Compositions and processes for downhole cementing operations

Abstract

The present invention relates to methods of cementing, for example, an oil or gas well. The method may involve pumping a suspension of a filler mixture and at least about 5 weight percent of a thermosetting resin based on the total weight of resin and filler mixture. Advantages may include superior properties and reliability as compared to conventional cementing operations often involving Portland cement.

What is claimed is: 
     
         1 . A composition comprising: (1) from about 10 to about 25 weight percent of a thermosetting resin based on the total weight of the composition; (2) from about 15 to about 25 weight percent of a filler based on the total weight of the composition; (3) from about 30 to about 70 weight percent of an aggregate based on the total weight of the composition; and (4) an amount of intercalatable nanoclay, an exfoliatable nanoclay, or a mixture thereof such that the composition when cured exhibits less crack propagation when subjected to stress than a comparable composition without said nanoclay. 
     
     
         2 . The composition of  claim 1  wherein the nanoclay comprises from about 0.5 to about 2 weight percent based on the total weight of the composition. 
     
     
         3 . The composition of  claim 1  wherein the nanoclay further comprises a nanoclay selected from the group consisting of montmorillonite, bentonite, various silicates, quartzes and other intercalatable or exfoliatable mineral compounds. 
     
     
         4 . The composition of  claim 1  which further comprises a catalyst. 
     
     
         5 . The composition of  claim 1  wherein the nanoclay further comprises montmorillonite. 
     
     
         6 . The composition of  claim 1  wherein the nanoclay further comprises bentonite. 
     
     
         7 . The composition of  claim 1  wherein the nanoclay further comprises a silicate. 
     
     
         8 . The composition of  claim 1  wherein the nanoclay further comprises an intercalatable nanoclay. 
     
     
         9 . The composition of  claim 1  wherein the nanoclay further comprises an exfoliatable nanoclay. 
     
     
         10 . The composition of  claim 1  wherein the nanoclay further comprises an intercalatable nanoclay and comprises from about 0.5 to about 2 weight percent nanoclay based on the total weight of the composition. 
     
     
         11 . The composition of  claim 1  wherein the nanoclay further comprises an exfoliatable nanoclay and comprises from about 0.5 to about 2 weight percent nanoclay based on the total weight of the composition. 
     
     
         12 . The composition of  claim 1  wherein the thermosetting resin is selected from the group consisting of an epoxy resin, a polyester resin, a vinyl ester resin, a polyurethane resin, a carboxylic based resin, a phenolic based resin, a cross-linked thermoplastic resin, an epoxy novolac, a cellulose based resin, and mixtures thereof. 
     
     
         13 . The composition of  claim 1  wherein the thermosetting resin is selected from the group consisting of a polyester resin, a vinyl ester resin, and mixtures thereof. 
     
     
         14 . The composition of  claim 1  wherein the filler is selected from the group consisting of calcium carbonate, talc, silica, and mixtures thereof. 
     
     
         15 . The composition of  claim 1  wherein the filler has an average particle size distribution of from about 0.5 microns to about 100 microns based on laser scattering.