WO2017189302A1 - New multi-purpose additive for oil and gas cementing applications - Google Patents

New multi-purpose additive for oil and gas cementing applications Download PDF

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Publication number
WO2017189302A1
WO2017189302A1 PCT/US2017/028350 US2017028350W WO2017189302A1 WO 2017189302 A1 WO2017189302 A1 WO 2017189302A1 US 2017028350 W US2017028350 W US 2017028350W WO 2017189302 A1 WO2017189302 A1 WO 2017189302A1
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Prior art keywords
additive
amps
functional additive
cement
functional
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PCT/US2017/028350
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French (fr)
Inventor
Roderick Pernites
Kern L. Smith
Ashok Santra
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Lubrizol Oilfield Solutions, Inc.
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Publication of WO2017189302A1 publication Critical patent/WO2017189302A1/en

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    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/42Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
    • C09K8/46Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement
    • C09K8/467Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement containing additives for specific purposes
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/0028Aspects relating to the mixing step of the mortar preparation
    • C04B40/0039Premixtures of ingredients
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/0027Standardised cement types
    • C04B2103/0028Standardised cement types according to API
    • C04B2103/0035Type G
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/0027Standardised cement types
    • C04B2103/0028Standardised cement types according to API
    • C04B2103/0036Type H
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2201/00Mortars, concrete or artificial stone characterised by specific physical values
    • C04B2201/40Mortars, concrete or artificial stone characterised by specific physical values for gas flow through the material
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2201/00Mortars, concrete or artificial stone characterised by specific physical values
    • C04B2201/50Mortars, concrete or artificial stone characterised by specific physical values for the mechanical strength
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Definitions

  • This invention relates to a multifunctional additive for wellbore cementing that simultaneously provides desirable properties at wide temperature ranges up to and including 450 °F.
  • the multifunctional additive can provide control of gas flow, efficient fluid loss control, high and early cement strength, short static gel transition time, negligible free water, slurry stability and practical pumpablity, all from a single additive.
  • cementing is considered as one of the most essential and challenging operations in wellbore construction generally due to high temperatures and pressures that can cause significant changes to the properties of the cement slurry; particularly slurries that contain multiple chemical additives.
  • Fluid migration which encompasses both gas flow and shallow water migration, is a serious and perennial problem in well cementing operations that can compromise the overall structural integrity of a very costly well, potentially leading to well blowouts/explosions as well as damaging the environment and loss of scarce natural resources.
  • the high price associated with this problem plus stricter environmental regulations have forced operators and services companies to find effective chemicals and/or mechanical solutions for preventing gas flow.
  • gas flow can occur after cement placement downhole, particularly during the gelation stage (neither fluid nor solid state). This stage occurs prior to cement strength development when the hydrostatic pressure drops below the formation pore pressure, causing higher chances for fluid migration to occur (also generation of unwanted and permanent gas channels) from the formation layers to the annular column, as well as gas rising through the annular column and even up to the surface over time. Fluid migration increases cement permeability and decreases cement strength over time.
  • the postulated mechanisms for the loss in hydrostatic pressure of the pumped cement includes severe dehydration, longer term gelation and chemical shrinkage.
  • the disclosed technology solves the above-mentioned problems by providing a new multifunctional additive for wellbore cementing compositions.
  • the multi-functional cement additive includes a) water, b) at least one noncrystalline silica containing extender material, and c) at least one 2-Acrylamido-2- methylpropane sulfonic acid (AMPS) containing polymer.
  • the ratio of the non-crystalline silica to the AMPS containing polymer (i.e., 'b) to c)'), can be from about 1 : 10 to about 10: 1.
  • the water can be present at from about 50 to about 90 wt% of the multi-functional additive
  • the at least one non-crystalline silica containing extender material in the multifunctional additive can be at least one of nanosilica, alkali metal silicate, or nano-calcium silicate hydrate (nano-CSH) seeding material, or combinations thereof.
  • the nanosilica extender material can have an average particle size of from about 1 to about 100 nanometers.
  • the non-crystalline silica containing extender material can be present at from about 5 to about 40 wt% of the multi-functional additive.
  • the at least one AMPS containing polymer in the multifunctional additive can be a homopolymer. In other embodiments, the AMPS containing polymer can be a copolymer. In some embodiments, the AMPS containing polymer can be is at least one of AMPS-N,N dimethylacrylamide (AMPS-NNDMA), AMPS-NNDMA-acrylic acid (AMPS-NNDMA- A A), AMPS-NNDMA-styrene sulfonate (AMPS-NNDMA-SS), AMPS-NNDMA-maleic acid anhydride (AMPS- NNDMA-MAA), AMPS-NNDMA-vinyl phosphonic acid (AMPS-NNDMA-VPA), humic acid grafted AMPS-based copolymers, or combinations thereof. In an embodiment, the at least one AMPS containing polymer can be present at from about 5 to about 60 wt% of the multi-functional additive.
  • the multi-functional additive can contain at least one fur- ther ingredient, such as, for example, at least one polymeric dispersant, at least one defoamer, at least one salt, at least one rheology stabilizer, at least one silica fume, at least one expansion additive, such as, for example, magnesium oxide (MgO) and/ or calcium oxide (CaO), or combinations thereof.
  • at least one fur- ther ingredient such as, for example, at least one polymeric dispersant, at least one defoamer, at least one salt, at least one rheology stabilizer, at least one silica fume, at least one expansion additive, such as, for example, magnesium oxide (MgO) and/ or calcium oxide (CaO), or combinations thereof.
  • MgO magnesium oxide
  • CaO calcium oxide
  • the cementing composition can include the multifunctional additive as described above and a hydraulic cement, such as, for example, at least one of API class G or H hydraulic cement.
  • the multifunctional additive can be added to the hydraulic cement at about 0.1 to about 3 gallons of the multifunctional additive per sack of hydraulic cement.
  • a further aspect of the present technology includes a method of cementing a subterranean zone penetrated by a wellbore.
  • the method includes the steps of a) forming a pumpable cementing composition comprising: (i) hydraulic cement, and (ii) a multi-functional cement additive as described above, followed by b) pumping the cementing composition into the subterranean zone by way of the wellbore; and c) allowing the cement composition to set therein.
  • the technology disclosed herein includes a multifunctional additive com- prising, consisting essentially of, or consisting of a) water, b) at least one non-crystalline silica containing extender material, and c) at least one 2-acrylamido-2-methylpro- pane sulfonic acid (“AMPSTM”) containing polymer.
  • AMPSTM 2-acrylamido-2-methylpro- pane sulfonic acid
  • the water in the multifunctional additive can be any type of freshwater, such as, for example, tap water or distilled water.
  • the water is generally present in the multifunctional additive at from about 50 to about 90 wt%. In some embodiments, the water can be present at from about 55 to about 85 wt%, of from about 60 to 80 wt%, or even about 60 to about 75 wt%. of the multi-functional additive.
  • the multifunctional additive contains non-crystalline silica extender material.
  • the non-crystalline silica extender material can help suspend particulates, bind water molecules, aid expansion in water extended cement slurry, as well as reduce the set-cement permeability relevant for preventing gas flow.
  • non-crystalline silica extender material also referred to herein simply as "non-crystalline silica” suitable for the multifunctional additive are not particularly limited.
  • Some examples of non-crystalline silica can include, for example, of nanosilica, alkali metal silicate, or nano-calcium silicate hydrate (nano-CSH) seeding material, or combinations thereof.
  • nanosilica can include sodium and potassium silicate having particle sizes of from about 1 to about 100 nanometers, or from about 2 to about 95 nm, or even about 3 to about 90 nm, or 4 to 85 nm. In some embodiments, nanosilica can include sodium or potassium silicate having particle sizes of from about 1 to about 10 nm, or about 2 to about 9 nm, or about 3 to about 8 nm.
  • alkali metal silicate examples include those having a weight ratio of S1O2 to alkali metal oxide of about 1 to about5, or about 1.5 to about 4 or 4.5.
  • Such alkali silicates are generally provided in the form of syrupy liquids, or coarse lumpy solids.
  • Sodium and potassium are the typical alkali metals employed to stabilize such noncrystalline silicas.
  • nano-CSH refers to hydrated calcium silicate compounds obtained by reacting calcium oxide and silica in various ratios, such as, for example, 3CaOSi0 2 , Ca 3 Si0 5 ; 2CaOSi0 2 , Ca 2 Si0 4 ; 3CaO2Si0 2 , Ca 3 Si 2 0 7 and CaOSi0 2 , CaSi0 3 , and having particle sizes of from about lnm to about 5 ⁇ .
  • Suitable nano- CSH particles can have average particle sizes of less than about 5 ⁇ , and in some cases less than about 1 ⁇ .
  • the average particle size for nano- CSH can be, for example, less than about 500 nm, or even less than about 200 nm or 100 nm, such as, about 1 nm to about 100 or about 200nm, or even from about 10 to about 500nm, or about 20nm to about 1 or about 5 ⁇
  • Non-crystalline silica can be included in the multifunctional additive at from about 5 to about 40 wt%, or from about 7 to about 35 wt%, or from about 10 to about 30 wt%, or even from about 12 to about 30 wt%.
  • the multi-functional additive also includes at least one 2-acrylamido-2- methylpropane sulfonic acid (AMPS) containing polymer.
  • AMPS 2-acrylamido-2- methylpropane sulfonic acid
  • Such polymer can be an AMPS homopolymer or a copolymer of AMPS and at least one other monomer. Methods of copolymerizing AMPS and co-monomers are well known and not dis- cussed here.
  • a suitable co-monomer for the AMPS containing polymer can include, for example, acrylamides; alkyl acrylamides; styrene sulfonic acid; carboxylic acids, such as, for example, acrylic acids, alkyl acrylic acids, or maleic acid; vinyl phosphonic acid; and combinations thereof.
  • AMPS copolymers suitable for use in the multifunctional additive can include, for example, AMPS- ⁇ , ⁇ dimethylacrylamide (AMPS- NNDMA), AMP S-NNDM A- acrylic acid (AMP S-NNDM A- AA), AMPS-NNDMA- styrene sulfonate (AMP S-NNDM A- SS), AMP S -NNDM A-mal ei c acid anhydride (AMP S-NNDM A-MAA), AMP S-NNDM A- vinyl phosphonic acid (AMPS-NNDMA- VP A), humic acid grafted AMPS-based copolymers, or combinations thereof.
  • AMPS- NNDMA AMPS- ⁇ , ⁇ dimethylacrylamide
  • AMP S-NNDM A- acrylic acid AMP S-NNDM A- AA
  • AMPS-NNDMA- styrene sulfonate AMP S-NNDM A- SS
  • the AMPS containing polymers can have weight average molecular weights (Mw) of from about 500,000 to about 3,000,000, from about 750,000 to about 2,500,000, and in some embodiments from about 1,000,000 to about 2,000,000. At least about 30 wt% of the AMPS containing polymer is derived from AMPS monomer, or at least about 40 wt%, or at least about 50wt%.
  • the AMPS containing polymer can be present in the multifunctional additive at from about 5 to about 60 wt% of the multi-functional additive. In some embodiments, the AMPS containing polymer can be present in the multifunctional additive at from about 10 to about 55 wt%, of from about 15 to about 50 wt%, or even about 15 to about 45wt%.
  • the multi-functional additive can contain at least one further ingredient, such as, for example, at least one polymeric dispersant, at least one defoamer, at least one salt, at least one rheology stabilizer, at least one silica fume, at least one expansion additive, such as, for example, magnesium oxide (MgO) and/or calcium oxide (CaO), or combinations thereof.
  • at least one polymeric dispersant such as, for example, at least one polymeric dispersant, at least one defoamer, at least one salt, at least one rheology stabilizer, at least one silica fume, at least one expansion additive, such as, for example, magnesium oxide (MgO) and/or calcium oxide (CaO), or combinations thereof.
  • MgO magnesium oxide
  • CaO calcium oxide
  • Polymeric dispersants can, among other things, aid in minimizing viscosity of cement with low water-to-cement ratio. Polymeric dispersants suitable for cementing applications are well known, and any such polymeric dispersant can
  • polymeric dispersants suitable for the multifunctional additive include sulfonated naphthalene formaldehyde polycon- densate; acetone formaldehyde polycondensate; melamine formaldehyde polycon- densate; polycarboxylate; or combinations thereof.
  • Polymeric dispersants can be present in the multi-functional additive at from about 1 to about 10 wt% of the multi-functional additive. In some embodiments, polymeric dispersants can be present in the multi-functional additive at from about 1.5 to about 9wt%, or from about 2 to about 8wt%, or even from about 2.5 to about 6wt%.
  • Defoamers suitable for cementing applications are well known, and any such defoamer can be used in the multifunctional additive.
  • Defoamers can be present in the multi-functional additive at from about 0.1 to about 2wt% of the multi-functional additive.
  • defoamer can be present in the multi-functional additive at from about 0.2 to about 1.5wt%, or from about 0.25 to about 1.25wt%, or even from about 0.3 to about lwt%.
  • the multi-functional additive can also include from about 0.5 to about 5 wt% of a salt, such as, for example, sodium chloride or calcium chloride, to minimize full hydration of any polymeric fluid loss control additives present.
  • a salt such as, for example, sodium chloride or calcium chloride
  • the salt can be present in the multifunctional additive at from about 0.75 to about 4.5wt%, or from about 1 to about 4wt%, or even from about 1.5 to about 3wt%.
  • the multi-functional additive can further include from about 0.5 to about 10 wt% of at least one cellulose-based polymer as a fluid rheology stabilizer.
  • Cellulose-based polymers can include, for example, hydroxyethyl cellulose (HEC), hy- droxypropyl cellulose (HPC), or carboxy methyl HEC (CMHEC).
  • HEC hydroxyethyl cellulose
  • HPC hy- droxypropyl cellulose
  • CCMHEC carboxy methyl HEC
  • the cellulose-based polymer can be present in the multifunctional additive at from about 0.75 to about 4.5wt%, or from about 1 to about 4wt%, or even from about 1.5 to about 3 wt%.
  • the multi-functional additive can additionally contain from about 0.5 to about 25 wt%, or from about 1 to about 20wt%, or from about 2 to about 15wt%, or even from about 3 to about 12wt% of a silica fume.
  • the multi-functional additive can also include from about 0.5 to about 15 wt% of at least one expansion additive.
  • Expansion additives can include, for example, magnesium oxide (MgO), calcium oxide (CaO), or combinations thereof.
  • the expansion additive can be present in the multifunctional additive at from about 0.75 to about 10wt%, or from about 1 to about 8wt%, or even from about 1.5 to about 5wt%.
  • the present technology also provides a cementing composition containing the multifunctional additive described above.
  • the cementing composition can contain, in addition to the multifunctional additive, hydraulic cement and water.
  • Water typically makes up about 30 to about 60% by volume of cementing compositions. Both fresh water and/or sea water may be used in cement compositions. Typically water with low mineral content is preferred, such as tap water.
  • Hydraulic cement typically makes up about 15 to about 50% by volume of cementing compositions.
  • the term "hydraulic cement” means a cementing composition that sets up to a hard monolithic mass under water.
  • any hydraulic cement may be used in the present invention.
  • Portland ce- ment may be used because of its low cost, availability, and general utility.
  • Portland cements of American Petroleum Institute' s (“API") Classes A, B, C, H, and/or G may be used in the invention.
  • API Classes of cements such as calcium aluminate and gypsum cement, may be used.
  • mixtures or combinations of these cement components can be used.
  • the Portland cements includes classes G and/or H, but other cements which are known in this art can also be used to advantage.
  • aluminous cements and Port- land/plaster mixtures for deep-water wells, for example
  • cement/silica mixtures for wells where the temperature exceeds 120° C, for example
  • the cementing compositions can also be optimized by adding additives which are common to the majority of cementing compositions, such as, for example, set retarders, suspension agents, dispersing agents, anti-foaming agents, expansion agents (for exam- pie magnesium oxide or a mixture of magnesium and calcium oxides), line particles, fluid loss control agents, fluid migration control agents, retarders or setting accelerators.
  • additives which are common to the majority of cementing compositions, such as, for example, set retarders, suspension agents, dispersing agents, anti-foaming agents, expansion agents (for exam- pie magnesium oxide or a mixture of magnesium and calcium oxides), line particles, fluid loss control agents, fluid migration control agents, retarders or setting accelerators.
  • the multifunctional additive can be included in the cementing composition at about 0.1 to about 3 gallons per sack of hydraulic cement (gal/sack), or in some embodiments, from about 0.2 to about 2.5 gal/sack, or from about 0.3 to about 2 gal/sack, or even from about 0.4 to about 1.5 gal/sack.
  • each chemical component described is presented exclusive of any solvent or diluent oil, which may be customarily present in the commercial material, that is, on an active chemical basis, unless otherwise indicated.
  • each chemical or composition referred to herein should be interpreted as being a commercial grade material which may contain the isomers, by-products, derivatives, and other such materials which are normally understood to be present in the commercial grade.
  • the term "about” means that a value of a given quantity is within ⁇ 20% of the stated value. In other embodiments, the value is within ⁇ 15% of the stated value. In other embodiments, the value is within ⁇ 10% of the stated value. In other embodiments, the value is within ⁇ 5% of the stated value. In other embodiments, the value is within ⁇ 2.5% of the stated value. In other embodiments, the value is within ⁇ 1% of the stated value.
  • the cement composition can be employed in a method of cementing a subterranean zone penetrated by a wellbore.
  • the cement composition is prepared by admixing in a suitable vessel the hydraulic cement, water, multifunctional additive, and any other optional additives that may be desired.
  • the resulting cement composition can then be pumped into a well bore or conduit disposed therein to a subterranean zone wherein the cement composition is to be placed.
  • the method can include the steps of: 1) forming a pumpable set retarded cement composition comprising hydraulic cement, water, and the multifunctional additive as described herein, 2) pumping said cement composition into said zone by way of said wellbore; and 3) allowing the cement composition to set therein.
  • the multifunctional additive described herein can provide control of gas flow in the cement at ultra-high temperature, such as, for example, temperatures of up to about 450° F, as well as provide efficient fluid loss control, high and early cement strength, short static gel transition time, negligible free water, slurry stability and practically pumpable cement slurry.
  • composition 1 Composition 2
  • composition 3 Composition 4
  • Nanosilica (8 nm size) 5.90 nano-CSH 4.40
  • Cement composition were prepared using the above sample multifunctional additive by standard API RP 10B mixing procedure. Cement slurry formulations are summarized in table below.
  • the transitional term "comprising,” which is synonymous with “including,” “containing,” or “characterized by,” is inclusive or open-ended and does not exclude additional, un-recited elements or method steps.
  • the term also encompass, as alternative embodiments, the phrases “consisting essentially of and “consisting of,” where “consisting of excludes any element or step not specified and “consisting essentially of permits the inclusion of additional un-recited elements or steps that do not materially affect the essential or basic and novel characteristics of the composition or method under consideration.

Abstract

This invention relates to a multifunctional additive for wellbore cementing that simulta-neously provides multiple desirable properties at wide temperature ranges up to and including 450 °F. For instance, the multifunctional additive can provide control of gas flow, efficient fluid loss control, high and early cement strength, short static gel transi-tion time, negligible free water, slurry stability and practically pumpable cement slurry, all from a single additive.

Description

TITLE
NEW MULTI-PURPOSE ADDITIVE FOR OIL AND GAS CEMENTING
APPLICATIONS BACKGROUND OF THE INVENTION
[0001] This invention relates to a multifunctional additive for wellbore cementing that simultaneously provides desirable properties at wide temperature ranges up to and including 450 °F. For instance, the multifunctional additive can provide control of gas flow, efficient fluid loss control, high and early cement strength, short static gel transition time, negligible free water, slurry stability and practical pumpablity, all from a single additive.
[0002] Successful cementing operations are extremely crucial to reliable well completion prior to well production. Cementing is considered as one of the most essential and challenging operations in wellbore construction generally due to high temperatures and pressures that can cause significant changes to the properties of the cement slurry; particularly slurries that contain multiple chemical additives.
[0003] Fluid migration, which encompasses both gas flow and shallow water migration, is a serious and perennial problem in well cementing operations that can compromise the overall structural integrity of a very costly well, potentially leading to well blowouts/explosions as well as damaging the environment and loss of scarce natural resources. The high price associated with this problem plus stricter environmental regulations have forced operators and services companies to find effective chemicals and/or mechanical solutions for preventing gas flow.
[0004] Briefly, gas flow can occur after cement placement downhole, particularly during the gelation stage (neither fluid nor solid state). This stage occurs prior to cement strength development when the hydrostatic pressure drops below the formation pore pressure, causing higher chances for fluid migration to occur (also generation of unwanted and permanent gas channels) from the formation layers to the annular column, as well as gas rising through the annular column and even up to the surface over time. Fluid migration increases cement permeability and decreases cement strength over time. The postulated mechanisms for the loss in hydrostatic pressure of the pumped cement includes severe dehydration, longer term gelation and chemical shrinkage. Thus, as a chemical approach to combat fluid migration in a cemented annulus, it is important to smartly design the cement slurry to efficiently control fluid loss, free water and cement shrinkage via addition of appropriate chemical additives.
[0005] There is always strong demand and urgent need in the market for a gas tight cement slurry to address the gas flow problem, while also providing other essential properties of a highly competent cements, such as, for example, efficient fluid loss control, high and early cement strength, short static gel transition time, negligible free water, slurry stability and practical pumpablity.
SUMMARY OF THE INVENTION
[0006] The disclosed technology solves the above-mentioned problems by providing a new multifunctional additive for wellbore cementing compositions.
[0007] The multi-functional cement additive includes a) water, b) at least one noncrystalline silica containing extender material, and c) at least one 2-Acrylamido-2- methylpropane sulfonic acid (AMPS) containing polymer. The ratio of the non-crystalline silica to the AMPS containing polymer (i.e., 'b) to c)'), can be from about 1 : 10 to about 10: 1. In an embodiment, the water can be present at from about 50 to about 90 wt% of the multi-functional additive
[0008] In an embodiment, the at least one non-crystalline silica containing extender material in the multifunctional additive can be at least one of nanosilica, alkali metal silicate, or nano-calcium silicate hydrate (nano-CSH) seeding material, or combinations thereof. In embodiments, the nanosilica extender material can have an average particle size of from about 1 to about 100 nanometers. In some embodiments, the non-crystalline silica containing extender material can be present at from about 5 to about 40 wt% of the multi-functional additive.
[0009] In embodiments, the at least one AMPS containing polymer in the multifunctional additive can be a homopolymer. In other embodiments, the AMPS containing polymer can be a copolymer. In some embodiments, the AMPS containing polymer can be is at least one of AMPS-N,N dimethylacrylamide (AMPS-NNDMA), AMPS-NNDMA-acrylic acid (AMPS-NNDMA- A A), AMPS-NNDMA-styrene sulfonate (AMPS-NNDMA-SS), AMPS-NNDMA-maleic acid anhydride (AMPS- NNDMA-MAA), AMPS-NNDMA-vinyl phosphonic acid (AMPS-NNDMA-VPA), humic acid grafted AMPS-based copolymers, or combinations thereof. In an embodiment, the at least one AMPS containing polymer can be present at from about 5 to about 60 wt% of the multi-functional additive.
[0010] In embodiments, the multi-functional additive can contain at least one fur- ther ingredient, such as, for example, at least one polymeric dispersant, at least one defoamer, at least one salt, at least one rheology stabilizer, at least one silica fume, at least one expansion additive, such as, for example, magnesium oxide (MgO) and/ or calcium oxide (CaO), or combinations thereof.
[0011] Another aspect of the present technology includes a cementing composi- tion. The cementing composition can include the multifunctional additive as described above and a hydraulic cement, such as, for example, at least one of API class G or H hydraulic cement. In an embodiment, the multifunctional additive can be added to the hydraulic cement at about 0.1 to about 3 gallons of the multifunctional additive per sack of hydraulic cement.
[0012] A further aspect of the present technology includes a method of cementing a subterranean zone penetrated by a wellbore. The method includes the steps of a) forming a pumpable cementing composition comprising: (i) hydraulic cement, and (ii) a multi-functional cement additive as described above, followed by b) pumping the cementing composition into the subterranean zone by way of the wellbore; and c) allowing the cement composition to set therein.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Various preferred features and embodiments will be described below by way of non-limiting illustration.
[0014] The technology disclosed herein includes a multifunctional additive com- prising, consisting essentially of, or consisting of a) water, b) at least one non-crystalline silica containing extender material, and c) at least one 2-acrylamido-2-methylpro- pane sulfonic acid ("AMPS™") containing polymer.
[0015] The water in the multifunctional additive can be any type of freshwater, such as, for example, tap water or distilled water. The water is generally present in the multifunctional additive at from about 50 to about 90 wt%. In some embodiments, the water can be present at from about 55 to about 85 wt%, of from about 60 to 80 wt%, or even about 60 to about 75 wt%. of the multi-functional additive. [0016] The multifunctional additive contains non-crystalline silica extender material. The non-crystalline silica extender material can help suspend particulates, bind water molecules, aid expansion in water extended cement slurry, as well as reduce the set-cement permeability relevant for preventing gas flow.
[0017] The types of non-crystalline silica extender material (also referred to herein simply as "non-crystalline silica) suitable for the multifunctional additive are not particularly limited. Some examples of non-crystalline silica can include, for example, of nanosilica, alkali metal silicate, or nano-calcium silicate hydrate (nano-CSH) seeding material, or combinations thereof.
[0018] Examples of nanosilica can include sodium and potassium silicate having particle sizes of from about 1 to about 100 nanometers, or from about 2 to about 95 nm, or even about 3 to about 90 nm, or 4 to 85 nm. In some embodiments, nanosilica can include sodium or potassium silicate having particle sizes of from about 1 to about 10 nm, or about 2 to about 9 nm, or about 3 to about 8 nm.
[0019] Examples of alkali metal silicate are those having a weight ratio of S1O2 to alkali metal oxide of about 1 to about5, or about 1.5 to about 4 or 4.5. Such alkali silicates are generally provided in the form of syrupy liquids, or coarse lumpy solids. Sodium and potassium are the typical alkali metals employed to stabilize such noncrystalline silicas.
[0020] As used herein, nano-CSH refers to hydrated calcium silicate compounds obtained by reacting calcium oxide and silica in various ratios, such as, for example, 3CaOSi02, Ca3Si05; 2CaOSi02, Ca2Si04; 3CaO2Si02, Ca3Si207 and CaOSi02, CaSi03, and having particle sizes of from about lnm to about 5 μπι. Suitable nano- CSH particles can have average particle sizes of less than about 5 μηι, and in some cases less than about 1 μηι. In some embodiments, the average particle size for nano- CSH can be, for example, less than about 500 nm, or even less than about 200 nm or 100 nm, such as, about 1 nm to about 100 or about 200nm, or even from about 10 to about 500nm, or about 20nm to about 1 or about 5 μτη
[0021] Non-crystalline silica can be included in the multifunctional additive at from about 5 to about 40 wt%, or from about 7 to about 35 wt%, or from about 10 to about 30 wt%, or even from about 12 to about 30 wt%. [0022] The multi-functional additive also includes at least one 2-acrylamido-2- methylpropane sulfonic acid (AMPS) containing polymer. Such polymer can be an AMPS homopolymer or a copolymer of AMPS and at least one other monomer. Methods of copolymerizing AMPS and co-monomers are well known and not dis- cussed here.
[0023] A suitable co-monomer for the AMPS containing polymer can include, for example, acrylamides; alkyl acrylamides; styrene sulfonic acid; carboxylic acids, such as, for example, acrylic acids, alkyl acrylic acids, or maleic acid; vinyl phosphonic acid; and combinations thereof.
[0024] Particular examples of AMPS copolymers suitable for use in the multifunctional additive can include, for example, AMPS-Ν,Ν dimethylacrylamide (AMPS- NNDMA), AMP S-NNDM A- acrylic acid (AMP S-NNDM A- AA), AMPS-NNDMA- styrene sulfonate (AMP S-NNDM A- SS), AMP S -NNDM A-mal ei c acid anhydride (AMP S-NNDM A-MAA), AMP S-NNDM A- vinyl phosphonic acid (AMPS-NNDMA- VP A), humic acid grafted AMPS-based copolymers, or combinations thereof.
[0025] The AMPS containing polymers can have weight average molecular weights (Mw) of from about 500,000 to about 3,000,000, from about 750,000 to about 2,500,000, and in some embodiments from about 1,000,000 to about 2,000,000. At least about 30 wt% of the AMPS containing polymer is derived from AMPS monomer, or at least about 40 wt%, or at least about 50wt%.
[0026] The AMPS containing polymer can be present in the multifunctional additive at from about 5 to about 60 wt% of the multi-functional additive. In some embodiments, the AMPS containing polymer can be present in the multifunctional additive at from about 10 to about 55 wt%, of from about 15 to about 50 wt%, or even about 15 to about 45wt%.
[0027] In embodiments, the multi-functional additive can contain at least one further ingredient, such as, for example, at least one polymeric dispersant, at least one defoamer, at least one salt, at least one rheology stabilizer, at least one silica fume, at least one expansion additive, such as, for example, magnesium oxide (MgO) and/or calcium oxide (CaO), or combinations thereof. [0028] Polymeric dispersants can, among other things, aid in minimizing viscosity of cement with low water-to-cement ratio. Polymeric dispersants suitable for cementing applications are well known, and any such polymeric dispersant can be used in the multifunctional additive. Some examples of polymeric dispersants suitable for the multifunctional additive include sulfonated naphthalene formaldehyde polycon- densate; acetone formaldehyde polycondensate; melamine formaldehyde polycon- densate; polycarboxylate; or combinations thereof.
[0029] Polymeric dispersants can be present in the multi-functional additive at from about 1 to about 10 wt% of the multi-functional additive. In some embodiments, polymeric dispersants can be present in the multi-functional additive at from about 1.5 to about 9wt%, or from about 2 to about 8wt%, or even from about 2.5 to about 6wt%.
[0030] Defoamers suitable for cementing applications are well known, and any such defoamer can be used in the multifunctional additive. Defoamers can be present in the multi-functional additive at from about 0.1 to about 2wt% of the multi-functional additive. In some embodiments, defoamer can be present in the multi-functional additive at from about 0.2 to about 1.5wt%, or from about 0.25 to about 1.25wt%, or even from about 0.3 to about lwt%.
[0031] The multi-functional additive can also include from about 0.5 to about 5 wt% of a salt, such as, for example, sodium chloride or calcium chloride, to minimize full hydration of any polymeric fluid loss control additives present. In some embodiments, the salt can be present in the multifunctional additive at from about 0.75 to about 4.5wt%, or from about 1 to about 4wt%, or even from about 1.5 to about 3wt%.
[0032] The multi-functional additive can further include from about 0.5 to about 10 wt% of at least one cellulose-based polymer as a fluid rheology stabilizer. Cellulose-based polymers, can include, for example, hydroxyethyl cellulose (HEC), hy- droxypropyl cellulose (HPC), or carboxy methyl HEC (CMHEC). In some embodiments, the cellulose-based polymer can be present in the multifunctional additive at from about 0.75 to about 4.5wt%, or from about 1 to about 4wt%, or even from about 1.5 to about 3 wt%. [0033] The multi-functional additive can additionally contain from about 0.5 to about 25 wt%, or from about 1 to about 20wt%, or from about 2 to about 15wt%, or even from about 3 to about 12wt% of a silica fume.
[0034] The multi-functional additive can also include from about 0.5 to about 15 wt% of at least one expansion additive. Expansion additives can include, for example, magnesium oxide (MgO), calcium oxide (CaO), or combinations thereof. In some embodiments, the expansion additive can be present in the multifunctional additive at from about 0.75 to about 10wt%, or from about 1 to about 8wt%, or even from about 1.5 to about 5wt%.
[0035] The present technology also provides a cementing composition containing the multifunctional additive described above. The cementing composition can contain, in addition to the multifunctional additive, hydraulic cement and water.
[0036] Water typically makes up about 30 to about 60% by volume of cementing compositions. Both fresh water and/or sea water may be used in cement compositions. Typically water with low mineral content is preferred, such as tap water.
[0037] Hydraulic cement typically makes up about 15 to about 50% by volume of cementing compositions. The term "hydraulic cement" means a cementing composition that sets up to a hard monolithic mass under water. Generally, any hydraulic cement may be used in the present invention. In certain embodiments, Portland ce- ment may be used because of its low cost, availability, and general utility. In other embodiments, Portland cements of American Petroleum Institute' s ("API") Classes A, B, C, H, and/or G may be used in the invention. In other embodiments, other API Classes of cements, such as calcium aluminate and gypsum cement, may be used. In addition, mixtures or combinations of these cement components can be used. The characteristics of these cements are described in API Specification for Materials and Testing for Well Cements, API Spec 10 A, First Edition, January 1982, which is hereby incorporated by reference. In certain embodiments, the Portland cements includes classes G and/or H, but other cements which are known in this art can also be used to advantage. For low-temperature applications, aluminous cements and Port- land/plaster mixtures (for deep-water wells, for example) or cement/silica mixtures (for wells where the temperature exceeds 120° C, for example) may be used, or cements obtained by mixing a Portland cement, slurry cements and/or fly ash. [0038] Depending on the specifications regarding the conditions for use, the cementing compositions can also be optimized by adding additives which are common to the majority of cementing compositions, such as, for example, set retarders, suspension agents, dispersing agents, anti-foaming agents, expansion agents (for exam- pie magnesium oxide or a mixture of magnesium and calcium oxides), line particles, fluid loss control agents, fluid migration control agents, retarders or setting accelerators.
[0039] The multifunctional additive can be included in the cementing composition at about 0.1 to about 3 gallons per sack of hydraulic cement (gal/sack), or in some embodiments, from about 0.2 to about 2.5 gal/sack, or from about 0.3 to about 2 gal/sack, or even from about 0.4 to about 1.5 gal/sack.
[0040] The amount of each chemical component described is presented exclusive of any solvent or diluent oil, which may be customarily present in the commercial material, that is, on an active chemical basis, unless otherwise indicated. However, unless otherwise indicated, each chemical or composition referred to herein should be interpreted as being a commercial grade material which may contain the isomers, by-products, derivatives, and other such materials which are normally understood to be present in the commercial grade.
[0041] It is known that some of the materials described above may interact in the final formulation, so that the components of the final formulation may be different from those that are initially added. For instance, metal ions can migrate to other acidic or anionic sites of other molecules. The products formed thereby, including the products formed upon employing the composition of the present invention in its intended use, may not be susceptible of easy description. Nevertheless, all such modifications and reaction products are included within the scope of the present invention; the present invention encompasses the composition prepared by admixing the components described above.
[0042] As used herein, the term "about" means that a value of a given quantity is within ±20% of the stated value. In other embodiments, the value is within ±15% of the stated value. In other embodiments, the value is within ±10% of the stated value. In other embodiments, the value is within ±5% of the stated value. In other embodiments, the value is within ±2.5% of the stated value. In other embodiments, the value is within ±1% of the stated value.
[0043] The cement composition can be employed in a method of cementing a subterranean zone penetrated by a wellbore. In carrying out the method, the cement composition is prepared by admixing in a suitable vessel the hydraulic cement, water, multifunctional additive, and any other optional additives that may be desired. The resulting cement composition can then be pumped into a well bore or conduit disposed therein to a subterranean zone wherein the cement composition is to be placed.
[0044] The method can include the steps of: 1) forming a pumpable set retarded cement composition comprising hydraulic cement, water, and the multifunctional additive as described herein, 2) pumping said cement composition into said zone by way of said wellbore; and 3) allowing the cement composition to set therein.
[0045] The multifunctional additive described herein can provide control of gas flow in the cement at ultra-high temperature, such as, for example, temperatures of up to about 450° F, as well as provide efficient fluid loss control, high and early cement strength, short static gel transition time, negligible free water, slurry stability and practically pumpable cement slurry.
[0046] The foregoing may be better understood with reference to the following examples.
EXAMPLES
[0047] Four example multifunctional additive formulations were prepared by sequential mixing of the following ingredients: addition of defoamer to water for 15 seconds at 1000 to 1500 rpm, then addition of NaCl for 60 seconds at 1500 rpm, followed by loading the silica material extender for 60 seconds at 2000 rpm to 3000 rpm, and finally addition of AMPS containing polymer with either HEC fluid stabilizer or any polymer dispersant in dry blend. The formulations are shown below.
Composition 1 Composition 2
I ngredient wt% I ngredient wt%
Water 74.03 Water 75.58
Na-Silicate (Si02/Na20 wt. ra6.87 Na-Silicate (Si02/Na20 wt. ra4.93 tio 3.22) tio 4.5)
Hydroxyl ethyl cellulose 3.00 Hydroxyl ethyl cellulose 3.06
AM PS-Acryla mide-Acrylic acid 13.06 AM PS-Acryla mide-Acrylic acid 13.33 NaCI 2.71 NaCI 2.77
Defoamer 0.32 Defoamer 0.33
Total 100.00 Total 100.00
Composition 3 Composition 4
Ingredient wt% I ngredient wt%
Water 74.80 Water 76.00
Nanosilica (8 nm size) 5.90 nano-CSH 4.40
Hydroxyl ethyl cellulose 3.03 Hydroxyl ethyl cellulose 3.08
AM PS-Acryla mide-Acrylic 13.20 AM PS-Acryla mide-Acrylic 13.41 acid acid
NaCI 2.74 NaCI 2.79
Defoamer 0.32 Defoamer 0.33
Total 100.00 Total 100.00
[0048] Cement composition were prepared using the above sample multifunctional additive by standard API RP 10B mixing procedure. Cement slurry formulations are summarized in table below.
[0049] The cement compositions were then tested for free fluid, fluid loss, and compressive strength via ultrasonic cement analyzer (UCA) following standard API RP 10B recommendations.
Cement Slurry Formulation # 1 # 2 # 3 # 4
Density (gm/cc) 1.68 1.68 1.68 1.68
Dyckerhoff, Class G Cement, % 100 100 100 100
200 mesh silica flour, % by weight of ce35 35 35 35 ment (bwoc)
Defoamer, %bwoc 0.18 0.18 0.18 0.18
Multifunctional additive composition 11.1 11.1 11.1 11.1
%bwoc (compo(compo(compo(composition #1) sition sition sition
#2) #3) #4)
Reactive Water, %bwoc 88 88 88 88
Summary of Performance Testing Data
Free Fluid, 2 hr @ Room temperature <0.5% 2% 2% 2%
Free Fluid, 2 hr @ 125°F ~0% <0.5% 2% 3%
API Fluid loss at 125F, 1000 psi, 325 mesh 44cc <50cc 46cc <50cc screen
Transition time (*SGSA method), 28 30 min 50 min 34 min 25 min mins ramp time, 125°F and 1000 psi
Compressive Strength Analysis via **UCA
Testing Condition: 28 min ramp, 125°F &
lOOOpsi Compressive strength @ 12 hrs, psi 634 0 210 403
Compressive strength @ 24 hrs, psi 1103 848 952 957
* SGSA= static gel strength machine; * *UCA = ultrasonic cement analyzer
[0050] The table above shows that cement formulations containing the claimed multifunctional additive compositions 1-4 provide desired low free fluid, <50cc API fluid loss, shorter transition time and compressive strength development of >800 psi in 24hrs for low density cement slurry of 1.68 gm/cc (14 ppg). All these properties are essential to obtain a gas tight cement slurry.
[0051] As used herein, the transitional term "comprising," which is synonymous with "including," "containing," or "characterized by," is inclusive or open-ended and does not exclude additional, un-recited elements or method steps. However, in each recitation of "comprising" herein, it is intended that the term also encompass, as alternative embodiments, the phrases "consisting essentially of and "consisting of," where "consisting of excludes any element or step not specified and "consisting essentially of permits the inclusion of additional un-recited elements or steps that do not materially affect the essential or basic and novel characteristics of the composition or method under consideration.
[0052] While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. In this regard, the scope of the invention is to be limited only by the following claims.

Claims

What is claimed is:
1. A multi-functional cement additive comprising
a) water,
b) at least one non-crystalline silica containing extender material, and c) at least one 2-Acrylamido-2-methylpropane sulfonic acid (AMPS) containing polymer,
wherein the ratio of b) to c) is from about 1 : 10 to about 10: 1.
2. The multi-functional additive of claim 1, wherein the non-crystalline silica containing extender material is at least one of nanosilica, alkali metal silicate, or nano-calcium silicate hydrate (nano-CSH) seeding material, or combinations thereof.
3. The multi-functional additive of claim 1 or 2, wherein the nanosilica has average particle sizes of from about 1 to about 100 nanometers.
4. The multi-functional additive of claim 1, 2 or 3, wherein the at least one silica containing material is present from about 5 to about 40 wt% of the multifunctional additive.
5. The multi-functional additive of any of claims 1 to 4, wherein the at least one AMPS containing polymer is at least one of AMPS-Ν,Ν dimethylacrylamide (AMPS-NNDMA), AMP S -NNDM A-acryli c acid (AMPS -NNDM A- AA), AMP S -NNDM A- styrene sulfonate (AMPS-NNDMA-SS), AMPS-NNDMA- maleic acid anhydride (AMPS -NNDM A-MAA), AMPS -NNDM A-vinyl phos- phonic acid (AMPS -NNDM A- VP A), humic acid grafted AMPS-based copolymers, or combinations thereof.
6. The multi-functional additive of any of claims 1 to 5, wherein the at least one AMPS containing polymer is present from about 5 to about 60 wt% of the multi-functional additive.
7. The multi-functional additive of any of claims 1 to 6, further comprising at least one polymeric dispersant.
8. The multi-functional additive of claim 7, wherein the at least one polymeric dispersant is at least one of sulfonated naphthalene formaldehyde polyconden- sate; an acetone formaldehyde polycondensate; melamine formaldehyde pol- ycondensate; polycarboxylate; or combinations thereof.
9. The multi-functional additive of any of claims 1 to 8, wherein the at least one polymeric dispersant is present from about 1 to about 10 wt% of the multifunctional additive.
10. The multi-functional additive of any of claims 1 to 9, wherein the water is present from about 50 to about 90 wt% of the multi-functional additive.
1 1. The multi-functional additive of any of claims 1 to 10, further comprising from about 0.1 to about 2 wt% of a defoamer.
12. The multi-functional additive of any of claims 1 to 1 1, further comprising from about 0.5 to about 5 wt% of a salt.
13. The multi-functional additive of any of claims 1 to 12, further comprising from about 0.5 to about 10 wt% of at least one cellulose-based polymer as a fluid rheology stabilizer.
14. The multifunctional additive of claim 13, wherein the cellulose-based polymer comprises at least one of hydroxy ethyl cellulose (HEC), hydroxypropyl cellulose (HPC), carboxy methyl HEC (CMHEC).
15. The multi-functional additive of any of claims 1 to 14, further comprising from about 0.5 to about 25 wt% of a silica fume.
16. The multi-functional additive of any of claims 1 to 15, further comprising from about 0.5 to about 15 wt% of at least one expansion additive comprising at least one of magnesium oxide (MgO), calcium oxide (CaO), or combinations thereof.
17. A cementing composition comprising the multifunctional additive of any of claims 1 to 16, and a hydraulic cement.
18. The cementing composition of claim 17, wherein the hydraulic cement is at least one of API class G or H.
19. The cementing composition of claim 17 or 18, wherein the multifunctional additive is added at about 0.1 to about 3 gallons per sack of hydraulic cement.
20. A method of cementing a subterranean zone penetrated by a wellbore comprising the steps of:
a. forming a pumpable cementing composition comprising:
i. hydraulic cement, and
ii. a multi-functional cement additive comprising
1) water,
2) at least one non-crystalline silica containing extender material , and
3) at least one 2-Acrylamido-2-methylpropane sulfonic acid (AMPS) containing polymer
wherein the ratio of 2) to 3) is from about 1 : 10 to about 10: 1
b. pumping said cementing composition into said zone by way of said well- bore; and
c. allowing said cement composition to set therein.
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