Aqueous based epoxy slurry for forming a consolidated gravel pack

Claim 2

In a slurry suitable for use in emplacing a permeably consolidated particulate mass in communication with a permeable subterranean formation, of the type containing an epoxy resin-solvent mixture, a curing agent for the epoxy resin, a particulate material, and a coupling agent, the improvement which comprises: (a) an aqueous based carrying fluid for the slurry, and (b) a surfactant in the slurry, selected from the group consisting of quaternary ammonium salts corresponding to the formula ##STR6## wherein: R 1 and R 3 are each independently lower alkyl, hydroxy substituted lower alkyl, or polyoxyethylene alkyl of the formula --(CH 2 CH 2 O) n H wherein n is 2 or 3; R 2 is an 8- through 18-carbon hydrocarbon chain; R 4 is an aliphatic hydrocarbon chain or an alkyl aryl group, containing 7 to 18 carbon atoms; and X is fluorine, chlorine, bromine, or iodine; the components of said slurry being provided in amounts and admixed in a sequence such that a pumpable slurry is obtained from which a permeable, consolidated mass can be formed after a suitable curing time.

Claim 3

The slurry of claim 1 wherein the surfactant is employed in an amount of from about 0.01 to about 0.23 percent, based on the weight of the particulate.

Claim 4

The slurry of claim 1 wherein X represents Cl.

Claim 5

The slurry of claim 1 wherein the aqueous carrier is a brine containing at least one alkali metal halide.

Claim 6

The slurry of claim 1 wherein the aqueous carrier is substantially free of free polyvalent metal cations.

Claim 7

The slurry of claim 5 wherein the aqueous carrier contains from about 1 to about 3 weight percent KCl.

Claim 8

The slurry of claim 1 wherein the aqueous carrier contains an effective amount of a gelling agent to enhance the solids carrying capacity of the slurry.

Claim 9

The slurry of claim 7 wherein the gelling agent is hydroxyethylcellulose.

Claim 10

The slurry of claim 7 wherein the aqueous carrier contains an agent to cause the gel formed by the gelling agent to break to a determinable extent once the slurry has been emplaced.

Claim 11

The slurry of claim 1 wherein R 4 is alkylaryl.

Claim 12

The slurry of claim 10 wherein X represents Cl.

Claim 13

The slurry of claim 10 wherein R 4 is benzyl.

Claim 14

The slurry of claim 1 wherein R 1 and R 3 each contain at least one hydroxyl group.

Claim 15

The slurry of claim 13 wherein X represents Cl.

Claim 16

The slurry claim 14 wherein R 4 is alkylaryl.

Claim 17

The slurry of claim 15 wherein R 4 is benzyl.

Claim 18

The slurry of claim 16 wherein the surfactant is employed in an amount of from about 0.01 to about 0.23 percent, based on the weight of the particulate.

Claim 19

The slurry of claim 16 wherein the surfactant is at least one alkyl (C 8 -C 18 ) bis(2-hydroxyethyl)benzylammonium chloride.

Claim 20

The slurry of claim 18 wherein the particulate is present in an amount of from about 7 to about 20 pounds per gallon of total liquid in the slurry; wherein the epoxy resin is present in an amount of from about 2 to about 10 percent by weight of the particulate; wherein the curing agent is present in an amount of from about 40 to about 125 percent of that stoichiometrically required to react with the resin; wherein the coupling agent is present in an amount of from about 0.05 to about 2 percent by weight of the particulate; wherein sufficient gelling agent is present so that the aqueous carrier component of the slurry has a viscosity at about 25° C of from about 130 to 350 centipoise; and wherein the surfactant is present in an amount of from about 0.01 to about 0.23 percent based on the weight of the particulate.

Claim 21

The slurry of claim 18 wherein the epoxy resin is a glycidyl polyether of a dihydric phenol; and wherein the coupling agent is an organosilane.

Claim 22

The slurry of claim 20 wherein the particulate is sand having a diameter ranging from about 0.065 to about 0.01 inch and is present in an amount of from about 14 to about 16 pounds per gallon of total liquid in the slurry; wherein the epoxy resin is of the bisphenol A/epichlorohydrin type and is present in an amount of from about 3.5 to about 5.5 percent, based on the weight of the sand; wherein a blend of xylene and ethylene glycol ethyl ether is present as a solvent for said resin, the weight ratio of xylene and said ether to one another being from about 1.5:1 to about 0.3:1, said blend being present in an amount of from about 20 to about 75 percent based on the weight of the resin; wherein the curing agent is 4,4'-dimethylenedianiline, and wherein said curing agent is present in an amount of from about 85 to about 100 percent of that stoichiometrically required to react with the resin; wherein the coupling agent is gamma-aminopropyltriethoxysilane and said coupling agent is present in an amount of from about 0.3 to about 0.9 percent based on the weight of the sand; wherein the aqueous carrier is a brine substantially free from free polyvalent metal cations, containing, based on the weight of the water, from about 1 to about 3 weight percent KCl and from about 0.5 to about 0.75 weight percent hydroxyethylcellulose; and wherein the surfactant is present in an amount of from about 0.03 to about 0.1 percent, based on the weight of the sand.

Claim 25

The method of claim 22 wherein the surfactant is employed in an amount of from about 0.01 to about 0.23 percent, based on the weight of the particulate.

Claim 26

The slurry of claim 22 wherein X represents Cl.

Claim 27

The method of claim 22 wherein the aqueous carrier is a brine containing at least one alkali metal halide.

Claim 28

The method of claim 22 wherein the aqueous carrier is substantially free of free polyvalent metal cations.

Claim 29

The method of claim 22 wherein the aqueous carrier contains from about 1 to about 3 weight percent KCl.

Claim 30

The method of claim 22 wherein the aqueous carrier contains an effective amount of a gelling agent to enhance the solids carrying capacity of the slurry.

Claim 31

The method of claim 28 wherein the gelling agent is hydroxyethylcellulose.

Claim 32

The method of claim 28 wherein the aqueous carrier contains an agent to cause the gel formed by the gelling agent to break to a determinable extent once the slurry has been emplaced.

Claim 33

The method of claim 22 wherein R 4 is alkylaryl.

Claim 34

The method of claim 31 wherein X represents Cl.

Claim 35

The method of claim 31 wherein R 4 is benzyl.

Claim 36

The method of claim 22 wherein R 1 and R 3 each contain at least one hydroxyl group.

Claim 37

The method of claim 34 wherein X represents Cl.

Claim 38

The method of claim 35 wherein R 4 is alkylaryl.

Claim 39

The method of claim 36 wherein R 4 is benzyl.

Claim 40

The method of claim 37 wherein the surfactant is employed in an amount of from about 0.01 to about 0.23 percent, based on the weight of the particulate.

Claim 41

The method of claim 37 wherein the surfactant is at least one alkyl (C 8 -C 18 ) bis(2-hydroxyethyl)benzylammonium chloride.

Claim 42

The method of claim 39 wherein the particulate is employed in an amount of from about 7 to about 20 pounds per gallon of total liquid in the slurry; wherein the epoxy resin is employed in an amount of from about 2 to about 10 percent by weight of the particulate; wherein the curing agent is employed in an amount of from about 40 to about 125 percent of that stoichiometrically required to react with the resin; wherein the coupling agent is employed in an amount of from about 0.05 to about 2 percent by weight of the particulate; wherein sufficient gelling agent is employed so that the aqueous carrier component of the slurry has a viscosity at about 25° C of from about 130 to 350 centipoise; and wherein the surfactant is employed in an amount of from about 0.01 to about 0.23 percent based on the weight of the particulate.

Claim 43

The method of claim 39 wherein the epoxy resin is a glycidyl polyether of a dihydric phenol; and wherein the coupling agent is an organosilane.

Claim 44

The method of claim 41 wherein the particulate is sand having a diameter ranging from about 0.065 to about 0.01 inch and is employed in an amount of from about 14 to about 16 pounds per gallon of total liquid in the slurry; wherein the epoxy resin is of the bisphenol A/epichlorohydrin type and is employed in an amount of from about 3.5 to about 5.5 percent, based on the weight of the sand; wherein a blend of xylene and ethylene glycol ethyl ether is employed as a solvent for said resin, the weight ratio of xylene and said ether to one another being from about 1.5:1 to about 0.3:1, said blend being employed in an amount of from about 20 to about 75 percent based on the weight of the resin; wherein the curing agent is 4,4'-dimethylenedianiline, and wherein said curing agent is employed in an amount of from about 85 to about 100 percent of that stoichiometrically required to react with the resin; wherein the coupling agent is gamma-aminopropyltriethoxysilane and said coupling agent is present in an amount of from about 0.3 to about 0.9 percent based on the weight of the sand; wherein the aqueous carrier is a brine substantially free from free polyvalent metal cations, containing, based on the weight of the water, from about 1 to about 3 weight percent KCl and from about 0.5 to about 0.75 weight percent hydroxyethylcellulose; and wherein the surfactant is employed in an amount of from about 0.03 to about 0.01 percent, based on the weight of the sand.