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US-12617998-B1 - Well cementing with a composition including red mud

US12617998B1US 12617998 B1US12617998 B1US 12617998B1US-12617998-B1

Abstract

A cementing composition is flowed into an annulus between a tubular disposed within a wellbore formed in a subterranean formation and a wall of the wellbore. The cementing composition includes red mud, an epoxy resin, and a curing agent. The curing agent includes nitrogen. The curing agent crosslinks the epoxy resin to solidify the cementing composition, thereby cementing the tubular within the wellbore.

Inventors

  • Khawlah ALANQARI
  • Abdullah Saleh Hussain Al-Yami
  • Abdulaziz Alhelal

Assignees

  • SAUDI ARABIAN OIL COMPANY

Dates

Publication Date
20260505
Application Date
20250106

Claims (19)

  1. 1 . A method comprising: flowing a cementing composition into an annulus between a tubular disposed within a wellbore formed in a subterranean formation and a wall of the wellbore, wherein the cementing composition comprises: red mud; an epoxy resin selected from the group consisting of 2,3-epoxypropyl-o-tolyl ether, C12-C14 alkyl glycidyl ether, or 1,6-hexanediol diglycidyl ether; and a curing agent selected from the group consisting of trimethyl hexamethylene diamine (TMD), diethylenetriamine (DETA), triethylenetetramine (TETA), meta-xylenediamine (MXDA), tetraethylenepentamine (TEPA), polyetheramine, isophoronediamine (IPDA), or beta-hydroxyalkyl amide (HAA); and crosslinking, by the curing agent, the epoxy resin to solidify the cementing composition in response to exposure to a downhole condition of the wellbore, thereby cementing the tubular within the wellbore.
  2. 2 . The method of claim 1 , wherein: a concentration of the red mud in the cementing composition is in a range of from about 8 weight percent (wt. %) to about 14 wt. %; a concentration of the epoxy resin in the cementing composition is in a range of from about 80 wt. % to about 95 wt. %; and a concentration of the curing agent in the cementing composition is in a range of from about 2.0 wt. % to about 4.0 wt. %.
  3. 3 . The method of claim 1 , wherein the epoxy resin has an epoxy value in a range of from 4.5 epoxy equivalents per kilogram of the epoxy resin to 5.5 epoxy equivalents per kilogram of the epoxy resin, wherein the epoxy equivalent is the weight of the epoxy resin in grams that contain one equivalent weight of epoxy, wherein the equivalent weight of epoxy is the molecular weight of the epoxy resin divided by an average number of epoxy groups in the epoxy resin.
  4. 4 . The method of claim 1 , wherein the curing agent has an amine value in a range of from about 250 milligrams of potassium hydroxide per gram (mg KOH/g) to about 1,700 mg KOH/g, wherein the amine value is a weight of potassium hydroxide in milligrams needed to neutralize one gram of the curing agent.
  5. 5 . The method of claim 1 , wherein the curing agent has an amine hydrogen equivalent weight (AHEW) in a range of from about 20 grams (g) to about 120 g, wherein the AHEW is the molecular weight of the curing agent divided by a number of active hydrogens per molecule of the curing agent.
  6. 6 . The method of claim 1 , wherein the cementing composition is maintained within the annulus for a curing time in a range of from about 4 hours to about 12 hours, such that the curing agent crosslinks the epoxy resin.
  7. 7 . A composition for cementing a wellbore, the composition comprising: red mud; an epoxy resin selected from the group consisting of 2,3-epoxypropyl-o-tolyl ether, C12-C14 alkyl glycidyl ether, or 1,6-hexanediol diglycidyl ether; and a curing agent configured to crosslink the epoxy resin to solidify the composition in response to exposure to a downhole condition of the wellbore, thereby cementing the wellbore, wherein the curing agent is selected from the group consisting of trimethyl hexamethylene diamine (TMD), diethylenetriamine (DETA), triethylenetetramine (TETA), meta-xylenediamine (MXDA), tetraethylenepentamine (TEPA), polyetheramine, isophoronediamine (IPDA), or beta-hydroxyalkyl amide (HAA).
  8. 8 . The composition of claim 7 , wherein a concentration of the red mud in the composition is in a range of from about 8 weight percent (wt. %) to about 14 wt. %.
  9. 9 . The composition of claim 8 , wherein a concentration of the epoxy resin in the composition is in a range of from about 80 wt. % to about 95 wt. %.
  10. 10 . The composition of claim 9 , wherein a concentration of the curing agent in the composition is in a range of from about 2.0 wt. % to about 4.0 wt. %.
  11. 11 . The composition of claim 7 , wherein the epoxy resin has an epoxy value in a range of from 4.5 epoxy equivalents per kilogram of the epoxy resin to 5.5 epoxy equivalents per kilogram of the epoxy resin, wherein the epoxy equivalent is the weight of the epoxy resin in grams that contain one equivalent weight of epoxy, wherein the equivalent weight of epoxy is the molecular weight of the epoxy resin divided by an average number of epoxy groups in the epoxy resin.
  12. 12 . The composition of claim 7 , wherein the curing agent has an amine value in a range of from about 250 milligrams of potassium hydroxide per gram (mg KOH/g) to about 1,700 mg KOH/g, wherein the amine value is a weight of potassium hydroxide in milligrams needed to neutralize one gram of the curing agent.
  13. 13 . The composition of claim 7 , wherein the curing agent has an amine hydrogen equivalent weight (AHEW) in a range of from about 20 grams (g) to about 120 g, wherein the AHEW is the molecular weight of the curing agent divided by a number of active hydrogens per molecule of the curing agent.
  14. 14 . The composition of claim 7 , wherein the composition is substantially free of water.
  15. 15 . A system comprising: a wellbore formed in a subterranean formation; a tubular disposed within the wellbore; a cementing composition comprising: red mud; an epoxy resin selected from the group consisting of 2,3-epoxypropyl-o-tolyl ether, C12-C14 alkyl glycidyl ether, or 1,6-hexanediol diglycidyl ether; and a curing agent selected from the group consisting of trimethyl hexamethylene diamine (TMD), diethylenetriamine (DETA), triethylenetetramine (TETA), meta-xylenediamine (MXDA), tetraethylenepentamine (TEPA), polyetheramine, isophoronediamine (IPDA), or beta-hydroxyalkyl amide (HAA); and a pump configured to flow the cementing composition into an annulus between the tubular and a wall of the wellbore, wherein the curing agent is configured to crosslink the epoxy resin to solidify the cementing composition in response to exposure to a downhole condition of the wellbore, thereby cementing the tubular within the wellbore.
  16. 16 . The system of claim 15 , wherein: a concentration of the red mud in the cementing composition is in a range of from about 8 weight percent (wt. %) to about 14 wt. %; a concentration of the epoxy resin in the cementing composition is in a range of from about 80 wt. % to about 95 wt. %; and a concentration of the curing agent in the cementing composition is in a range of from about 2.0 wt. % to about 4.0 wt. %.
  17. 17 . The system of claim 15 , wherein the epoxy resin has an epoxy value in a range of from 4.5 epoxy equivalents per kilogram of the epoxy resin to 5.5 epoxy equivalents per kilogram of the epoxy resin, wherein the epoxy equivalent is the weight of the epoxy resin in grams that contain one equivalent weight of epoxy, wherein the equivalent weight of epoxy is the molecular weight of the epoxy resin divided by an average number of epoxy groups in the epoxy resin.
  18. 18 . The system of claim 15 , wherein the curing agent has an amine value in a range of from about 250 milligrams of potassium hydroxide per gram (mg KOH/g) to about 1,700 mg KOH/g, wherein the amine value is a weight of potassium hydroxide in milligrams needed to neutralize one gram of the curing agent.
  19. 19 . The system of claim 15 , wherein the curing agent has an amine hydrogen equivalent weight (AHEW) in a range of from about 20 grams (g) to about 120 g, wherein the AHEW is the molecular weight of the curing agent divided by a number of active hydrogens per molecule of the curing agent.

Description

TECHNICAL FIELD This disclosure relates to cementing fluids, and in particular, cementing fluids for well cementing. BACKGROUND Natural resources such as gas, oil, and water in a subterranean formation can be produced by drilling a wellbore into the subterranean formation while circulating a drilling fluid in the wellbore. A well is cemented prior to hydrocarbon production. Well cementing includes introducing cement to provide a hydraulic seal that establishes zone isolation, prevents fluid communication between producing zones in the borehole, and blocks the escape of fluids to the surface. Well cementing also anchors and supports tubulars installed in the wellbore and protects the tubulars against corrosion by formation fluids. SUMMARY This disclosure describes technologies relating to cementing wells formed in subterranean formations. The subject matter described in this disclosure can be implemented in particular implementations, so as to realize one or more of the following advantages. The compositions, methods, and systems described can be used to cement a well formed in a subterranean formation. Red mud, which is typically considered a waste material, can be incorporated into the compositions described to improve viscosity of the cementing fluids. Thus, the compositions, methods, and systems described can support sustainability of oil and gas operations by reusing and incorporating waste materials, such as red mud, in performing useful operations, such as cementing wells. The details of one or more implementations of the subject matter of this disclosure are set forth in the accompanying drawings and the description. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims. DESCRIPTION OF DRAWINGS FIG. 1 is a schematic diagram of an example rig system for drilling a wellbore in a subterranean formation. FIG. 2 is a progression of schematics depicting example stages of cementing a well. FIG. 3 is a flow chart of an example method for cementing a well. DETAILED DESCRIPTION This disclosure describes cementing a well using a composition including an epoxy resin, a crosslinker (also referred to as a curing agent), and red mud (which is typically a waste material and also referred to as bauxite residue). The red mud facilitates generation of a hard gel that becomes rigid downhole for creating a seal in well cementing applications. In some cases, the composition includes an emulsifier for improved mixing. Weighting materials can also be included in the composition. The crosslinker increases viscosity of the composition. Setting time of the composition to form the seal can be controlled by varying the type of resin and/or the type of crosslinker. Setting time of the composition to form the seal can be controlled by varying the concentration of crosslinker in the composition. Red mud is a highly basic material which can raise environmental concerns if not disposed of properly. By re-using red mud that is generated as an industrial by-product to generate a value-added product for cementing wells, wells can be constructed more sustainably. Red mud (also referred to as bauxite residue) is an industrial waste by-product that can be produced during the production of alumina, for example, via the Bayer process. Typically, about one to two tons of red mud are produced for every ton of aluminum produced. Over 175 million tons of red mud are produced globally. Red mud is highly basic, with a pH ranging from about 10 to about 12, which can introduce environment concerns if not disposed of properly. Red mud is composed of a mixture of solid and metallic oxides (mainly aluminum oxide (Al2O3) and silicon dioxide (SiO2)) and can be added to the cementing fluid to increase viscosity and serve as a weighting material. Extracting hydrocarbons from subterranean sources may require drilling a hole from the surface to the subterranean geological formation housing the hydrocarbons. Specialized drilling techniques and materials are utilized to form the bore hole and extract the hydrocarbons. Specialized materials utilized in drilling operations include materials for sealing the casing-casing annulus of the wellbore, which may be formulated for specific downhole conditions. A wellbore is a hole that extends from the surface to a location below the surface to permit access to hydrocarbon-bearing subterranean formations. The wellbore contains at least a portion of a fluid conduit that links the interior of the wellbore to the surface. The fluid conduit connecting the interior of the wellbore to the surface may be capable of permitting regulated fluid flow from the interior of the wellbore to the surface and may permit access between equipment on the surface and the interior of the wellbore. The fluid conduit may be defined by one or more tubular strings, such as casings for example, inserted into the wellbore and secured in the wellbore. FIG. 1 is a partial