CEMENTING COMPOSITIONS COMPRISING CEMENT KILN DUST,
VITRIFIED SEIALE, ZEOLITE, AND/OR AMORPHOUS SILICA UTILIZING A
PACKING VOLUfim FRACTION, AND ASSOCIATED METHODS
BACKGROUND
The present invention relates to cementing operations and, more particularly,
to the use of cementing compositions comprising water, cement kiln dust ("CKD"), vitrified
shale, zeolite, andor amorphous silica, 'that are prepared by utilizing a packing volume
fraction, and associated methods of use.
Cementing compositions are commonly utilized in a variety of subterranean
operations. Subterranean applications that may involve cementing compositions include, but
are not limited to, primary cementing, remedial cementing, and drilling operations. For
example, cement compositions are used in primary cementing operations whereby pipe
strings such as casings and liners are cemented in well bores. In performing primary
cementing, cement compositions are pumped into the annular space between the walls of a
well bore and the exterior surface of the pipe string disposed therein. The cement
composition is permitted to set in the annular space, thereby forming an annular sheath of
hardened substantially impermeable cement therein that substantially supports and positions
the pipe string in the well bore and bonds the exterior surface of the pipe string to the walls
of the well bore. Cement compositions are also used in plugging and abandonment
operations as well as in remedial cementing operations such as plugging permeable zones or
fractures in well bores, plugging cracks and holes in pipe strings, and the like. Cementing
compositions also may be used in surface applications, for example, construction cementing.
Cementing compositions used heretofore commonly comprise Portland
cement. Portland cement generally is a major component of the cost for the cementing
compositions. To reduce the cost of such cementing compositions, other solid particulate
components may be included in the cementing composition in addition to, or in place of, the
Portland cement. The resulting combination of multiple solid particulate materials in the
cementing compositions can result in a "settling effect," in which different sized particulate
materials will settle separately at different speeds. This settling of the solids in a cement
composition may result in defective cementing procedures and failure of the set cement to
provide zonal isolation. Thus, among other things, there are needs for an improved
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cementing composition for well cements which can be utilized without resulting in settling
of solid particulates.
SUiVSiMARY
The present invention relates to cementing operations and, more particularly,
to cementing compositions comprising water, CKD, vitrified shale, zeolite, andlor
amorphous silica, that are prepared by utilizing a packing volume fraction, and associated
methods of use.
In one embodiment, the present invention provides a composition comprising
water; and at least three particulate materials chosen fiom the group consisting of: (a)
cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size in the
range of from about 7 nanometers to about 50 nanometers; (b) cement kiln dust, vitrified
shale, zeolite, or amorphous silica having a particle size in the range of from about 0.05
microns to about 0.5 microns; (c) cement kiln dust, vitrified shale, zeolite, or amorphous
silica having a particle size in the range of from about 0.5 microns to about 10 microns; (d)
cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size in the
range of from about 10 microns to about 20 microns; (e) cement kiln dust, vitrified shale,
zeolite, or amorphous silica having a particle size in the range of from about 20 microns to
about 200 microns; (0 cement kiln dust, vitrified shale, zeolite, or amorphous silica having a
particle size in the range of from about 200 microns to about 800 microns; and (g) cement
kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size greater than about
1 millimeter, wherein a solids volume total of the at least three particulate materials
comprises a maximum packing volume fraction.
In one embodiment, the present invention provides a method comprising
providing an unhydrated mixture of at least three particulate materials chosen from the group
consisting of: (a) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a
particle size in the range of from about 7 nanometers to about 50 nanometers; (b) cement
kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size in the range of
from about 0.05 microns to about 0.5 microns; (c) cement kiln dust, vitrified shale, zeolite,
or amorphous silica having a particle size in the range of from about 0.5 microns to about 10
microns; (d) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle
size in the range of fiom about 10 microns to about 20 microns; (e) cement kiln dust,
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vitrified shale, zeolite, or amorphous silica having a particle size in the range of from about
20 microns to about 200 microns; ( f ) cement kiln dust, vitrified shale, zeolite, or amorphous
silica having a particle size in the range of from about 200 microns to about 800 microns;
and (g) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a
particle size greater than about 1 millimeter, wherein a solids volume total of the at least
three particulate materials comprises a maximum packing volume fraction; and adding
water to the unhydrated mixture to form a settable composition.
In one embodiment, the present invention provides a method comprising
providing a cementing composition, wherein the cementing composition comprises water;
and at least three particulate materials chosen from the group consisting of: (a) cement kiln
dust, vitrified shale, zeolite, or amorphous silica having a particle size in the range of from
about 7 nanometers to about 50 nanometers; (b) cement kiln dust, vitrified shale, zeolite, or
amorphous silica having a particle size in the range of from about 0.05 microns to about 0.5
microns; (c) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle
size in the range of from about 0.5 microns to about 10 microns; (d) cement kiln dust,
vitrified shale, zeolite, or amorphous silica having a particle size in the range of fiom about
10 microns to about 20 microns; (e) cement kiln dust, vitrified shale, zeolite, or amorphous
silica having a particle size in the range of from about 20 microns to about 200 microns; ( f )
cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size in the
range of from about 200 microns to about 800 microns; and (g) cement kiln dust, vitrified
shale, zeolite, or amorphous silica having a particle size greater than about 1 millimeter,
wherein a solids volume total of the at least three particulate materials comprises a
maximum packing volume fraction; and placing the cementing composition in a
subterranean formation.
The features and advantages of the present invention will be apparent to those
skilled in the art. While numerous changes may be made by those skilled in the art, such
changes are within the spirit of the invention.
DESCRIPTION OF PREFERRED ENIBODI3IENTS
The present invention relates to cementing operations and, more particularly,
to cementing compositions comprising water, CKD, vitrified shale, zeolite, andlor
amorphous silica, that are prepared by utilizing a packing volume fraction, and associated
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methods of use. The cementing compositions of the present invention may be used in a
variety of subterranean applications, including primary cementing, remedial cementing, and
drilling operations. The cementing compositions of the present invention also may be used
in surface applications, for example, construction cementing.
In some embodiments, cementing compositions of the present invention
comprise water, CKD, vitrified shale, zeolite, andlor amorphous silica, that utilize a packing
volume fraction. Optional additives also may be included in the cementing compositions of
the present invention as desired, including, but not limited to, hydraulic cement, other
materials such as silica, hematite or other iron oxide, barium hydroxide, carbonates, alumina
etc., and organic products such as plastic wastes and other compatible wastes. The
cementing composition may further include set retarding additives, set accelerating
additives, dispersing agents, fluid loss control additives, lightweight additives, and the like.
The cementing compositions of the present invention should utilize a pachng
volume fraction suitable for a particular application as desired. As used herein, the term
"packing volume fraction7' refers to the volume of the solid particulate materials in a fluid
divided by the total volume of the fluid. The size ranges of the preferred solid particulate
materials are selected, as well as their respective proportions, in order to provide a maximum
(or close as possible to maximum) packing volume fraction so that the fluid is in a hindered
settling state. It is known that, in such a state, the solid particulate materials behave
"collectively" like a porous solid material. The hndered settling state is believed to
correspond, in practice, to a much higher solid material concentration in the fluid than that
present in the prior art.
The present invention consists of the combination of at least three features to
obtain a maximum packing volume fraction. One is the use of at least three particulate
materials wherein the at least three particulate materials are in size ranges "disjointed" from
one another. Another feature of the present invention is the choice of the proportions of the
three particulate materials in relation to the mixing, such that the fluid, when mixed, is in a
hindered settling state. Another feature is the choice of the proportions of the three
particulate materials between each other, and according to their respective size ranges, such
that the maximum packing volume fraction is at least substantially achieved for the sum total
of all particulate materials in the fluid system. Packing volume fraction is described in
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further detail in United States Patent No, 5,518,996, the entire disclosure of which is
incorporated herein by reference.
The present invention employs the use of at least three particulate materials
comprising CKD, vitrified shale, zeolite, andor amorphous silica. The sizes of these
materials may be "ultra fine," "very fine," "fine," "small," "medium," "large," and "very
large" particulate materials. "Ultra fine" particulate materials may be present with a size in
the range of from about 7 nanometers to about 50 nanometers. "Very fine" particulate
materials may be present with a size in the range of from about 0.05 microns to about 0.5
microns. "Fine" particulate materials may be present with a size in the range of from about
0.5 microns to about 10 microns. "Small" particulate materials may be present with a size in
the range of from about 10 microns to about 20 microns. "Medium" particulate materials
may be present with a size in the range of from about 20 microns to about 200 microns.
"Large" particulate materials may be present with a size in the range of from about 200
microns to about 800 microns. "Very large" particulate materials may be present with a size
greater than about 1 millimeters. As recognized by one skilled in the art, the proportion of
particulates chosen in the composition depend on the end use. In any event, the particulates
and the relative sizes and concentrations in a given composition should be chosen based on a
maximum packing volume fraction as disclosed herein.
In certain embodiments, the cementing compositions of the present invention
may comprise CKD, a waste material generated during the manufacture of cement. CKD, as
that term is used herein, refers to a partially calcined kiln feed that is removed from the gas
stream and collected in a dust collector during the manufacture of cement. The chemical
analysis of CKD from various cement manufactues varies depending on a number of
factors, includng the particular kiln feed, the efficiencies of the cement production
operation, and the associated dust colIection systems. CKD generally may comprise a
variety of oxides, such as SiO2, A1203, Fez03, CaO, MgO, SO3, Na20, and KzO. In some
embodiments, the CKD may be present as fine particulate materials. In other embodiments,
the CKD may be present as small particulate materials. In other embodiments, the CKD
may be present as medium particulate materials. In other embodiments, the CKD may be
present as large particulate materials. In certain embodiments, the CKD inay be present in
the cementing compositions of the present invention in an amount in the range of from about
25% to about 75% by weight of composition ("bwoc") therein.
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In certain embodiments, the cementing compositions of the present invention
may comprise vitrified shale in an amount sufficient to provide the desired compressive
strength, density, and/or cost. A variety of shales are suitable, including those comprising
silicon, aluminum, calcium, and/or magnesium. Suitable examples of vitrified shale include,
but are not limited to, TRESSUR-SEAL@ FINE LCW' material and "PRESSUR-SEAL@
COARSE LCM" material, which are commercially available from TXI Energy Services,
Inc., Houston, Texas. In certain embodiments, the vitrified shale may be present as large
particulate materials. In other embodiments, the vitrified shale may be present as very large
particulate materials. In certain embodiments, the vitrified shale may be present in the
cementing compositions of the present invention in an amount in the range of from about
10% to about 30% bwoc therein. One of ordinary skill in the art, with the benefit of this
disclosure, will recogmze the appropriate amount of the shale to include for a chosen
application.
In certain embodiments, the cementing compositions of the present invention
may comprise zeolite. Zeolite may be used in conjunction with vitrified shale in some
embodiments. In other embodiments, zeolite may be an alternative to vitrified shale. The
choice may be dictated by a number of factors, such as total extent of compressive strength
of the cement, time for cement composition to develop compressive strength, and density of
the composition. Zeolites generally are porous alumino-silicate minerals that may be either
a natural or synthetic material. Synthetic zeolites are based on the same type of structural
cell as natural zeolites, and may comprise aluminosilicate hydrates. As used herein, the term
"zeolite" refers to all natural and synthetic forms of zeolite. In certain embodiments, the
zeolite may be present as fine particulate materials. In other embodiments, the zeolite may
be present as small particulate materials. In other embodiments, the zeolite may be present
as medium particulate materials. In other embodiments, the zeolite may be present as large
particulate materials. In certain embodiments, the zeolite may be present in the cementing
compositions of the present invention in an amount in the range of from about 10% to about
25% bwoc therein.
In certain embodiments, suitable zeolites for use in present invention may
include "analcime" (which is hydrated sodium aluminum silicate), "bikitaite" (which is
lithium aluminum silicate), "brewsterite" (which is hydrated strontium barium calcium
aluminum silicate), "chabazite" (which is hydrated calcium aluminum silicate),
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"clinoptilolite" (which is hydrated sodium aluminum silicate), "faujasite" (which is hydrated
sodium potassium calcium magnesium aluminum silicate), "harmotome" (which is hydrated
barium aluminum silicate), "heulandite"(which is hydrated sodium calcium aluminum
silicate), "laumontite" (which is hydrated calcium aluminum silicate), c?nesolite" (which is
hydrated sodium calcium aluminum silicate), "natrolite" (which is hydrated sodium
aluminum silicate), "paulingitey' (which is hydrated potassium sodium calcium barium
aluminum silicate), "phillipsite" (which is hydrated potassium sodium calcium aluminum
silicate), "scolecite" (which is hydrated calcium aluminum silicate), "stellerite" (which is
hydrated calcium aluminum silicate), "stilbite" (which is hydrated sodium calcium
aluminum silicate), and "thomsonite" (which is hydrated sodium calcium aluminum silicate),
and combinations thereof. In certain embodiments, suitable zeolites for use in the present
invention include chabazite and clinoptilolite. An example of a suitable source of zeolite is
available fiom the C2C Zeolite Corporation of Calgary, Canada.
In certain embodiments, the cementing compositions of the present invention
may comprise amorphous silica. Amorphous silica is generally a byproduct of a fenosilicon
production process, wherein the amorphous silica may be formed by oxidation and
condensation of gaseous silicon suboxide, SiO, which is formed as an intermediate during
the process. An example of a suitable source of amorphous silica is commercially available
from Halliburton Energy Services, Inc., Duncan, Oklahoma, under the trade name
"SILICALITE." In certain embodiments, the amorphous silica may be present as very fine
particulate materials. In other embodiments, the amorphous silica may be present as fine
particulate materials. In other embodiments, the amorphous silica may be present as small
particulate materials. In other embodiments, the amorphous silica may be present as
medium particulate materials. In certain embodiments, the amorphous silica may be present
in the cementing compositions of the present invention in an amount in the range of from
about 5% to about 40% bwoc therein.
The water used in the cementing compositions of the present invention may
include freshwater, saltwater (e.g., water containing one or more salts dissolved therein),
brine (e.g., saturated saltwater produced from subterranean formations), seawater, or
combinations thereof. Generally, the water may be from any source, provided that it does
not contain an excess of compounds that may adversely affect other components in the
cementing composition. In some embodiments, the water may be included in an amount
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sufficient to form a pumpable slurry. In some embodiments, the water may be included in
the cementing compositions of the present invention in an amount in the range of fiom about
40% to about 200% by weight. As used herein, the term "by weight," when used herein to
refer to the percent of a component in the cementing composition, means by weight included
in the cementing compositions of the present invention relative to the weight of the dry
components in the cementing composition. In some embodiments, the water may be
included in an mount in the range of from about 40% to about 150% by weight.
The cementing compositions of the present invention may optionally comprise
a hydraulic cement. A variety of hydraulic cements may be utilized in accordance with the
present invention, including, but not limited to, those comprising calcium, aluminum,
silicon, oxygen, iron, andor sulfur, which set and harden by reaction with water. Suitable
hydraulic cements include, but are not limited to, Portland cements, pozzolana cements,
gypsum cements, high alumina content cements, slag cements, silica cements, and
combinations thereof. In certain embodiments, the hydraulic cement may comprise a
Portland cement. In some embodiments, the Portland cements that are suited for use in the
present invention are classified as Classes A, C, H, and G cements according to American
Petroleum Institute, API Specfication for Materials and Testing for Well Cements, MI
Specification 10, Fifth Ed., July 1, 1990. In certain embodiments, the cement may be
present in the cementing compositions of the present invention in an amount in the range of
from about 20% to about 50% bwoc therein.
In certain embodiments, the cementing compositions of the present invention
hrther may comprise a set retarding additive. As used herein, the term "set retarding
additive" refers to an additive that retards the setting of the cementing compositions of the
present invention. Examples of suitable set retarding additives include, but are not limited
to, ammonium, alkali metals, alkaline earth metals, metal salts of sulfoalkylated lignins,
hydroxycarboxy acids, copolymers that comprise acrylic acid or maleic acid, and
combinations thereof One example of a suitable sulfoalkylate lignin comprises a
sulfomethylated lignin. Suitable set retarding additives are disclosed in more detail in
United States Patent No. Re. 3 1,190, the entire disclosure of which is incorporated herein by
reference. Suitable set retarding additives are colnmercially available from Halliburton
Energy Services, kc. in Duncan, Oklahoma, under the tradenames "HR@ 4," '"@ 5," HR@
7," "HRQ 12," " I S R ~ ~ ~H,R"e 25," "SCRTM 100," and "SCRT" 500." Generally, where
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used, the set retarding additive may be included in the cementing compositions of the present
invention in an amount sufficient to provide the desired set retardation. In some
embodiments, the set retarding additive may be present in an amount in the range of from
about 0.1% to about 5% by weight.
Optionally, other additional additives may be added to the cementing
compositions of the present invention as deemed appropriate by one skilled in the art, with
the benefit of this disclosure. Examples of such additives include, but are not limited to,
accelerators, weight reducing additives, heavyweight additives, lost circulation materials,
filtration control additives, dispersants, and combinations thereof. Suitable examples of
these additives include crystalline silica compounds, amorphous silica, salts, fibers,
hydratable clays, microspheres, pozzolan lime, latex cement, thixotropic additives,
combinations thereof and the like.
An example of a cementing composition of the present invention may
comprise water, cement, CKD, amorphous silica, and vitrified shale. Another example of a
cementing composition of the present invention may comprise water, cement, CKD,
amorphous silica, zeolite, and vitrified shale. As desired by one of ordinary skill in the art,
with the benefit of this disclosure, such cementing composition of the present invention
further may comprise any of the above-listed additives, as well any of a variety of other
additives suitable for use in subterranean applications.
The cementing compositions of the present invention may be used in a variety
of subterranean applications, including, but not limited to, primary, cementing, remedial
cementing, and dnlling operations. The cementing compositions of the present invention
also may be used in surface applications, for example, construction cementing.
An example of a method of the present invention comprises providing a
cementing composition of the present invention comprising water and particulate materials
in a hindered settling state; placing the cementing composition in a location to be cemented;
and allowing the cementing composition to set therein. In some embodiments, the location
to be cemented may be above ground, for example, in construction cementing. In some
embodiments, the location to be cemented may be in a subterranean formation, for example,
in subterranean applications. As desired by one of ordinary skill in the art, with the benefit
of this disclosure, the cementing compositions of the present invention useful in this method
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further may comprise any of the above-listed additives, as well any of a variety of other
additives suitable for use in subterranean applications.
Therefore, the present invention is well adapted to attain the ends and
advantages mentioned as well as those that are inherent therein. While numerous changes
may be made by those skilled in the art, such changes are encompassed within the spirit of
this invention as defined by the appended claims. The terms in the claims have their plain,
ordinary meaning unless otherwise explicitly and clearly defined by the patentee.
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We claim:-
1. A method of cementing, comprising:
maximizing a packing volume fraction in a cementing composition using at least one
particulate material with a particle size in the range of from about 7 nanometers to
about 1 millimeter, the at least one particulate material selected from the group
consisting of cement kiln dust, vitrified shale, zeolite, and combinations thereof;
introducing the cementing composition into a subterranean formation; and
allowing the cementing composition to set in the subterranean formation.
2. The method of claim 1 wherein the cementing composition comprises a
hydraulic cement.
3. The method of claim 1 wherein the cementing composition comprises
Portland cement.
4. The method of claim 1 wherein the at least one particulate material
comprises the cement kiln dust.
5. The method of claim 1 wherein the at least one particulate material
comprises the vitrified shale.
6. The method of claim 1 wherein the at least one particulate material
comprises the zeolite.
7. The method of claim 1 wherein the cementing composition comprises at
least three different particle sizes selected from the group consisting of a particle size
in the range of from about 7 nanometers to about 50 nanometers, a particle size in the
range of from about 0.05 microns to about 0.5 microns, a particle size in the range of
from about 0.5 microns to about 10 microns, a particle size in the range of from about
10 microns to about 20 microns, a particle size in the range of from about 20 microns
to about 200 microns, a particle size in the range of from about 200 microns to about
800 microns, and a particle size greater than about 1 millimeter.
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8. A method of cementing, comprising:
introducing a cementing composition into a subterranean formation, wherein the
cementing composition comprises water, hydraulic cement, and at least one
particulate material with a particle size in the range of from about 7 nanometers to
about 1 millimeter, the at least one particulate material selected from the group
consisting of cement kiln dust, vitrified shale, zeolite, and combinations thereof;
wherein a solids volume total in the cementing compositions comprises a maximum
packing volume fraction; and
allowing the cementing composition to set in the subterranean formation.
9. The method of claim 8 wherein the hydraulic cement comprises Portland
cement.
10. The method of claim 8 wherein the at least one particulate material
comprises the cement kiln dust.
11. The method of claim 8 wherein the at least one particulate material
comprises the vitrified shale.
12. The method of claim 8 wherein the at least one particulate material
comprises the zeolite.
13. The method of claim 8 wherein the solids volume present in the cement
composition comprises at least three different particle sizes selected from the group
consisting of a particle size in the range of from about 7 nanometers to about 50
nanometers, a particle size in the range of from about 0.05 microns to about 0.5
microns, a particle size in the range of from about 0.5 microns to about 10 microns, a
particle size in the range of from about 10 microns to about 20 microns, a particle size
in the range of from about 20 microns to about 200 microns, a particle size in the
range of from about 200 microns to about 800 microns, and a particle size greater
than about 1 millimeter.
14. A method of cementing comprising:
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providing an unhydrated mixture of at least three particulate materials chosen from
the group consisting of:
(a) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 7 nanometers to about 50 nanometers;
(b) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 0.05 microns to about 0.5 microns;
(c) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 0.5 microns to about 10 microns;
(d) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle
size in the range of from about 10 microns to about 20 microns;
(e) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 20 microns to about 200 microns;
(f) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 200 microns to about 800 microns; and
(g) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
greater than about 1 millimeter,
wherein a solids volume total of the at least three particulate materials comprises a
maximum packing volume fraction
adding water to the unhydrated mixture to form a settable composition; and
placing the settable composition in a subterranean formation.
15. The method of claim 14 wherein the settable composition comprises a
hydraulic cement.
16. The method of claim 14 wherein the unhydrated mixture comprises at
least one material selected from the group consisting of silica, hematite, iron oxide,
barium hydroxide, a carbonate, alumina, an organic product, and combinations
thereof.
17. The method of claim 14 wherein the cement kiln dust is present in the
settable composition in an amount in the range of from about 25% to about 75% by
weight of the settable composition.
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18. The method of claim 14 wherein the vitrified shale is present in the
settable composition an amount in the range of from about 10% to about 30% by
weight of the settable composition.
19. The method of claim 14 wherein the zeolite is present in the settable
composition in an amount in the range of from about 10% to about 25% by weight of
the settable composition.
20. The method of claim 14 wherein the amorphous silica is present in the
settable composition in an amount in the range of from about 5% to about 40% by
weight of the settable composition.
21. A method comprising:
providing a cementing composition, wherein the cementing composition comprises
water; and at least three particulate materials chosen from the group consisting of:
(a) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 7 nanometers to about 50 nanometers;
(b) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 0.05 microns to about 0.5 microns;
(c) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 0.5 microns to about 10 microns;
(d) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle
size in the range of from about 10 microns to about 20 microns;
(e) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 20 microns to about 200 microns;
(f) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 200 microns to about 800 microns; and
(g) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
greater than about 1 millimeter,
wherein a solids volume total of the at least three particulate materials comprises a
maximum packing volume fraction; and
placing the cementing composition in a subterranean formation.
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22. The method of claim 21 further comprising the step of allowing the
cementing composition to set therein.
23. The method of claim 21 wherein the water is selected from the group
consisting of freshwater, saltwater, a brine, seawater, and combinations thereof.
24. The method of claim 21 wherein the cementing composition comprises a
hydraulic cement.
25. The method of claim 21 wherein the cementing composition comprises at
least one material selected from the group consisting of silica, hematite, iron oxide,
barium hydroxide, a carbonate, alumina, an organic product, and combinations
thereof.
26. The method of claim 21 wherein the cementing composition comprises at
least one additive selected from the group consisting of a set retarding additive, an
accelerator, a lost circulation material, a filtration control additive, a dispersant, and
combinations thereof.
27. The method of claim 21 wherein the cement kiln dust is present in the
cementing composition in an amount in the range of from about 25% to about 75%
by weight of the cementing composition.
28. The method of claim 21 wherein the vitrified shale is present in the
cementing composition an amount in the range of from about 10% to about 30% by
weight of the cementing composition.
29. The method of claim 21 wherein the zeolite is present in the cementing
composition in an amount in the range of from about 10% to about 25% by weight of
the cementing composition.
30. The method of claim 21 wherein the amorphous silica is present in the
cementing composition in an amount in the range of from about 5% to about 40% by
weight of the cementing composition.
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31. A method of cementing, comprising:
introducing a cementing composition into an annular space between a subterranean
formation and a pipe string disposed in the subterranean formation, wherein the
cementing composition comprises water, and at least three particulate materials
chosen from the group consisting of:
(a) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 7 nanometers to about 50 nanometers;
(b) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 0.05 microns to about 0.5 microns;
(c) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 0.5 microns to about 10 microns;
(d) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle
size in the range of from about 10 microns to about 20 microns;
(e) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 20 microns to about 200 microns;
(f) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
in the range of from about 200 microns to about 800 microns; and
(g) cement kiln dust, vitrified shale, zeolite, or amorphous silica having a particle size
greater than about 1 millimeter,
wherein a solids volume total of the at least three particulate materials comprises a
maximum packing volume fraction; and
allowing the cementing composition to set in the annular space.
32. The method of claim 31 wherein the cement kiln dust is present in the
cementing composition in an amount in the range of from about 25% to about 75%
by weight of the cementing composition.
33. The method of claim 31 wherein the vitrified shale is present in the
cementing composition an amount in the range of from about 10% to about 30% by
weight of the cementing composition.