chloride. In some examples, thecapsule 110 may release amine compounds such as triethanol amine, tripropanol amine, tri-isopropanol amine, and/or diethanol amine. In some implementations, thecapsule 110 may release the activator in a sufficient amount to set thecement slurry 108 within about 1 minute to about 24 hours. In implementations including sodium chloride as the released activator, the concentration may be in the range of from about 3% to about 30% by weight of the cement in thecement slurry 108. In implementations including calcium chloride as the released activator, the concentration may be in the range of from about 0.5% to about 5% by weight of the cement in thecement slurry 108. In the case that thesettable slurry 108 comprises resin, the release activator may include amine accelerators for a epoxy/novalac resins. - In some implementations, the
capsule 110 may “flash-set” thecement slurry 108. As referred to herein, the term “flash-set” will be understood to mean the initiation of setting of thecement slurry 108 within about 1 minute to about 15 minutes after contacting the released activator. In some implementations, the previously identified activators may flash set thecement slurry 108. Flash-set activators may include sodium hydroxide, sodium carbonate, potassium carbonate, bicarbonate salts of sodium or potassium, sodium silicate salts, sodium aluminate salts, ferrous and ferric salts (e.g., ferric chloride and ferric sulfate), polyacrylic acid salts, and/or others. In some implementations, the following activators can flash-set thecement slurry 108 based on these activators exceeding a specified concentration: calcium nitrate, calcium acetate, calcium chloride, and/or calcium nitrite. In some implementations, thecapsule 110 may release a solid activator. - In some implementations, the
cement slurry 108 may comprise a “delayed set” cement compositions that remain in a slurry state (e.g., resistant to setting or gelation) for an extended period of time. In such implementations, a delay-setcement slurry 108 may include a cement, a base fluid, and a set retarder. In these and other implementations, activation may change the state of the cement slurry from delay set to neutral, to accelerated, or to less delayed. Thecement slurry 108 may include other additives. The delayed-setcement slurry 108 typically remains in a slurry state for in range of about 6 hours to about 4 days under downhole or other conditions. That said, thecement slurry 108 may include components that result in a slurry state for a greater, or shorter, amount of time. For example, thecement slurry 108 may be mixed or otherwise made well ahead of positioning theslurry 108 in theannulus 122. The delayed-setcement slurry 108 can, in some implementations, include a cement, a base fluid, and a set retarder. The delayed-setcement slurry 108 may be set at a desired time, such as after placement, by activating thecapsules 110 to release one or more activators. - In regards to cements included in the
cement slurry 108, any cement suitable for use in subterranean applications may be suitable for use in the present invention. For example, delayed-setcement slurry 108 may include a hydraulic cement. In general, hydraulic cements typically include calcium, aluminum, silicon, oxygen, and/or sulfur and may set and harden by reaction with water. Hydraulic cements include, but are not limited to, Portland cements, pozzolanic cements, high aluminate cements, gypsum cements, silica cements, high alkalinity cements, and/or Sorel cements. In addition, the delayed-setcement slurry 108 may include cements based on shale or blast furnace slag. In these instances, the shale may include vitrified shale, raw shale (e.g., unfired shale), and/or a mixture of raw shale and vitrified shale. In some implementations, thesettable composition 108 includes a polymer additive comprising at least one of a monomer, a pre-polymer, an oligomer, or a short chain polymer that polymerizes in response to the sonic signal - In regards to base fluids included in the
cement slurry 108, the delayed-setcement slurry 108 may include one or more base fluids such as, for example, an aqueous-based base fluid, a nonaqueous-based base fluid, or mixtures thereof. Aqueous-based may include water from any source that does not contain an excess of compounds (e.g., dissolved organics, such as tannins) that may adversely affect other compounds in thecement slurry 108. For example, the delayed-setcement slurry 108 may include fresh water, salt water (e.g., water containing one or more salts), brine (e.g., saturated salt water), and/or seawater. Nonaqueous-based may include one or more organic liquids such as, for example, mineral oils, synthetic oils, esters, and/or others. Generally, any organic liquid in which a water solution of salts can be emulsified may be suitable for use as a base fluid in the delayed-setcement slurry 108. In some implementations, the base fluid exceeds a concentration sufficient to form a pumpable slurry. For example, the base fluid may be water in an amount in the range of from about 25% to about 150% by weight of cement (“bwoc”) such as one or more of the following ranges: about 30% to about 75% bwoc; about 35% to about 50% bwoc; about 38% to about 46% bwoc; and/or others. - In regards to set retarders in the
cement slurry 108, thecement slurry 108 may include one or more different types of set retarders such as, for example, phosphonic acid, phosphonic acid derivatives, lignosulfonates, salts, organic acids, carboxymethylated hydroxyethylated celluloses, synthetic co- or ter-polymers comprising sulfonate and carboxylic acid groups, and/or borate compounds. And In some implementations, the set retarders used in the present invention are phosphonic acid derivatives. Examples of set retarders may include phosphonic acid derivatives commercially available from, for example, Solutia Corporation of St. Louis, Mo. under the trade name “DEQUEST.” Another example set retarder may include a phosphonic acid derivative commercially available from Halliburton Energy Services, Inc., under the trade name “MICRO MATRIX CEMENT RETARDER.” Example borate compounds may include sodium tetraborate, potassium pentaborate, and/or others. A commercially available example of a suitable set retarder comprising potassium pentaborate is available from Halliburton Energy Services, Inc. under the trade name “Component R.” Example organic acids may include gluconic acid, tartaric acid, and/or others. An example of a suitable organic acid may be commercially available from Halliburton Energy Services, Inc. under the trade name “HR® 25.” Other examples of set retarders may be commercially available from Halliburton Energy Services, Inc. under the trade names “SCR-100” and “SCR-500.” Generally, the set retarder in the delayed-setcement slurry 108 may be in an amount sufficient to delay the setting in a subterranean formation for a specified time. The amount of the set retarder included in thecement slurry 108 may be in one or more of the following ranges: about 0.1% to about 10% bwoc; about 0.5% to about 4% bwoc; and/or others. - In some implementations, the
cement slurry 108 may not include a set retarder. For example, thesystem slurry 108 may include high aluminate cements and/or phosphate cements independent of a set retarder. In these instances, the activators may initiate setting of theslurry 108. For example, these activators may include alkali metal phosphate salts. High aluminate cement may comprise calcium aluminate in an amount in the range of from about 15% to about 45% by weight of the high aluminate cement, Class F fly ash in an amount in the range of from about 25% to about 45% by weight of the high aluminate cement, and sodium polyphosphate in an amount in the range of from about 5% to about 15% by weight of the high aluminate cement. In certain embodiments of the present invention wherein a cement composition comprising a phosphate cement is used, a reactive component of the cement composition (e.g., the alkali metal phosphate salt) may be used as an activator. -
FIGS. 2A and 2B illustrate a cross sectional view of thewell system 100 including activated setcement 202 in at least a portion of theannulus 122. In particular, thecapsules 110 released activators in at least a portion of thecement slurry 108 to form theset cement 202. InFIG. 2A , the cement slurry flowed into theannulus 122 through thecasing 116, and in response to at least a signal, thecapsules 110 in theslurry 108 released an activator. In the illustrated example, substantially allcapsules 110 in theannulus 122 released activators to form theset cement 202 along substantially the entire length of theannulus 122. Referring toFIG. 2B , thecement slurry 108 flowed into theannulus 122 through thecasing 116, and in response to at least an ultrasonic signal, thecapsules 110 in theslurry 108 released activators within a specifiedlocation 204. In the illustrated example, the region orlocation 204 is located proximate thezone 102. In other words, thecapsules 110 proximate thezone 102 may release activators and form theset cement 202 located in theregion 204. The ultrasonic signal may be localized to the region identified by 204, and in response to at least the localized signal, theset cement 204 forms. In some implementations, an initial amount of thecement slurry 108 may be exposed to an ultrasonic signal such that the setting period may be substantially equal to a period of time for the settingcement slurry 108 to flow to thelocation 204. In these examples, thecement slurry 108 may be exposed to the ultrasonic signal as theslurry 108 including thecapsules 110 enters thecasing 116. As the leading edge ofcement slurry 108 begins to set, fluid flow through theannulus 122 may become more restricted and may eventually cease. Thus, thecement slurry 108 may be substantially prevented from flowing onto thesurface 112 through theannulus 122. The remainder of thecement slurry 108 may set in theannulus 122 behind the leading edge as illustrated inFIG. 2A or thecement slurry 108 may set at a later time as illustrated inFIG. 2B . In the later, the remainingcement slurry 108 may be exposed to ultrasonic signals at a later time to initiate or accelerate the setting processes. -
FIGS. 3A and 3B illustrates anexample capsule 110 ofFIG. 1 in accordance with some implementations of the present disclosure. In this implementation, thecapsule 110 is spherical but may be other shapes as discussed above. Thecapsule 110 is ashell 302 encapsulating one ormore activators 304 as illustrated inFIG. 3B . Thecapsule 110 releases one or more storedactivators 304 in response to at least an ultrasonic signal. For example, thecapsule 110 may crack or otherwise form one or more holes in response to at least the ultrasonic signal. The illustratedcapsule 110 is for example purposes only, and thecapsule 110 may include some, none, or all of the illustrated elements without departing from the scope of this disclosure. -
FIGS. 4A and 4B illustrate example implementations of thecapsules 110 releasing one or more activators. Thecapsules 110 may release activators by heating one or more portions to form at least one opening, destroying or otherwise removing one or more portions, and/or other processes. The following implementations are for illustration purposes only, and thecapsules 110 may release activators using some, all or none of these processes. - Referring to
FIG. 4A , thecapsule 110 forms an opening through heat formed from ultrasonic signals. For example, the ultrasonic signals may directly heat the membrane of thecapsule 110 and/or heat the surroundingcement slurry 108 to a temperature above the melting point. Thecapsule 110 may be a gold shell that when vibrated at its natural frequency melts at least a portion of the shell to release the enclosed activators. In these instances, the generated heat may melt or otherwise deform the shell to form an opening. In addition to metal membranes, thecapsule 110 may be other materials such as a polymer. Referring toFIG. 4B , thecapsule 110 forms cracks, breaks, or openings in response ultrasonic signals. For example, the ultrasonic signal may crack or otherwise destroy portions of thecapsule 110. In some implementations, the ultrasound may form defects in the membrane of the capsule and, as a result, form one or more openings as illustrated. -
FIGS. 5 and 6 are flow diagrams illustratingexample methods well system 100 ofFIG. 1 , but these methods could be used by any other system. Moreover, wellsystem 100 may use any other techniques for performing these tasks. Thus, many of the steps in these flowcharts may take place simultaneously and/or in different order than as shown. Thewell system 100 may also use methods with additional steps, fewer steps, and/or different steps, so long as the methods remain appropriate. - Referring to
FIG. 5 ,method 500 begins atstep 502 where capsules are selected based, at least in part, on one or more parameters. For example, thecapsules 110 and the enclosed activators may be based, at least in part, on components of thecement slurry 108. In some implementations, thecapsules 110 may be selected based on downhole conditions (e.g., temperature). Atstep 504, the selected capsules are mixed with a cement slurry. In some examples, thecapsules 110 may be mixed with thecement slurry 108 as thetruck 130 pumps the slurry into theannulus 122. In some examples, thecapsules 110 may be mixed with dry cement prior to generating thecement slurry 108. Next, atstep 506, the cement slurry including the capsules are pumped downhole. In some instances, thecement slurry 108 including thecapsules 110 may be pumped into theannulus 122 at a specified rate. One or more ultrasonic signals are transmitted to the at least a portion of the downhole cement slurry atstep 508. Again in the example, the transmitter may be lowered into the casing to transmit signals at a portion of thecement slurry 108. In this example, the transmitted signals may activate thecapsules 110 proximate theshoe 132 to set that portion of thecement slurry 108 as illustrated inFIG. 2B . In some instances, thecasing 116 may be moved (e.g., up/down) to assist in distributing the activators as desired. - Referring to
FIG. 6 , themethod 600 begins atstep 602 where a first emulsification step is performed. For example, a polystyrene dissolved in CH2Cl2 where saturated aqueous CaCl2 may be emulsified using WS-36 (Sorbitan Monooleate). Next, atstep 604, the first emulsification may then again be emulsified in a second step. In the example, the first emulsion may then be subsequently emulsified into a large volume (e.g., 10× excess) of a 2% polyvinylalcohol solution. -
FIGS. 7A-F illustrate an example implementation of thecapsules 110 in accordance with some implementations of the present disclosure. In this example, implementation, thecapsules 110 encapsulate activators, and power ultrasound may break the capsules to release the activators on command. The illustratedcapsules 110 are polystyrene microcapsules encapsulating aqueous CaCl2. Though, thecapsules 110 may be formed from other materials such as ethylene/vinyl acetate copolymer, polymethylmethacrylate, and/or others. In some instances, these types ofcapsules 110 may be created using a double emulsion technique. For example, the technique may include a polystyrene dissolved in CH2Cl2 where saturated aqueous CaCl2 was emulsified using WS-36 (Sorbitan Monooleate). Next, this emulsion may then be subsequently emulsified into a large volume (e.g., 10× excess) of a 2% polyvinylalcohol solution. The double emulsion was stirred and heated to about 30° C. to drive off CH2Cl2 and concentrate the polystyrene ultimately forming liquid filled microcapsules. To evaluate these capsules, four different cement slurries were tested and the results are graphed inFIGS. 7C-F . A retarded slurry, a retarded slurry with CaCl2, a retarded slurry with the microcapsules, and a retarded slurry with the microcapsules treated with sonication were evaluated. A 20 kHz ultrasonic horn was used for ten minutes at 50% power to treat the sonicated sample. The composition and results are listed in Tables 1-3 below. -
TABLE 1 Slurry 1 Slurry 2Slurry 3Slurry 4Base Retarded w/ Encapsulated Sonicated Description Retarded CaCl2 CaCl2 Encap CaCl2 Water 39.4% bwc 39.4% bwc 39.4% bwc 39.4% bwc 332 g 332 g 332 g 332 g Class H 100 % bwc 100 % bwc 100 % bwc 100% bwc 842.5 g 842.5 g 842.5 g 842.5 g HR-800 0.25% bwc 0.25% bwc 0.25% bwc 0.25% bwc 2.1 g 2.1 g 2.1 g 2.1 g CaCl2 0.27% bwc 2.3 g Encapsulated 0.27% bwc 0.27% bwc CaCl2 2.3 g 2.3 g -
TABLE 2 Density- 16.4 ppg Yield- 1.07 ft3/sk -
TABLE 3 Slurry 1 Slurry 2Slurry 3Slurry 4Pump time 14:19 9:17 12:20 7:35 (70BC) Hydration Heat 16:00 11:00 16:00 11:20 - The illustrated parameters including operating conditions are for illustration purposes only. The
system 100 may use some, all or none of the values without departing from the scope of this disclosure. -
FIG. 8 is anotherexample system 100 that directly activates thecement slurry 108 using ultrasonic signals. For example,ultrasonic transducers casing 116 and emit ultrasound to sonically activate the cement slurry. By sonically activating the cement slurry, thesystem 100 may set cement on-demand. For example, thesystem 100 may set thecement slurry 108 in a period of the range from 1 hour to 1 day. The sonic transducers 802 may directly activate thecement slurry 108 using one or more different mechanisms responsive to sonic signals. The one or more different mechanisms may include modifying chemical properties, releasing chemicals, modifying physical properties (e.g., particle size), updating operating conditions (e.g., pressure, temperature), and/or other mechanisms responsive to sonic signals. For example, the sonic transducers 802 may reduce the particulate size in thecement slurry 108 and, as a result, may increase the surface area. By increasing the surface area, the setting process may be initiated, accelerated, or otherwise activated. Alternatively or in combination, the sonic signals may increase the pressure and/or temperature and, as a result, may initiate, accelerate, or otherwise activate the setting process. In some implementations, the ultrasonic transducers 802 may activate accelerators in thecement slurry 108 and/or deactivate cement retarders in thecement slurry 108 to set the cement on demand. For example, the ultrasonic transducers 802 may generate ultrasonic or acoustic waves to initiate the setting process of thecement slurry 108 through, for example, the selective activation of accelerators in thecement slurry 108 such as CaCl2 and/or the deactivation of cement retarders in thecement slurry 108 such as xylose. In some implementations, cement hydration inhibitors (in relatively low concentration) can work to alter the surface energy of the tricalcium aluminate, silicate and/or other compounds in thecement slurry 108, which can make the compounds more hydrophobic. The transducers 802 may ultrasonically agitate thecement slurry 108 to reduce the effect of hydrophobic surfactants, which may enable the compounds to enter into solution and/or partially hydrate. The transducers 802 may generate ultrasonic signals having a frequency that substantially matches the resonant conditions for inhibitor neutralization. In some implementations, thesystem 100 may execute frequency tuning to substantially optimize frequency and power combinations for a given geometry and inhibitor chemistry. In these instances, a user of thesystem 100 may remotely control the initiation of cement hydration. In addition, thesystem 100 may initiate an autocatalytic process. For example, the transducers 802 may generate ultrasonic signals that sets off an autocatalytic free-radical release that propagates through thecement slurry 108. In these instances, this process may initiate from a single point. Thecement slurry 108 may include additives (e.g., free-radical dopants) that release free-radical species through out theslurry 108 in response to at least ultrasonic initiation or hydration. -
FIGS. 9A-H illustrate example graphs demonstrating affects of sonic signals on cement slurries. In these examples, measurements were made on cement slurries that were sonically activated in comparison to cement slurries not sonically activated. In particular, ultrasound was used to accelerated the set of retarded cement slurries. The cement slurries were retarded using one of the following three retarders: EDTA; a combination of FDP-C742A and EDTA; and a combination of FDP-C742A and Component R. Without exposure to ultrasound, the cement slurries pumped between 6.5 hours to 80 hours. After exposure to 20 kHz of ultrasound, the pump times for these slurries may be reduced 40-50%. In addition, a control pump time using neat cement with and without exposure to ultrasound was run. The ultrasound exposure did not appear to affect the pump time of the neat cement. Based, at least in part, on the data, the ultrasound appears to target the retarders and may be accelerating the setting process as a result. - Referring to
FIG. 9A , thegraph 910 plots data for cement slurry comprising 16.4 PPG (Class H cement, neat) operating at 120° F. and 3600 PSI in 30 minutes. The cement slurry was not exposed to ultrasound. Thegraph 910 includes apeak 912 indicating the pump time to be 2 hours and 23 minutes. Referring toFIG. 9B , thegraph 920 plots data for the same cement slurry asgraph 910 including exposure to 20 kHz ultrasound for seven minutes. In this experiment, the ultrasound was shut off after 5 minutes to due to an increase in the cement-slurry temperature. The cement slurry was exposed to an additional 2 minutes of the ultrasound once cooled. Thegraph 920 includes apeak 922 indicating the pump time to be 2 hours. - Referring to
FIG. 9C , thegraph 930 plots data for cement slurry comprising 16.4 PPG (Class H cement, 1% EDTA) operating at 120° F. and 3600 PSI in 30 minutes. The cement slurry was not exposed to ultrasound. Thegraph 930 includes apeak 932 indicating the pump time to be 7 hours and 45 minutes. Referring toFIG. 9D , thegraph 940 plots data for the same cement slurry asgraph 930 including exposure to 20 kHz ultrasound for 7 minutes (5 minutes on, 2 minutes off, 2 minutes on). In this experiment, the ultrasound was shut off after 5 minutes due to an increase in the cement-slurry temperature. The cement slurry was exposed to an additional 2 minutes of the ultrasound once cooled. The pump time was 4hours 15 minutes. - Referring to
FIG. 9E , thegraph 950 plots data for cement slurry comprising 16.4 PPG (Class G cement w/35% SSA-1; 10.4 SSA-1; 1% CFR-3; 0.8% Halad-200; 0.4 gal/sk Gascon 469; 1.8% FDP-C742A; 1.8% EDTA; 0.3 gal/sk NF-6) with the % in bwoc. The operating conditions were 400° F. and 13100 PSI in 90 minutes. The cement slurry was not exposed to ultrasound. The pump time was 6 hours and 46 minutes. Referring toFIG. 9F , thegraph 960 plots data for the same cement slurry asgraph 950 including exposure to 20 kHz ultrasound for 15 minutes (10 minutes on, 1 minutes off, 5 minutes on). In this experiment, the ultrasound was shut off after 10 minutes due to an increase in the cement-slurry temperature. The cement slurry was exposed to an additional 5 minutes of the ultrasound once cooled. The pump time was 3hours 15 minutes. - Referring to
FIG. 9G , thegraph 970 plots data for cement slurry comprising 16.4 PPG (Class G cement w/35% SSA-1; 10.4 SSA-1; 1% CFR-3; 0.8% Halad-200; 0.4 gal/sk Gascon 469; 1.8% FDP-C742A; 0.8% Compound R; 0.3 gal/sk NF-6) with the % in bwoc. The operating conditions were 422° F. and 13100 PSI in 90 minutes. The cement slurry was not exposed to ultrasound. The pump time was 79 hours. Referring toFIG. 9H , thegraph 980 plots data for the same cement slurry asgraph 970 including exposure to 20 kHz ultrasound for 15 minutes (5 minutes intervals). The pump time was 50 hours. - The present invention is well adapted to attain the ends and advantages mentioned as well as those that 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. 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. In particular, every range of values (of the form, “about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “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 explicitly and clearly defined by the patentee.
Claims (32)
Priority Applications (8)
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US12/547,286 US20110048697A1 (en) | 2009-08-25 | 2009-08-25 | Sonically activating settable compositions |
BR112012004122A BR112012004122B1 (en) | 2009-08-25 | 2010-08-18 | method of sonically activating curable compositions, and composition for treating a wellbore |
AU2010288346A AU2010288346B2 (en) | 2009-08-25 | 2010-08-18 | Sonically activating settable compositions and methods of activating them |
PCT/GB2010/001560 WO2011023934A2 (en) | 2009-08-25 | 2010-08-18 | Sonically activating settable compositions and methods of activating them |
CA2771619A CA2771619C (en) | 2009-08-25 | 2010-08-18 | Sonically activating settable compositions and methods of activating them |
ARP100103084A AR077947A1 (en) | 2009-08-25 | 2010-08-24 | METHODS FOR SONICALLY ACTIVATING CEMENT COMPOSITIONS AND FRAGUABLE ACTIVATED COMPOSITIONS OF THAT MODE |
NO20120353A NO20120353A1 (en) | 2009-08-25 | 2012-03-23 | Sonically activated stiffenable mixture and method using the same |
AU2015202876A AU2015202876B2 (en) | 2009-08-25 | 2015-05-27 | Sonically activating settable compositions and methods of activating them |
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