Cement-based particulates and methods of use
Methods of making particulates for use in a subterranean application comprising: providing particulates of a settable composition comprising a cementitious material, a filler material, and an activator of the cementitious material; and pre-curing the particulates until the particulates reach a crush strength of about 50 psi or greater; and curing the pre-cured particulates at a temperature in the range of about 230° F. to about 600° F., so that at least a portion of the particulates comprise a newly formed crystalline phase.
1. A method of fracturing a subterranean formation comprising:
providing a subterranean treatment fluid that comprises a plurality of particulates that comprise a cementitious material and a filler material, wherein the particulates are produced through a process comprising
forming particulates that comprise a settable composition comprising
the cementitious material,
the filler material, and
an activator of the cementitious material;
pre-curing the particulates until the particulates reach a crush strength of about 50 psi or greater; and
curing the pre-cured particulates at a temperature in the range of about 230° F. to about 600° F., so that at least a portion of the particulates comprise a newly formed crystalline structure; and
placing the subterranean treatment fluid in a portion of a subterranean formation at a pressure sufficient to create or enhance one or more fractures in the portion of the subterranean formation.
2. The method of claim 1 wherein forming particulates that comprise a settable composition comprising a cementitious material, a filler material, and an activator of the cementitious material comprises:
combining the components comprising the cementitious material, the filler material, and the activator of the cementitious material to form a settable composition; and
forming a plurality of particulates from the settable composition.
3. The method of claim 1 wherein forming particulates that comprise a settable composition comprising a cementitious material, a filler material, and an activator of the cementitious material comprises:
combining the components comprising the cementitious material, the filler material, and a granulating agent to form a un-activated cement blend;
forming a plurality of particulates from the un-activated cement blend; and
contacting the un-activated cement blend particulates with the activator of the cementitious material.
4. The method of claim 1 wherein the cementitious material comprises a hydraulic cement and the activator of the cementitious material is water.
5. The method of claim 1 wherein the cured particulates have a specific gravity in the range of about 0.8 to about 3.5.
6. The method of claim 1 wherein the pre-cured particulates are cured at a temperature in the range of about 230° F. to about 400° F.
7. The method of claim 1 , wherein the cementitious material comprises a hydraulic cement selected from the group consisting of a Portland cement, a pozzolanic material, a fly ash, a slag, calcined metakaolin, a phosphate cement, a gypsum cement, an aluminous cement, a silica cement, an alkaline cement, a high content alumina cement, a magnesium oxide cement, an acid resistant silicate cement, an oxysalt cementitious system, a silico phosphate cement, a glass phosphate cement, and any mixture thereof.
8. The method of claim 1 wherein the filler material comprises a material selected from the group consisting of a mineral compound, a silica, an alumina, a bauxite, a talc, a zeolite, a feldspar, a kaolin, a slag, a hollow glass bead, a glass fiber, a zeolite, an organic compound, a nut shell, a carbon fiber, a pozzolanic power, and mixtures thereof.
9. The method of claim 1 wherein the filler material comprises fly ash.
10. The method of claim 1 wherein the filler material comprises a lightweight filler material selected from the group consisting of a hollow mineral glass sphere, a hollow cenosphere, a hollow microsphere, wood dust, a walnut hull, a rice husk, an expanded perlite, a fly ash, and mixtures thereof.
11. The method of claim 1 wherein the cured particulates have an average diameter of about 150 micrometers to about 2.5 millimeters.
12. The method of claim 1 wherein forming the cured particulates have a sphericity of 0.7 or higher.
13. The method of claim 1 wherein the cured particulates have an API crush strength of higher than 5000 psi.
14. The method of claim 1 wherein the particulates further comprise high surface area silica.
15. The method of claim 1 wherein the particulates further comprise an admixture.
16. The method of claim 1 wherein the particulates are at least partially coated with an inert material.
17. The method of claim 1 wherein the particulates are at least partially coated with a resin.
18. The method of claim 1 wherein the step of pre-curing the particulates is at a temperature in the range of about 70° F. to about 230° F.
19. The method of claim 1 wherein the particulates are suspended in the subterranean treatment fluid.
20. The method of claim 1 wherein the particulates are deposited in the one or more fractures.