Spent Catalyst Cement Expansion Additive
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Solution Overview
Problem
Conventional cement expansion additives in subterranean cementing operations often compromise compressive strength or increase slurry viscosity, and there is a need for a petroleum process byproduct that can provide expansion while maintaining desirable cement properties.
Innovation Solution
A cement composition incorporating spent silica-alumina cracking catalyst as an expansion additive, which includes a blend of active alumina, silica, phosphorous pentoxide, sulfur trioxide, calcium oxide, iron oxide, cobalt oxide, nickel oxide, and molybdenum oxide, added in specific concentrations to hydraulic cements, enhancing expansion and thickening without impairing compressive strength or slurry viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional cement expansion additives are used, then cement expansion is improved, but compressive strength is impaired
Solution Approach 1:
The patent changes the chemical composition parameters of the expansion additive by using spent silica-alumina cracking catalyst containing specific oxides (Al2O3, SiO2, P2O5, SO3, CaO, Fe2O3, CoO, NiO, MoO3) in controlled amounts, rather than conventional additives. This parameter change allows expansion while preserving compressive strength through the catalytic activity and chemical composition of the spent catalyst.
Solution Approach 2:
The invention uses a composite material approach by incorporating spent silica-alumina cracking catalyst, which is a composite of multiple metal oxides, into the cement slurry. This composite additive provides expansion functionality while the synergistic effect of its components maintains or enhances compressive strength properties.
2Shape
If conventional cement expansion additives are used, then cement expansion is improved, but slurry viscosity is increased
Solution Approach 1:
The patent modifies the additive composition parameters by using spent cracking catalyst with specific oxide ratios and particle characteristics, which provides expansion without the excessive viscosity increase associated with conventional additives. The controlled chemical composition and physical properties of the spent catalyst enable better slurry flow characteristics.
3Reliability
If petroleum process byproducts are utilized, then environmental sustainability is improved, but cement property consistency may be worsened
Solution Approach 1:
The patent addresses composition consistency by specifying precise ranges for oxide content in the spent catalyst (e.g., Al2O3: 65-95%, SiO2: 1-15%, P2O5: 1-10%, SO3: 1-5%, CaO: 0.1-1.0%, Fe2O3: 2-5%, CoO: 0.5-1.0%, NiO: 1-3%, MoO3: 5-30%). These controlled parameters ensure consistent cement properties while utilizing the petroleum process byproduct.
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 spent catalyst-based cement composition achieves significant expansion, accelerated thickening, and maintains compressive strength, ensuring effective zonal isolation and wellbore integrity while being recyclable and environmentally friendly.
Implementation Method 1
The spent catalyst-based cement composition achieves significant expansion
Implementation Method 2
a cement composition is provided that includes cement, water, and an expansion additive... spent silica-alumina cracking catalyst... blend of active alumina, silica, phosphorous pentoxide, sulfur trioxide, calcium oxide
Implementation Method 3
accelerated thickening... includes a blend of active alumina, silica, phosphorous pentoxide, sulfur trioxide, calcium oxide... hydraulic cements
Data Source
AI summary
A cement composition and method for well treatment employing the cement composition that is effective at achieving zonal isolation, controlling gas migration, preventing corrosive conditions and sustaining wellbore integrity during drilling or construction of boreholes in such subterranean formations. The cement composition includes spent cracking catalyst from oil cracking processes.