Settable fluids comprising particle-size distribution-adjusting agents and methods of use

Abstract

The present invention relates to subterranean operations, and more particularly, to settable fluids comprising particle-size distribution-adjusting agents, and methods of using such settable fluids in subterranean and surface applications. In certain exemplary embodiments of the present invention, the settable fluid comprises a cement, a set retarder, and a particle-size distribution-adjusting agent. Exemplary methods of the present invention include, but are not limited to, methods of drilling with the settable fluids of the present invention, methods of cementing with the settable fluids of the present invention, and methods of using a settable fluid of the present invention to displace another fluid from a well bore in a subterranean formation.

1 . A method of cementing, comprising the steps of: providing a cement composition comprising a hydraulic cement, a set retarder, and a particle-size distribution-adjusting agent; activating the cement composition; placing the cement composition in a desired location; and permitting the cement composition to set therein.  
     
     
         2 . The method of  claim 1  wherein the cement composition further comprises water, and wherein the water is fresh water, salt water, brine, sea water, or a mixture thereof.  
     
     
         3 . The method of  claim 2  wherein the water is present in the cement composition in an amount sufficient to form a pumpable slurry.  
     
     
         4 . The method of  claim 3  wherein the water is present in the cement composition in an amount in the range of from about 25% to about 150% by weight of the cement.  
     
     
         5 . The method of  claim 1  wherein the hydraulic cement is a Portland cement, pozzolana cement, gypsum cement, high alumina cement, silica cement, or a high alkalinity cement.  
     
     
         6 . The method of  claim 2  wherein the step of providing a cement composition comprises providing a densified cement composition.  
     
     
         7 . The method of  claim 6  wherein the step of providing a densified cement composition comprises the step of adding high-density particles to the cement composition.  
     
     
         8 . The method of  claim 6  wherein the step of providing a densified cement composition comprises the step of reducing the amount of water in the cement composition.  
     
     
         9 . The method of  claim 6  wherein the cement composition further comprises a yield stress reducing agent.  
     
     
         10 . The method of  claim 1  wherein the set retarder is phosphonic acid or a phosphonic acid derivative.  
     
     
         11 . The method of  claim 10  wherein the phosphonic acid derivative is a sodium salt of phosphonic acid.  
     
     
         12 . The method of  claim 1  wherein the set retarder is present in the cement composition in an amount in the range of from about 0.1% to about 5% by weight of the cement.  
     
     
         13 . The method of  claim 1  wherein the step of activating the cement composition comprises adding an activator composition to the cement composition.  
     
     
         14 . The method of  claim 13  wherein the activator composition is added in an amount sufficient to enable the cement composition to achieve a desired compressive strength in a desired thickening time.  
     
     
         15 . The method of  claim 14  wherein the activator composition is added in an amount in the range of from about 0.1 to about 5% by weight of the cement.  
     
     
         16 . The method of  claim 15  wherein the activator composition comprises a mixture of a trialkanolamine and an alkali or alkaline earth metal hydroxide.  
     
     
         17 . The method of  claim 16  wherein the trialkanolamine is selected from the group consisting of: triethanolamine, tripropanolamine, and triisopropanolamine.  
     
     
         18 . The method of  claim 16  wherein the alkali or alkaline earth metal hydroxide is selected from the group consisting of sodium hydroxide and potassium hydroxide.  
     
     
         19 . The method of  claim 16  wherein the trialkanolamine is present in an amount in the range of from about 0.1% to about 50% by weight of the activator composition.  
     
     
         20 . The method of  claim 16  wherein the alkali metal hydroxide is present in an amount in the range of from about 50% to about 99.9% by weight of the activator composition.  
     
     
         21 . The method of  claim 18  wherein the alkali metal hydroxide is sodium hydroxide.  
     
     
         22 . The method of  claim 16  wherein the activator composition is added to the cement composition in the form of a solution diluted by water.  
     
     
         23 . The method of  claim 16  wherein the activator composition is added to the cement composition while the cement composition is in storage.  
     
     
         24 . The method of  claim 16  wherein the activator composition is added to the cement composition while the cement composition is being placed in the subterranean formation.  
     
     
         25 . The method of  claim 1  wherein the particle-size distribution-adjusting agent is present in the cement composition in an amount sufficient to adjust the particle-size distribution of the cement composition to a desired range.  
     
     
         26 . The method of  claim 1  wherein the cement composition comprising the particle-size distribution-adjusting agent has a particle-size distribution that is narrower than that of the cement composition lacking the particle-size distribution-adjusting agent.  
     
     
         27 . The method of  claim 1  wherein the particle-size distribution-adjusting agent is present in the cement composition in an amount in the range of from about 0.01% to about 4% by weight of the cement.  
     
     
         28 . The method of  claim 1  wherein the particle-size distribution-adjusting agent is a compound that affects the particle-size distribution of the cement such that the rheology of the cement composition remains substantially stable for a desired period of time.  
     
     
         29 . The method of  claim 1  wherein the particle-size distribution-adjusting agent is a cationic polymer.  
     
     
         30 . The method of  claim 29  wherein the cationic polymer is selected from the group consisting of: cationic polyacrylamides; cationic hydroxyethyl cellulose; poly(dimethyldiallylammonium chloride); and cationic starches.  
     
     
         31 . The method of  claim 1  wherein the cement composition further comprises a surfactant, a dispersant, a salt, mica, a formation conditioning agent, a fixed-density weighting agent, vitrified shale, fumed silica, bentonite, fly ash, a fluid loss control additive, an expanding additive, a defoamer, a viscosifier, or a mixture thereof.  
     
     
         32 . The method of  claim 1  further comprising the step of permitting the cement composition to remain in a slurry state for at least 24 hours.  
     
     
         33 . The method of  claim 1  further comprising the step of permitting the cement composition to remain in a slurry state for at least two weeks.  
     
     
         34 . The method of  claim 1  further comprising the step of permitting the cement composition to remain in a slurry state for more than two weeks.  
     
     
         35 . The method of  claim 1  wherein the suspension properties of the cement composition are substantially uniform throughout the cement composition.  
     
     
         36 . The method of  claim 32  wherein the rheological properties of the cement composition remain substantially constant while the cement composition remains in a slurry state.  
     
     
         37 . The method of  claim 9  wherein the yield stress reducing agent is selected from the group consisting of a sulfonated melamine formaldehyde condensate; a sulfonated napthalene condensate; and a sulfite adduct of an acetone formaldehyde condensate.  
     
     
         38 . The method of  claim 1  wherein the cement composition has a density in the range of from about 4 pounds per gallon to about 25 pounds per gallon.  
     
     
         39 . The method of  claim 1  wherein the cement composition further comprises water, and wherein the water is present in the cement composition in an amount in the range of from about 25% to about 150% by weight of the cement; wherein the set retarder is a phosphonic acid or phosphonic acid derivative; wherein the step of activating the cement composition comprises adding an activator composition to the cement composition; wherein the activator composition comprises a mixture of triethanolamine and an alkali metal hydroxide; wherein the particle-size distribution-adjusting agent is present in the cement composition in an amount in the range of from about 0.01% to about 4% by weight of the cement; wherein the particle-size distribution-adjusting agent is a cationic polymer.  
     
     
         40 . A method of drilling in a subterranean formation comprising the step of drilling a well bore in a subterranean formation using a drilling fluid comprising a cement, a set retarder, and a particle-size distribution-adjusting agent.  
     
     
         41 . The method of  claim 40  further comprising the step of placing a casing string within the well bore.  
     
     
         42 . The method of  claim 40  further comprising the step of mixing an activator composition with the drilling fluid.  
     
     
         43 . The method of  claim 40  further comprising the step of permitting the drilling fluid to set behind the casing string.  
     
     
         44 . The method of  claim 40  wherein the drilling fluid further comprises water, and wherein the water is fresh water, salt water, brine, sea water, or a mixture thereof.  
     
     
         45 . The method of  claim 44  wherein the water is present in the drilling fluid in an amount in the range of from about 25% to about 150% by weight of the cement.  
     
     
         46 . The method of  claim 40  wherein the hydraulic cement is a Portland cement, pozzolana cement, gypsum cement, high alumina cement, silica cement, or a high-alkalinity cement.  
     
     
         47 . The method of  claim 40  wherein the drilling fluid further comprises a yield stress reducing agent.  
     
     
         48 . The method of  claim 40  wherein the set retarder is phosphonic acid or a phosphonic acid derivative.  
     
     
         49 . The method of  claim 48  wherein the phosphonic acid derivative is a sodium salt of phosphonic acid.  
     
     
         50 . The method of  claim 40  wherein the set retarder is present in the drilling fluid in an amount in the range of from about 0.1% to about 5% by weight of the cement.  
     
     
         51 . The method of  claim 42  wherein the activator composition is added in an amount sufficient to enable the drilling fluid to achieve a desired compressive strength in a desired thickening time.  
     
     
         52 . The method of  claim 51  wherein the activator composition is added in an amount in the range of from about 0.1 to about 5% by weight of the cement.  
     
     
         53 . The method of  claim 52  wherein the activator composition comprises a mixture of a trialkanolamine and an alkali or alkaline earth metal hydroxide.  
     
     
         54 . The method of  claim 53  wherein the trialkanolamine is selected from the group consisting of: triethanolamine, tripropanolamine, and triisopropanolamine.  
     
     
         55 . The method of  claim 53  wherein the alkali or alkaline earth metal hydroxide is selected from the group consisting of sodium hydroxide and potassium hydroxide.  
     
     
         56 . The method of  claim 53  wherein the trialkanolamine is present in an amount in the range of from about 0.1% to about 50% by weight of the activator composition.  
     
     
         57 . The method of  claim 53  wherein the alkali metal hydroxide is present in an amount in the range of from about 50% to about 99.9% by weight of the activator composition.  
     
     
         58 . The method of  claim 55  wherein the alkali metal hydroxide is sodium hydroxide.  
     
     
         59 . The method of  claim 40  wherein the particle-size distribution-adjusting agent is present in the drilling fluid in an amount in the range of from about 0.01% to about 4% by weight of the cement.  
     
     
         60 . The method of  claim 40  wherein the particle-size distribution-adjusting agent is a cationic polymer.  
     
     
         61 . The method of  claim 60  wherein the cationic polymer is selected from the group consisting of: cationic polyacrylamides; cationic hydroxyethyl cellulose; poly(dimethyldiallylammonium chloride); and cationic starches.  
     
     
         62 . The method of  claim 47  wherein the yield stress reducing agent is selected from the group consisting of: a sulfonated melamine formaldehyde condensate; a sulfonated napthalene condensate; and a sulfite adduct of an acetone formaldehyde condensate.  
     
     
         63 . A method of using a fluid in a subterranean formation comprising the step of: placing a displacement fluid comprising a cement, a set retarder, a particle-size distribution-adjusting agent, and an activator composition in a well bore in a subterranean formation so as to displace a second fluid therefrom.  
     
     
         64 . The method of  claim 63  wherein the second fluid is a drilling fluid.  
     
     
         65 . The method of  claim 63  further comprising the step of placing a casing string within the well bore.  
     
     
         66 . The method of  claim 63  further comprising the step of placing a cement composition within the well bore so as to displace at least a portion of the displacement fluid therefrom.  
     
     
         67 . The method of  claim 63  further comprising the step of permitting the cement composition to set in the well bore.  
     
     
         68 . The method of  claim 63  further comprising the step of permitting any undisplaced displacement fluid to set in the well bore.  
     
     
         69 . The method of  claim 63  wherein the displacement fluid further comprises water, and wherein the water is fresh water, salt water, brine, sea water, or a mixture thereof.  
     
     
         70 . The method of  claim 69  wherein the water is present in the displacement fluid in an amount in the range of from about 25% to about 150% by weight of the cement.  
     
     
         71 . The method of  claim 63  wherein the hydraulic cement is a Portland cement, pozzolana cement, gypsum cement, high alumina cement, silica cement, or a high alkalinity cement.  
     
     
         72 . The method of  claim 63  wherein the displacement fluid further comprises a yield stress reducing agent.  
     
     
         73 . The method of  claim 63  wherein the set retarder is phosphonic acid or a phosphonic acid derivative.  
     
     
         74 . The method of  claim 73  wherein the phosphonic acid derivative is a sodium salt of phosphonic acid.  
     
     
         75 . The method of  claim 63  wherein the set retarder is present in the displacement fluid in an amount in the range of from about 0.1% to about 5% by weight of the cement.  
     
     
         76 . The method of  claim 63  wherein the activator composition is present in an amount in the range of from about 0.1 to about 5% by weight of the cement.  
     
     
         77 . The method of  claim 63  wherein the activator composition comprises a mixture of a trialkanolamine and an alkali or alkaline earth metal hydroxide.  
     
     
         78 . The method of  claim 77  wherein the trialkanolamine is selected from the group consisting of: triethanolamine, tripropanolamine, and triisopropanolamine.  
     
     
         79 . The method of  claim 77  wherein the alkali or alkaline earth metal hydroxide is selected from the group consisting of sodium hydroxide and potassium hydroxide.  
     
     
         80 . The method of  claim 77  wherein the trialkanolamine is present in an amount in the range of from about 0.1% to about 50% by weight of the activator composition.  
     
     
         81 . The method of  claim 77  wherein the alkali metal hydroxide is present in an amount in the range of from about 50% to about 99.9% by weight of the activator composition.  
     
     
         82 . The method of  claim 79  wherein the alkali metal hydroxide is sodium hydroxide.  
     
     
         83 . The method of  claim 63  wherein the particle-size distribution-adjusting agent is present in the displacement fluid in an amount in the range of from about 0.01% to about 4% by weight of the cement.  
     
     
         84 . The method of  claim 63  wherein the particle-size distribution-adjusting agent is a cationic polymer.  
     
     
         85 . The method of  claim 84  wherein the cationic polymer is selected from the group consisting of: cationic polyacrylamides; cationic hydroxyethyl cellulose; poly(dimethyldiallylammonium chloride); and cationic starches.  
     
     
         86 . The method of  claim 72  wherein the yield stress reducing agent is selected from the group consisting of: a sulfonated melamine formaldehyde condensate; a sulfonated napthalene condensate; and a sulfite adduct of an acetone formaldehyde condensate.  
     
     
         87 . A settable fluid comprising a hydraulic cement, a set retarder, and a particle-size distribution-adjusting agent.  
     
     
         88 . The settable fluid of  claim 87  further comprising water, wherein the water comprises fresh water, salt water, brine, seawater, or a mixture thereof.  
     
     
         89 . The settable fluid of  claim 88  wherein the water is present in an amount sufficient to form a pumpable slurry.  
     
     
         90 . The settable fluid of  claim 89  wherein the water is present in an amount in the range of from about 25% to about 150% by weight of the cement.  
     
     
         91 . The settable fluid of  claim 87  wherein the hydraulic cement is a Portland cement, pozzolana cement, gypsum cement, high alumina cement, silica cement, or a high alkalinity cement.  
     
     
         92 . The settable fluid of  claim 87  further comprising a yield stress reducing agent.  
     
     
         93 . The settable fluid of  claim 92  wherein the yield stress reducing agent is selected from the group consisting of: a sulfonated melamine formaldehyde condensate, and a sulfite adduct of an acetone formaldehyde condensate.  
     
     
         94 . The settable fluid of  claim 87  wherein the set retarder is phosphonic acid or a phosphonic acid derivative.  
     
     
         95 . The settable fluid of  claim 94  wherein the phosphonic acid derivative is a sodium salt of phosphonic acid.  
     
     
         96 . The settable fluid of  claim 87  wherein the set retarder is present in an amount in the range of from about 0.1% to about 5% by weight of the cement.  
     
     
         97 . The settable fluid of  claim 87  further comprising an activator composition.  
     
     
         98 . The settable fluid of  claim 97  wherein the activator composition is present in an amount in the range of from about 0.1% to about 5% by weight of the cement.  
     
     
         99 . The settable fluid of  claim 97  wherein the activator composition comprises a mixture of a trialkanolamine and an alkali or alkaline earth metal hydroxide.  
     
     
         100 . The settable fluid of  claim 99  wherein the trialkanolamine is selected from the group consisting of: triethanolamine, tripropanolamine, and triisopropanolamine.  
     
     
         101 . The settable fluid of  claim 99  wherein the alkali or alkaline earth metal hydroxide is selected from the group consisting of sodium hydroxide and potassium hydroxide.  
     
     
         102 . The settable fluid of  claim 101  wherein the alkali metal hydroxide is sodium hydroxide.  
     
     
         103 . The settable fluid of  claim 99  wherein the trialkanolamine is present in an amount in the range of from about 0.1% to about 50% by weight of the activator composition.  
     
     
         104 . The settable fluid of  claim 99  wherein the alkali metal hydroxide is present in an amount in the range of from about 50% to about 99.9% by weight of the activator composition.  
     
     
         105 . The settable fluid of  claim 87  wherein the particle-size distribution-adjusting agent is present in an amount sufficient to adjust the particle-size distribution of the settable fluid to a desired range.  
     
     
         106 . The settable fluid of  claim 105  wherein the particle-size distribution-adjusting agent is present in an amount in the range of from about 0.01% to about 4% by weight of the cement.  
     
     
         107 . The settable fluid of  claim 87  wherein the particle-size distribution-adjusting agent is a compound that affects the particle size distribution of the settable fluid such that the rheology of the settable fluid remains substantially stable for a desired period of time.  
     
     
         108 . The settable fluid of  claim 87  wherein the particle-size distribution-adjusting agent is a cationic polymer.  
     
     
         109 . The settable fluid of  claim 108  wherein the cationic polymer is selected from the group consisting of cationic polyacrylamides; cationic hydroxyethyl cellulose; poly(dimethyldiallylammonium chloride); and cationic starches.  
     
     
         110 . The settable fluid of  claim 87  further comprising a surfactant, a dispersant, a salt, mica, a formation conditioning agent, a fixed-density weighting agent, vitrified shale, fumed silica, bentonite, fly ash, a fluid loss control additive, an expanding additive, a defoamer, a viscosifier, or a mixture thereof.  
     
     
         111 . The settable fluid of  claim 87  wherein the suspension properties of the settable fluid are substantially uniform throughout the settable fluid.  
     
     
         112 . The settable fluid of  claim 87  having a density in the range of from about 4 pounds per gallon to about 25 pounds per gallon.  
     
     
         113 . The settable fluid of  claim 87  further comprising water, wherein the water is present in an amount in the range of from about 25% to about 150% by weight of the cement; wherein the set retarder is a phosphonic acid or phosphonic acid derivative; wherein the settable fluid further comprises an activator composition; wherein the activator composition comprises a mixture of triethanolamine and an alkali metal hydroxide; wherein the particle-size distribution-adjusting agent is present in the settable fluid in an amount in the range of from about 0.01% to about 4% by weight of the cement; wherein the particle-size distribution-adjusting agent is a cationic polymer.  
     
     
         114 . An activator composition for activating a settable fluid comprising a mixture of a trialkanolamine and an alkali or alkaline earth metal hydroxide.  
     
     
         115 . The activator composition of  claim 114  wherein the trialkanolamine is selected from the group consisting of: triethanolamine, tripropanolamine, and triisopropanolamine.  
     
     
         116 . The activator composition of  claim 114  wherein the alkali or alkaline earth metal hydroxide is selected from the group consisting of: sodium hydroxide and potassium hydroxide.  
     
     
         117 . The activator composition of  claim 114  wherein the trialkanolamine is present in an amount in the range of from about 0.1% to about 50% by weight.  
     
     
         118 . The activator composition of  claim 114  wherein the alkali metal hydroxide is present in an amount in the range of from about 50% to about 99.9% by weight.  
     
     
         119 . The activator composition of  claim 116  wherein the alkali metal hydroxide is sodium hydroxide.  
     
     
         120 . A particle-size distribution-adjusting agent for adjusting the particle size distribution of a settable fluid to a desired range, the particle-size distribution-adjusting agent comprising a cationic polymer.  
     
     
         121 . The particle-size distribution-adjusting agent of  claim 120  wherein the cationic polymer is selected from the group consisting of: cationic polyacrylamides; cationic hydroxyethyl cellulose; poly(dimethyldiallylammonium chloride); and cationic starches.  
     
     
         122 . The particle-size distribution-adjusting agent of  claim 120  wherein the cationic polymer is a cationic starch.