Cement with reduced permeability
11325865 · 2022-05-10
Assignee
Inventors
Cpc classification
C09K8/487
CHEMISTRY; METALLURGY
C04B14/043
CHEMISTRY; METALLURGY
C04B20/008
CHEMISTRY; METALLURGY
C04B28/105
CHEMISTRY; METALLURGY
C04B28/24
CHEMISTRY; METALLURGY
C04B20/008
CHEMISTRY; METALLURGY
C04B14/043
CHEMISTRY; METALLURGY
C04B28/02
CHEMISTRY; METALLURGY
C04B28/02
CHEMISTRY; METALLURGY
C09K8/46
CHEMISTRY; METALLURGY
C04B28/24
CHEMISTRY; METALLURGY
C09K8/493
CHEMISTRY; METALLURGY
C04B2111/00275
CHEMISTRY; METALLURGY
International classification
Abstract
A cementitious mixture to make structures with reduction of gas permeability was disclosed. The mixture includes, cementitious materials, and one or more divalent magnesium-iron silicate that in neutral or basic aqueous solutions have the capacity to be a latent hydraulic binder comprising 2% to 99% of divalent magnesium-iron silicate by weight of total hydraulic solid materials. This can be used to produce a cementitious structure for preventing gas transfer between a first region and a second region. A cement slurry was also disclosed.
Claims
1. A cementitious mixture for reduced gas permeability that comprises: a) an alkaline cement; b) one or more divalent magnesium-iron silicate from a natural earth-based system wherein more magnesium ions than iron ions are present that in neutral or basic aqueous solutions is a latent hydraulic binder comprising 2% to 99% of divalent magnesium-iron silicate by weight of total hydraulic solid materials.
2. The cementitious mixture of claim 1, wherein the magnesium-iron silicate is by weight of total hydraulic solid is between 10% and 98%.
3. The cementitious mixture of claim 1, wherein the magnesium-iron silicate by weight of total hydraulic solid is between 15% and 99%.
4. The cementitious mixture of claim 1, wherein the magnesium-iron silicate by weight of total hydraulic solid is between 10% and 55%.
5. The cementitious mixture of claim 1, wherein the magnesium-iron silicate by weight of total hydraulic solid is between 20% and 50%.
6. The cementitious mixture of claim 1, wherein the magnesium-iron silicate by weight of total hydraulic solid is between 20% and 80%.
7. The cementitious mixture of claim 1, wherein the magnesium-iron silicate by weight of total hydraulic solid is between 15% and 25%.
8. The cementitious mixture of claim 1, wherein the magnesium-iron silicate comprises mineral group olivines, orthopyroxenes, amphiboles, serpentines, or a mixture thereof.
9. The cementitious mixture of claim 1, wherein the magnesium-iron silicate consists of mineral group olivines, orthopyroxenes, amphiboles, serpentines, or a mixture thereof.
10. The cementitious mixture of claim 1, wherein the magnesium-iron silicate is of mineral group orthopyroxenes.
11. A cementitious slurry for reduced gas permeability that comprises: a) an alkaline cement; b) water; and c) one or more divalent magnesium-iron silicate from a natural earth-based system wherein more magnesium ions than iron ions are present that in neutral or basic aqueous solutions is a latent hydraulic binder comprising 2% to 99% of divalent magnesium-iron silicate by weight of total hydraulic solid materials.
12. The cementitious slurry of claim 11, wherein the magnesium-iron silicate by weight of total hydraulic solid is between 15% and 25%.
13. The cementitious slurry of claim 11, wherein the magnesium-iron silicate by weight of total hydraulic solid is between 10% and 55%.
14. The cementitious slurry of claim 11, wherein the magnesium-iron silicate by weight of total hydraulic solid is between 20% and 80%.
15. The cementitious slurry of claim 11, wherein the magnesium-iron silicate comprises mineral group olivines, orthopyroxenes, amphiboles, serpentines, or a mixture thereof.
16. The cementitious slurry of claim 11, wherein the magnesium-iron silicate is of mineral group orthopyroxenes.
17. The cementitious slurry according to claim 11, wherein the water has a chloride concentration of between 0.4% to 14 by weight.
18. The cementitious mixture of claim 5, wherein the magnesium-iron silicate is of mineral group orthopyroxenes.
19. The cementitious mixture of claim 7, wherein the magnesium-iron silicate is of mineral group orthopyroxenes.
20. The cementitious slurry of claim 13, wherein the magnesium-iron silicate is of mineral group orthopyroxenes.
Description
DESCRIPTION OF THE FIGURES
(1) The above and further features of the invention are a set forth with particularity in the appended claims and together with advantages thereof will become clearer from consideration of the following detailed description. Embodiments of the present invention will now be described, by way of example only, with reference to the following diagrams wherein:
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DESCRIPTION OF EMBODIMENTS OF THE INVENTION
(11) Reference will now be made in detail to the present embodiments of the inventions, examples of which are illustrated in the accompanying drawings. Alternative embodiments will also be presented. The drawings are intended to be read in conjunction with both the summary, the detailed description, and an any preferred and/or particular embodiments, specifically discussed or otherwise disclosed. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided by way of illustration only. Several further embodiments, or combinations of the presented embodiments, will be within the scope of one skilled in the art.
(12) Direction terms such as up, down, left, right, above, below, etc. are being used in reference to the orientation of the elements in the figures. In no way is this intended as limiting.
(13) This invention is an extension of previous work with a cementitious material that seal off liquids and gasses. However, we have found that the materials are significantly better at sealing off gaseous materials than previously predicted or expected. While liquids and supercritical fluids are in the reservoirs of petroleum systems at crustal pressures and temperatures, the phase transformation from liquid to fluid can bring on a major pressure release. This e.g. can occur when liquids in the reservoir zone under pressure flows toward and into the well with less pressure. This invention works well for saltwater or fresh water used in mixing the slurry.
(14) At formation pressures and temperatures a gas may be transformed to a supercritical fluid. An example is CO.sub.2 gas, which becomes supercritical at temperatures above 31° C. at a pressure of 73.8 bar. Supercritical fluids have a viscosity similar to a gas but a density similar to the corresponding liquid.
(15) Permeability is dependent on the viscosity of the gas or fluid that is flowing through the matrix. Therefore, the properties of the supercritical fluids are similar to the properties of the corresponding gas in this invention. The supercritical fluid of a gas molecule (e.g. CO.sub.2, H.sub.2S, N.sub.2, CH.sub.4) will behave roughly same as a non-supercritical fluid of a gas molecule with regards to the reduced permeability properties of the invention.
(16) The inventors observed that very low concentrations of magnesium-iron silicate may have properties that are significant for operations that need blends very close to ordinary blends, while exploiting gas proofing. Likewise, blends that are nearly all magnesium-iron silicates with a small concentration of cementitious materials will potentially need longer to set but will have a much lower permeability once set. As mentioned previously, the inventors observed that magnesium-iron silicates provided self-healing characteristics. However, the reduction in permeability was incredibly surprising even in the face of the potential self-healing properties.
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(18) Though
(19) The invention is well suited for use in making plugs and other cement structures to prevent gas from moving or flowing into areas where it is not wanted.
(20) The term “gas proof” refers to a structure having a low enough gas permeability that, ideally, a gas cannot cross from one region to another. However, depending upon the application, a gas permeability lower than an accepted threshold will be considered sufficiently “gas proof”.
CARBON DIOXIDE EXPERIMENTS
(21) Numerous experiments were performed to measure the permeability of a cement structure (e.g. plug) to water saturated with carbon dioxide. Note that usually a cement plug will be about 100 times more permeable to gas than it is to a liquid.
Carbon Dioxide Experiment 1
(22) Previous work in U.S. Ser. No. 10/774,001 has shown that a mixture including olivine has properties related to self-healing in the presence of water or carbon dioxide. This includes a disclosure of reduction of permeability after a multiple day exposure to water saturated with CO2. This was thought to be due to water or saltwater being carried into the pores and voids and triggering the “self-healing” reactions that result in matter being precipitated there.
(23) The results of such an experiment are shown in
(24) Prior to injection, the core sample was heated to a stable temperature of 60° C. and pressurized to a confining pressure of 110 bar, where both parameters, where kept constant throughout the experiment. Seawater (saturated with CO.sub.2) was subsequently injected into the core with a high pressure Quizix piston pump. Flow rate was set at low as 360 microliters/hour, and back pressure was set to 10 bars. Differential pressure was measured at steady state conditions at each rate, and permeability calculated according to Darcy's Law.
(25) An additional, a long-term seawater test was conducted, and the permeability calculated. The initial permeability was 0.26 μDarcy. After nearly 11 days of brine flooding and 45 ml of seawater injected, the permeability reduced to 0.129 μDarcy, as shown in
Carbon Dioxide Experiment 2
(26) An experiment was performed where sea water saturated with carbon dioxide was forced through the sample as it cured. The results are shown in
Carbon Dioxide Experiment 3
(27) Another experiment was performed that studied the results of permeability to brine that was saturated in CO2. Batch CO.sub.2 exposure was performed for seven days in an autoclave at 90° C. and 280 bar. The cores were submerged in 1.0 wt % NaCl-brine and dry CO.sub.2 was pumped in from the inlet at the top of the autoclave, forming a gas cap and ensuring that the brine was saturated with CO.sub.2. No brine was added or replaced during the exposure.
(28) Porosity before and after CO.sub.2 exposure for batches with different percentages of the magnesium-iron silicate (olivine in this case) as shown in Table 1 below:
(29) TABLE-US-00001 TABLE 1 Initial and final porosity after CO.sub.2 exposure as estimated from CT results. % Core Initial Final % Olivine Number Porosity Porosity Reduced 20% 4 0.5 0.1 80% 5 1.2 0.4 67% 6 0.75 0.3 60% 35% 5 0.8 0.2 75% 6 0.4 0.05 88% 50% 4 0.6 0.1 83%
(30) This again shows the ability of the present invention to greatly reduce the permeability of cement to CO.sub.2 across the percentage ranges of the magnesium-iron silicate. It would be expected that the results would extend over a wider range.
Carbon Dioxide Experiment 4
(31) Reference is now made to
Carbon Dioxide Experiment 5
(32) In an experiment, solid cementitious mineral admixture products were fabricated based on a mixture of 80% Portland cement, and 20% olivine (which is a divalent magnesium-iron solid solution silicate) by weight, and water having an ordinary W/C number (W/C=water to cement ratio). The fraction of olivine was 0.2 with denatured water added. A solid cementitious mineral admixture cylinder was prepared and flooded by a seawater analog brine for a period of eleven days. The changes of permeability was measured throughout the experiment and the porosity was evaluated before and after the experiment by using a CT scanner.
(33) The measurements showed that porosity of the product, when applying the inventive cementitious mineral admixture was reduced by as much as 55%, and permeability went down by 70% after said just eleven days exposed to brine. The experiments show that the gas permeability of the resulting cement decreased.
NITROGEN EXPERIMENTS
(34) We will now discuss a series of different permeability experiments using nitrogen gas. For these experiments, the gas will not be dissolved in water. This is a different type of experiment than has been performed previously.
(35) As discussed previously under Carbon Dioxide Experiment 1, when water or saltwater is forced into the body of the solidified cement plug, the self-healing reactions cause the pores to fill with new material. However, in experiments that do not have an appreciable amount of water, this cannot be the case.
(36) Any reduction in permeability of the cement to a gas which is not dissolved in water, is not expected in light of previous work with this inventive mixture for self-healing. Note that the amount of water vapor that can be dissolved in nitrogen is very low and will not significantly contribute reducing permeability through self-healing.
Nitrogen Experiment 1
(37) Reference is made to
(38) A study published in SPE/IADC-194158-MS, shows how neat cement cured at 66 degrees C. and silicate added cement cured at 120 degree C. inside a smooth casing tube under pressure, the cement was cured for four days and then N.sub.2 was allowed to be pushed through the cement-casing apparatus. The study indicated that neat and silicate added cement had fairly significant leaks through the experiment and was not a good seal against flow of N2 at even low differential pressures. The authors of the paper indicated that “Both cement systems, neat cement and silica cement, cured at their optimum temperature are not sufficient to produce a tight seal plug. Leak path development at the interface is consistent with shrinkage mechanism during hydration.”
(39) The inventors replicated this experiment using 66 degree Centigrade and 20% of the finely crushed olivine with 80% Portland cement in the mixture. The results are shown
(40) It can be shown that the permeability of a sample is inversely proportional to the square of the differential pressure.
Nitrogen Experiment 2
(41) An experiment was conducted over a range of pressures in order to establish the difference between the present invention and Portland G cement. Each were made using a standard process and a standard water to solid ratio.
(42) The setup consists of a custom-built test cell 10 containing the cement plug placed inside a heating cabinet for temperature control, and a process board located outside the heating cabinet with the process tubing, valves, flow meters, pressure indicators, an automated pressure regulator and an automated logging system. A technical drawing of the test cell 10 is shown in
(43) A pressure test at 100 bar and 22° C. was performed on the test cell showing no signs of deformation on pipe diameter or damage to the pipe threads.
(44) The test setup is also equipped with a temperature probe for control of the experimental conditions. The output data from the tests is the differential pressure needed to observe breakthrough of gas through the cement plug, and the relationship between the measured flow rate and differential pressure across the cement plug. Possible manipulated variables for the test setup can be the cement type and casing surface properties.
(45) Before every new experiment, a pressure test was performed on every new test cell. This was done by fully mounting the test setup with no cement inside the cell. The setup would then be pressured up to the working pressure (20 bar) and the main valve to the pressure bottle would be closed. By monitoring the decrease in pressure over a period of 1-2 hours, the level of gas leakage from the entire setup was monitored. In an ideal situation there would be zero leakage; in a case of losing more the ˜1 bar over 1 hour an attempt to localize the leakage would be performed. If the pressure test was assessed to be successful, the gas in the setup would be evacuated and the top cap to the test cell would be unscrewed.
(46) The cement placement was performed by moving the teflon piston in its top-position and by pouring the designated cement volume into the test cell. All valves would be opened, and the automated pressure regulator would be set to maintain a minimum pressure of 20 bar. The top cap would be screwed in place tightly and the cell would be carefully pressurized to 20 bars. The cement plug would be left to cure at 20 bar and 66° C. for 5 days.
(47) The cement plug integrity test started by moving the teflon piston down, leading to an open volume above and below the cement plug. By closing a valve, the two chambers would be isolated from each other and the only connection between them could be through the cement plug. By using the automated pressure-regulator a controlled differential pressure across the cement plug was generated. When the differential pressure was large enough for enabling flow through the cement plug, the pressure regulator connected to the bottom chamber would detect a decrease in pressure, and the regulator would try to maintain the set pressure. This flow of gas from the gas bottle through the process line would be detected by the flow meters. A sequential increase in the differential pressure would be applied to the cement plug. Thus, each experiment gives the pressure differential to which there is gas breakthrough the cement plug, and the relationship between the applied differential pressure and the flow rate through the cement plug. Figure (The one with the data) shows the raw data of flow rate and differential pressure plotted versus time for one of the experiments. For the data analysis and presentation of data stable values of the flow rate and differential pressure would be extracted and plotted against each other.
(48) Test samples were made using 0%, 20%, and 80% of olivine by weight of total cementitious solids. The results of this are shown in the table below:
(49) TABLE-US-00002 TABLE 2 Permeability of Sample/Permeability of net Portland Cement % of Permeability Magnesium- Relative % Iron Pressure to Portland Silicate (bar) Cement 20% 1.014 4.0% 20% 1.073 4.6% 20% 1.084 3.4% 20% 1.084 1.9% 80% 1.620 1.7% 80% 1.223 1.5% 80% 1.590 1.0%
(50) This clearly shows the improvement of the present invention when compared to Portland G for permeability to nitrogen over a wide range of pressures.
Nitrogen Experiment 3
(51) Reference is now made to
(52) The setup for a cement plug test consists of a custom-built test cell containing the cement plug placed inside a heating cabinet for temperature control, and a process board located outside the heating cabinet with the process tubing, valves, flow meters, pressure indicators, an automated pressure regulator and an automated logging system.
(53) The results of the 20% magnesium-iron silicate tests are shown in
(54) Compare those to the two other lines on
(55) Reference is made to
(56) It can be shown that the permeability of a sample is inversely proportional to the square of the differential pressure.
Nitrogen Experiment 5
(57) The permeability of a solidified test sample from the present invention was measured using an apparatus as disclosed in Appendix B-4.11 (“Permeability”) of “Well Cementing”, second edition, edited by Erik B. Nelson and Dominique Guillot. This type of test apparatus and setup is well known in the industry where cement permeability to gas needs to be measured.
(58) The samples had a measured permeability of between 0.03 μD and 0.006 μD to nitrogen gas.
(59) As nitrogen gas has a very small diameter, it is expected that molecules of approximately the same size (e.g. methane) or larger molecules (e.g. carbon dioxide) will also behave similarly.
(60) It is a very surprising for such a large reduction of gas permeability. The present invention should be able to achieve solid structures with a gas permeability of at most 1 μD, preferably 0.5 μD, more preferably 0.1 μD, even more preferably 0.05 μD, and most preferably 0.005 μD.
(61) Something that must be kept in mind is that gases have, in general, viscosities (compared to liquids) that indicate that if a low viscosity gas is not passing through, then the higher viscosity gas will not pass through (per Darcy's law). In other words, if nitrogen gas does not have the possibility to pass through the pores of the cement it will not be possible for gas types (e.g. CO2, CH4, and H2S being some of the most important) to pass through the pore pathway (e.g. permeability) of the cement.
(62) Additionally, this behavior will be the same if the cement is in saltwater or freshwater. Nitrogen does not dissolve appreciable in water, and salt would not change this situation, so it is readily apparent that the results of the nitrogen experiments can be extended to saltwater. It is well known that saltwater will degrade the structure of regular cement. Using freshwater causes less of this degradation. While it is surprising how well the present invention performs in saltwater, there is no reason to assume that it will not perform as well or better in fresh water. It is expected that water has a chloride concentration of between 0.4% to 14% by weight of water would not appreciably affect the previously presented permeability results. The most common saltwater that are found has a chloride concentration of between 0.7% and 10% by weight of water. Freshwater sources will normally have a chloride concentration of less than 250 mg/L.
(63) For guidance of one skilled in the art, the table below gives the percentage of magnesium-iron silicates in the solid mixture that are highly suited to different applications:
(64) TABLE-US-00003 TABLE 3 Effect of percentage of magnesium-iron silicates on different desired characteristics on the final cement structure Ideal % of Magnesium- Iron Silicate Characteristic Low High High Strength of Solid 2 35 Expansion to Compensate Shrinking 10 98 Sealing of Pores and Channels 15 99 Sealing of Pore Necks 2 99
(65) The table above is not a definitive statement of where the present invention has no effect. It is intended to give one skilled in the art an understanding of ranges to choose if one than one effect is important. For example, the range of 15% to 35% shows the best balance of characteristics for numerous applications. However, tests that have been performed of strength at 10% and 55% magnesium-iron silicate have demonstrated that the present invention is a significant improvement over Portland G.
(66) In the current state of the cement industry, 10-55% is the easiest range for a company to add to their current production line. With a change in the process, however, the other ranges of use described in the table above, will be achieved. As shown above, the gas permeability characteristics of the present invention are very desirable over a large range of percentages.