Sealant compositions and methods utilizing nano-particles

1. A method comprising:

providing water;

providing dry particles comprising nano-particles in an amount of about 75% or more by weight of the dry particles;

preparing a sealant composition by mixing at least the dry particles and water, wherein no additional dry particles are used in preparing the sealant composition;

introducing the sealant composition into a subterranean formation; and

allowing the sealant composition to form a seal in the subterranean formation.

2. The method of claim 1 wherein the nano-particles comprise at least about 90% or more by weight of the dry particles.

3. The method of claim 1 wherein the nano-particles comprise at least one nano-particle selected from the group consisting of a nano-hydraulic cement, a nano-silica, a nano-clay, a nano-alumina, a nano-zinc oxide, a nano-boron, a nano-iron oxide, and any combination thereof.

4. The method of claim 1 wherein the sealant composition further comprises at least one additive selected from the group consisting of a strength-retrogression additive, a set accelerator, a set retarder, a weighting agent, a lightweight additive, a gas-generating additive, a mechanical property enhancing additive, a lost-circulation material, a filtration-control additive, a dispersant, a fluid loss control additive, a defoaming agent, a foaming agent, a thixotropic additive, and any combination thereof.

5. The method of claim 1 wherein the sealant composition further comprises at least one additive selected from the group consisting of crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, calcined shale, vitrified shale, a microsphere, fly ash, slag, diatomaceous earth, metakaolin, rice husk ash, natural pozzolan, pumicite, zeolite, cement kiln dust, lime, an elastomer, an elastomeric particle, resin, latex, a swellable particle, and any combination thereof.

6. The method of claim 1 further comprising maximizing a packing volume fraction in the sealant composition using particulate material including the nano-particles.

7. A method comprising:

providing water;

providing dry particles comprising nano-particles in an amount of about 75% or more by weight of the dry particles;

preparing a sealant composition by mixing at least the dry particles and water, wherein no additional dry particles are used in preparing the sealant composition, wherein at least a portion of the nano-particles are introduced into the sealant composition in a liquid suspension;

introducing the sealant composition into a subterranean formation; and

allowing the sealant composition to form a seal in the subterranean formation.

8. The method of claim 7 wherein the nano-particles comprise at least one nano-particle selected from the group consisting of a nano-hydraulic cement, a nano-silica, a nano-clay, a nano-alumina, a nano-zinc oxide, a nano-boron, a nano-iron oxide, and any combination thereof.

9. The method of claim 7 wherein the sealant composition further comprises at least one additive selected from the group consisting of a strength-retrogression additive, a set accelerator, a set retarder, a weighting agent, a lightweight additive, a gas-generating additive, a mechanical property enhancing additive, a lost-circulation material, a filtration-control additive, a dispersant, a fluid loss control additive, a defoaming agent, a foaming agent, a thixotropic additive, and any combination thereof.

10. The method of claim 7 wherein the sealant composition further comprises at least one additive selected from the group consisting of crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, calcined shale, vitrified shale, a microsphere, fly ash, slag, diatomaceous earth, metakaolin, rice husk ash, natural pozzolan, pumicite, zeolite, cement kiln dust, lime, an elastomer, an elastomeric particle, resin, latex, a swellable particle, and any combination thereof.

11. A method comprising:

providing water;

providing dry particles comprising agglomerated nano-particles in an amount of about 75% or more by weight of the dry particles;

preparing a sealant composition by mixing at least the dry particles and water, wherein no additional dry particles are used in preparing the sealant composition;

introducing the sealant composition into a subterranean formation; and

allowing the sealant composition to form a seal in the subterranean formation.

12. The method of claim 11 wherein the agglomerated nano-particles comprise at least one nano-particle selected from the group consisting of a nano-hydraulic cement, a nano-silica, a nano-clay, a nano-alumina, a nano-zinc oxide, a nano-boron, a nano-iron oxide, and any combination thereof.

13. The method of claim 11 wherein the agglomerated nano-particles comprise nano-particles bound together by a water-soluble binder.

14. The method of claim 11 wherein the agglomerated nano-particles comprise pelletized nano-particles.

15. The method of claim 11 wherein the agglomerated nano-particles comprise a degradable material.

16. The method of claim 11 wherein the agglomerated nano-particles comprise at least one degradable material selected from the group consisting of a dextran, a cellulose, a chitin, a chitosan, a liquid ester, a protein, an aliphatic polyester, a poly(glycolide), a poly(e-caprolactone), a poly (hydroxybutyrate), a poly(anhydride), an aliphatic polycarbonate, an ortho ester, a poly(orthoester), a poly(amino acid), a poly (ethylene oxide), a polyphosphazene, and any combination thereof.

17. The method of claim 11 wherein the sealant composition further comprises at least one additive selected from the group consisting of a strength-retrogression additive, a set accelerator, a set retarder, a weighting agent, a lightweight additive, a gas-generating additive, a mechanical property enhancing additive, a lost-circulation material, a filtration-control additive, a dispersant, a fluid loss control additive, a defoaming agent, a foaming agent, a thixotropic additive, and any combination thereof.

18. The method of claim 11 wherein the sealant composition further comprises at least one additive selected from the group consisting of crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, calcined shale, vitrified shale, a microsphere, fly ash, slag, diatomaceous earth, metakaolin, rice husk ash, natural pozzolan, pumicite, zeolite, cement kiln dust, lime, an elastomer, an elastomeric particle, resin, latex, a swellable particle, and any combination thereof.

19. A method comprising:

providing water;

providing dry particles comprising nano-particles in an amount of about 75% or more by weight of the dry particles;

providing elastomeric particles;

preparing a sealant composition by mixing at least the dry particles, the elastomeric particles, and water, wherein no additional dry particles are used in preparing the sealant composition;

introducing the sealant composition into a subterranean formation; and

allowing the sealant composition to form a seal in the subterranean formation.

20. The method of claim 19 wherein the nano-particles comprise at least one nano-particle selected from the group consisting of a nano-hydraulic cement, a nano-silica, a nano-clay, a nano-alumina, a nano-zinc oxide, a nano-boron, a nano-iron oxide, and any combination thereof.

21. The method of claim 19 wherein the elastomeric particles comprise a block copolymer of styrene butadiene rubber.

22. The method of claim 19 wherein the sealant composition further comprises at least one additive selected from the group consisting of a strength-retrogression additive, a set accelerator, a set retarder, a weighting agent, a lightweight additive, a gas-generating additive, a mechanical property enhancing additive, a lost-circulation material, a filtration-control additive, a dispersant, a fluid loss control additive, a defoaming agent, a foaming agent, a thixotropic additive, and any combination thereof.

23. The method of claim 19 wherein the sealant composition further comprises at least one additive selected from the group consisting of crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, calcined shale, vitrified shale, a microsphere, fly ash, slag, diatomaceous earth, metakaolin, rice husk ash, natural pozzolan, pumicite, zeolite, cement kiln dust, lime, an elastomer, resin, latex, a swellable particle, and any combination thereof.

24. A method comprising:

providing water;

providing dry particles comprising nano-particles in an amount of about 75% or more by weight of the dry particles;

providing a swellable polymer;

preparing a sealant composition by mixing at least the dry particles, the swellable polymer, and water, wherein no additional dry particles are used in preparing the sealant composition;

introducing the sealant composition into a subterranean formation; and

allowing the sealant composition to form a seal in the subterranean formation.

25. The method of claim 24 wherein the nano-particles comprise at least one nano-particle selected from the group consisting of a nano-hydraulic cement, a nano-silica, a nano-clay, a nano-alumina, a nano-zinc oxide, a nano-boron, a nano-iron oxide, and any combination thereof.

26. The method of claim 24 wherein the swellable polymer is water swellable.

27. The method of claim 24 wherein the swellable polymer comprises at least one material selected from the group consisting of starch-polyacrylate acid graft copolymer and salts thereof, polyethylene oxide polymer, carboxymethyl cellulose type polymers, polyacrylamide, poly(acrylic acid) and salts thereof, poly(acrylic acid-co-acrylamide) and salts thereof, graft-poly(ethylene oxide) of poly(acrylic acid) and salts thereof, poly(2-hydroxyethyl methacrylate), poly(2-hydroxypropyl methacrylate), and any combination thereof.

28. The method of claim 24 wherein the swellable polymer is oil swellable.

29. The method of claim 24 wherein the swellable polymer comprises at least one material selected from the group consisting of natural rubber, acrylate butadiene rubber, polyacrylate rubber, isoprene rubber, choloroprene rubber, butyl rubber, brominated butyl rubber, chlorinated butyl rubber, chlorinated polyethylene, neoprene rubber, styrene butadiene copolymer rubber, sulphonated polyethylene, ethylene acrylate rubber, epichlorohydrin ethylene oxide copolymer, ethylene-propylene rubber, ethylene-propylene-diene terpolymer rubber, ethylene vinyl acetate copolymer, fluorosilicone rubber, silicone rubber, poly 2,2,1-bicyclo heptene (polynorborneane), alkylstyrene, and any combination thereof.

30. The method of claim 24 wherein the swellable polymer comprises a block copolymer of styrene butadiene rubber.

31. The method of claim 24 wherein the sealant composition further comprises at least one additive selected from the group consisting of a strength-retrogression additive, a set accelerator, a set retarder, a weighting agent, a lightweight additive, a gas-generating additive, a mechanical property enhancing additive, a lost-circulation material, a filtration-control additive, a dispersant, a fluid loss control additive, a defoaming agent, a foaming agent, a thixotropic additive, and any combination thereof.

32. The method of claim 24 wherein the sealant composition further comprises at least one additive selected from the group consisting of crystalline silica, amorphous silica, fumed silica, salt, fiber, hydratable clay, calcined shale, vitrified shale, a microsphere, fly ash, slag, diatomaceous earth, metakaolin, rice husk ash, natural pozzolan, pumicite, zeolite, cement kiln dust, lime, an elastomer, resin, latex, and any combination thereof.

33. The method of claim 1 wherein the nano-particles have a mean particle size of about 1 nanometer to about 100 nanometers.

34. The method of claim 1 wherein the nano-particles comprise nano-hydraulic cement in an amount of about 10% or more by weight of cementitious material.

35. The method of claim 1 wherein the sealant composition is allowed to set in the subterranean formation in a space between a pipe string and a well bore wall.