Cement Kiln Dust Settable Composition for Lost Circulation Control

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Solution Overview

Problem

Conventional methods for addressing lost circulation in subterranean operations, such as the use of drilling fluids and settable compositions, often fail to provide adequate control, leading to fluid loss into fractures, cracks, and other openings, resulting in increased costs and operational challenges.

Innovation Solution

A settable composition comprising cement kiln dust, alkali aluminate, and alkali silicate, which forms a non-flowable gel to bridge and plug lost circulation zones, with a minor active free fluid component for enhanced sealing and compressive strength, reducing fluid loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional lost circulation materials (fibrous, lamellated or granular) are placed into the formation, then some level of lost circulation control is achieved, but the control is inadequate in many circumstances and does not provide desirable sealing performance

Engineering Contradiction:

Improvelost circulation control effectivenessVSAvoidapplicability across different formation conditions

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent changes the physical and chemical parameters of the sealing material by using a settable composition that transitions from a pumpable slurry to a hardened mass. This transformation allows the material to adapt to different formation conditions and provide reliable sealing where conventional materials fail.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses a composite settable composition combining cementitious materials, water, and optional additives to create a material that exhibits both flowable and hardened properties. This composite approach provides superior adaptability and reliability compared to single-material conventional lost circulation materials.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a settable composition is placed into the wellbore to seal the lost circulation zone, then sealing capacity is improved, but the composition must balance between remaining pumpable and providing adequate sealing strength

Engineering Contradiction:

Improvesealing capacityVSAvoidcomposition formulation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The settable composition undergoes a parameter change from a fluid state during pumping to a solidified state during setting. This time-dependent transformation allows the material to be pumped through the wellbore and then provide effective sealing, resolving the contradiction between pumpability and sealing strength.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The composition is designed to maintain pumpable properties during injection and then automatically transition to a hardened sealing mass. This preliminary flowable state allows the material to reach the target zone before performing its primary sealing function, simplifying the overall operation.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If drilling fluid is lost into the formation through fractures and cracks, then operational costs increase and drilling efficiency decreases, but conventional methods fail to adequately prevent this fluid loss

Engineering Contradiction:

Improvedrilling efficiencyVSAvoiddrilling fluid loss

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The settable composition acts as a disposable sealing material that is injected into the formation to permanently plug lost circulation zones. Once set, it provides long-term prevention of fluid loss, improving drilling efficiency and reducing ongoing operational costs.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The settable composition serves as an intermediary material placed between the wellbore and the formation's lost circulation zones. It mediates the fluid flow by providing a seal that prevents drilling fluid from entering fractures and cracks, thereby reducing fluid loss and improving productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The composition effectively seals lost circulation zones by forming a hardened mass with reasonable compressive strength, preventing fluid loss and maintaining a flowable liquid state to further penetrate and seal the formation, thereby reducing operational expenses and improving drilling efficiency.

Implementation Method 1

forms a non-flowable gel to bridge and plug lost circulation zones

Methodology Applied

Scientific EffectGel formation: Gel

Implementation Method 2

A settable composition comprising cement kiln dust, alkali aluminate, and alkali silicate, which forms a non-flowable gel to bridge and plug lost circulation zones

Methodology Applied

Scientific EffectSetting reaction: Chemical Bonding

Data Source

PatentUS10883034B2Settable compositions comprising cement kiln dust and methods of use

Publication Date: 2021.01.05 HALLIBURTON ENERGY SERVICES INC

AI summary

Embodiments relate to the use of alkali aluminates and alkali silicates with cement kiln dust to form a settable composition for use in subterranean operations. An embodiment provides a method comprising: introducing a settable composition comprising cement kiln dust, an alkali aluminate, an alkali silicate, and an aqueous carrier fluid into a subterranean formation; and allowing the settable composition to set and thereby reduce fluid flow through a portion of the subterranean formation.