EP0061494B1 - Thermal enhancement - Google Patents
Thermal enhancement Download PDFInfo
- Publication number
- EP0061494B1 EP0061494B1 EP81902877A EP81902877A EP0061494B1 EP 0061494 B1 EP0061494 B1 EP 0061494B1 EP 81902877 A EP81902877 A EP 81902877A EP 81902877 A EP81902877 A EP 81902877A EP 0061494 B1 EP0061494 B1 EP 0061494B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- combustion
- zone
- fuel
- liquid
- chamber
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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- 238000002485 combustion reaction Methods 0.000 claims abstract description 141
- 239000007788 liquid Substances 0.000 claims abstract description 41
- 239000000446 fuel Substances 0.000 claims abstract description 35
- 239000000203 mixture Substances 0.000 claims abstract description 35
- 230000015572 biosynthetic process Effects 0.000 claims abstract description 26
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 26
- 238000002347 injection Methods 0.000 claims abstract description 17
- 239000007924 injection Substances 0.000 claims abstract description 17
- 238000007669 thermal treatment Methods 0.000 claims abstract description 10
- 230000002708 enhancing effect Effects 0.000 claims abstract description 5
- 230000003993 interaction Effects 0.000 claims abstract description 3
- 238000005755 formation reaction Methods 0.000 claims description 25
- 239000000463 material Substances 0.000 claims description 25
- 239000002826 coolant Substances 0.000 claims description 24
- 239000007800 oxidant agent Substances 0.000 claims description 15
- 238000000034 method Methods 0.000 claims description 14
- 230000008569 process Effects 0.000 claims description 14
- 238000011084 recovery Methods 0.000 claims description 12
- 230000008016 vaporization Effects 0.000 claims description 12
- 238000009834 vaporization Methods 0.000 claims description 11
- 230000006835 compression Effects 0.000 claims description 10
- 238000007906 compression Methods 0.000 claims description 10
- 230000003014 reinforcing effect Effects 0.000 claims description 10
- 239000011819 refractory material Substances 0.000 claims description 9
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 9
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 9
- 238000005507 spraying Methods 0.000 claims description 9
- 239000007921 spray Substances 0.000 claims description 8
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 7
- 239000011248 coating agent Substances 0.000 claims description 7
- 238000000576 coating method Methods 0.000 claims description 7
- 230000001590 oxidative effect Effects 0.000 claims description 7
- 239000001301 oxygen Substances 0.000 claims description 7
- 229910052760 oxygen Inorganic materials 0.000 claims description 7
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 6
- 239000004215 Carbon black (E152) Substances 0.000 claims description 5
- 238000010304 firing Methods 0.000 claims description 5
- 229930195733 hydrocarbon Natural products 0.000 claims description 5
- 150000002430 hydrocarbons Chemical class 0.000 claims description 5
- 230000002441 reversible effect Effects 0.000 claims description 5
- 239000000295 fuel oil Substances 0.000 claims description 4
- 239000003381 stabilizer Substances 0.000 claims description 4
- 229910001092 metal group alloy Inorganic materials 0.000 claims description 2
- 238000002156 mixing Methods 0.000 claims description 2
- 230000000717 retained effect Effects 0.000 claims description 2
- 150000003377 silicon compounds Chemical class 0.000 claims description 2
- 230000000638 stimulation Effects 0.000 abstract description 10
- 238000011144 upstream manufacturing Methods 0.000 abstract description 4
- 230000004044 response Effects 0.000 abstract description 2
- 239000000126 substance Substances 0.000 abstract description 2
- 239000010935 stainless steel Substances 0.000 description 10
- 229910001220 stainless steel Inorganic materials 0.000 description 10
- 230000007704 transition Effects 0.000 description 10
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 8
- 239000003921 oil Substances 0.000 description 6
- 238000007789 sealing Methods 0.000 description 6
- 239000006200 vaporizer Substances 0.000 description 6
- 238000003491 array Methods 0.000 description 5
- 230000008878 coupling Effects 0.000 description 5
- 238000010168 coupling process Methods 0.000 description 5
- 238000005859 coupling reaction Methods 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- 239000004568 cement Substances 0.000 description 4
- 230000035882 stress Effects 0.000 description 4
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 3
- 229910002092 carbon dioxide Inorganic materials 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 239000001257 hydrogen Substances 0.000 description 3
- 229910052739 hydrogen Inorganic materials 0.000 description 3
- 239000010743 number 2 fuel oil Substances 0.000 description 3
- 230000009471 action Effects 0.000 description 2
- 238000000889 atomisation Methods 0.000 description 2
- VLYDPWNOCPZGEV-UHFFFAOYSA-M benzyl-dimethyl-[2-[2-[2-methyl-4-(2,4,4-trimethylpentan-2-yl)phenoxy]ethoxy]ethyl]azanium;chloride;hydrate Chemical compound O.[Cl-].CC1=CC(C(C)(C)CC(C)(C)C)=CC=C1OCCOCC[N+](C)(C)CC1=CC=CC=C1 VLYDPWNOCPZGEV-UHFFFAOYSA-M 0.000 description 2
- 239000007767 bonding agent Substances 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
- 239000004020 conductor Substances 0.000 description 2
- 230000000593 degrading effect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 210000002445 nipple Anatomy 0.000 description 2
- 239000010747 number 6 fuel oil Substances 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 239000003208 petroleum Substances 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 125000006850 spacer group Chemical group 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 239000010963 304 stainless steel Substances 0.000 description 1
- -1 Hasteloy Inorganic materials 0.000 description 1
- 229910000589 SAE 304 stainless steel Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000004323 axial length Effects 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000010779 crude oil Substances 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000005188 flotation Methods 0.000 description 1
- 239000002828 fuel tank Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 229910001293 incoloy Inorganic materials 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 239000003129 oil well Substances 0.000 description 1
- 239000011236 particulate material Substances 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000004071 soot Substances 0.000 description 1
- 238000004901 spalling Methods 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 230000010512 thermal transition Effects 0.000 description 1
- LALRXNPLTWZJIJ-UHFFFAOYSA-N triethylborane Chemical compound CCB(CC)CC LALRXNPLTWZJIJ-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B36/00—Heating, cooling or insulating arrangements for boreholes or wells, e.g. for use in permafrost zones
- E21B36/02—Heating, cooling or insulating arrangements for boreholes or wells, e.g. for use in permafrost zones using burners
Definitions
- This invention relates to processes and apparatus for thermal treatment of subterranean geologic formations for enhancing recovery of geologic resources.
- Thermal treatment of subterranean geologic formations is frequently useful in enhancing the recovery of geologic resources.
- some petroleum materials the so-called “heavy crudes”
- have viscosity and gravity characteristics such that those materials do not flow readily through the porous earth formations, and hence their recovery is exceedingly difficult.
- Recovery of such petroleum materials may be enhanced by flowing heating materials into the subterranean reservoir for viscosity reduction, mobility enhancement, and like purposes.
- thermal treatment apparatus may be used to promote chemical reactions, to initiate in situ combustion or retorting and the like. While thermal treatment systems have been proposed for downhole use, their operation has not been entirely satisfactory, due in part to the nature of the remote, relatively inaccessible and frequently harsh environment. Simple and sturdy constructions as well as simple and reliable controls are desirable for effective operation. It is also frequently desirable that the system not introduce either particulate material or excess oxygen into the geologic formation being treated.
- thermal treatment apparatus for downhole deployment that includes a combustion stage with structure for intensely hot wall operation that defines a fuel-oxidant mixture combustion and retention zone, and ignition zone structure immediately upstream from the combustion zone in which a mixture of atomized liquid fuel and oxidant is ignited; together with a liquid injection stage immediately downstream from the combustion zone through which the stream of essentially particulate free, high temperature combustion products flows from the combustion zone and into which liquid to be vaporized is sprayed.
- the length of the chamber structure defining the hot wall combustion zone is preferably at least five times its width dimension and the zone is defined by a refractory wall whose surface is maintained at elevated temperature in excess of 1100°C in an arrangement in which the burning fuel-oxidant mixture is retained within the combustion zone until combustion is completed so that an essentially particulate free stream of combustion products is discharged from the combustion zone into the geologic formation to be treated.
- the liquid injection stage preferably has an elongated chamber of dimensions similar to and axially aligned with the hot wall combustion zone chamber.
- a thermal enhancement process in accordance with the invention for recovering hydrocarbon materials and the like from subterranean geologic formations includes the steps of positioning combustion chamber structure downhole adjacent the geologic formation to be treated, flowing an oxidant liquid fuel mixture at or below stoichiometric ratio into an ignition zone of the combustion chamber structure and igniting the mixture, flowing the burning mixture into a combustion zone defined by wall structure surface maintained at a temperature in excess of 1100°C retaining the burning oxidant-fuel mixture in the combustion zone sufficiently long to insure substantially complete combustion, and then discharging the resulting essentially particulate free, oxygen free product mixture into the subterranean formation to be treated.
- the invention provides reduced risk of plugging and/or degrading the natural porosity of the formation into which the mixture is discharged.
- the resulting stream of essentially particulate free combustion products is flowed through a vaporization zone while injecting water into the flowing combustion products stream, and a mixture of steam and combustion products including carbon dioxide is injected into an oil bearing formation for producing chemical and thermal stimulation interactions to enhance the speed and effectiveness of reservoir response.
- the thermal treatment apparatus includes an elongated cylindrical body about fifteen centimeters in outer diameter which is disposed downhole in a conventional oil well casing.
- a high temperature seal module is provided for deployment immediately above or below the thermal treatment apparatus for sealing the casing adjacent the geologic formation to be treated.
- That high temperature seal module includes annular die structure and metal sealing rings which are hydraulically extruded through the dies into the annulus between packer and the well casing. Other types of high temperature packers can also be used.
- the combustion and liquid injection stages are housed in axial alignment within a common elongated sleeve that fits within the well casing with an annular cooling jacket chamber that extends the length of both the combustion and liquid injection stages through which the liquid to be vaporized is flowed.
- the combustion stage includes structure that defines a fuel injection zone with an atomizing nozzle that introduces a well atomized spray of fuel into the ignition zone in a coaxial sheath of air, and a refractory lined combustion chamber whose surface is maintained at an intensely hot temperature. Air flowed into the ignition zone through swirk passage structure establishes a forced vortex flow which maximizes aerodynamic shear and fuel-air mixing rates in a highly stirred zone with moderate temperature rise that provides stable ignition and enhanced fuel evaporation in the toroidal vortex.
- the downstream boundary of the forced vortex ignition zone is defined by fixed flame stabilizer structure that includes convergent-divergent throat structure with an extensively and highly stirred reverse flow zone immediately downstream from the throat structure that maximizes the combustion rate in the upstream end of the hot wall combustion zone. Downstream from the reverse flow zone and continuing through the hot wall combustion zone is a region of free vortex plug flow in which combustion is completed.
- the system provides flame stabilization in two separate but interconnected regions, a first region serving as an ignition zone and the second region providing a hot gas recirculation pattern that provides flame stability in a zone of high swirl and intensely back mixed flow which promotes efficient combustion.
- the hot refractory wall surface maximizes combustion of any remaining unburned materials and the thermal lag of that surface provides a ready ignition source for relight and helps smooth out variations in heat release rate due to process fluctuations.
- the tubular combustion chamber unit housed within the tubular coolant jacket assembly includes a monolithic tube of refractory material whose inner surface defines the combustion zone.
- a metal reinforcing sleeve surrounds and extends the length of the refractory tube.
- the inner surface of the coolant jacket assembly and outer surface of the combustion chamber unit are dimensioned so that those surfaces are close to one another (less than one millimeter spacing) in standby or cool condition so that the combustion chamber unit has limited freedom to expand with that expansion being stabilized by the coolant jacket assembly so that compression forces in the refractory tube preferably do not exceed about one-half the safe compressive stress of the material; and the materials of the combustion chamber unit are selected to establish thermal gradient parameters across the combustion chamber unit to maintain the refractory tube in compression so that it is not subjected to tension forces that would produce fracturing of the refractory material during combustion system start up and cool down sequences, as well as during normal operation.
- Refractory bonding material between the reinforcing sleeve and the refractory tube provides a thermal transition region and the gradient of that region may be adjusted as desired, for example with the addition of thermally conductive particles in the bonding material.
- a thermal adjusting coating also may be applied to the outer surface of the metal sleeve.
- the coolant jacket assembly is an elongated cylindrical structure about 15 centimeters in outer diameter and about 11 centimeters in inner diameter.
- the combustion chamber unit disposed within the coolant jacket assembly includes a tube of cast silicon carbide that defines a combustion chamber about 7 1/2 centimeters in diameter and about 92 centimeters in length.
- a stainless steel reinforcing sleeve has an outer diameter of slightly less than 11.5 centimeters so that there is an annular space of about 0.25 millimeter between the outer surface of the liner unit and the inner surface of the coolant jacket assembly.
- a transition region between the stainless steel sleeve and the silicon carbide tube is filled with an aluminum oxide bonding agent that has a substantially greater thermal gradient than either the silicon carbide tube or the stainless steel sleeve.
- a thin coating of zirconia is provided on the outer surface of the metal reinforcing sleeve.
- the burner system includes ignition zone structure at one end of the combustion chamber unit for flowing an ignited fuel-oxidant mixture into the combustion chamber unit and a liquid injection stage immediately downstream from the combustion chamber unit through which a stream of essentially particulate free high temperature combustion products flows and into which liquid from the coolant jacket assembly is sprayed for vaporization.
- the system provides a burner system that is capable of operation for extended periods of time on an unsupervised basis in remote and inaccessible environments while maintaining stability and with minimal degradation, the refractory tube being maintained in compression without subjecting other system components to excessive stress.
- the downstream elongated liquid injection stage includes a tubular sleeve that supports an array of axially and circumferentially spaced spray nozzles through which water is injected at a controlled rate to generate steam and/or to control the temperature of the discharged mixture of combustion products and vaporized liquid.
- Liquid fuels are efficiently burned in downhole environments with processes and apparatus in accordance with the invention with complete combustion so that the resulting stream of combustion products is essentially particulate free.
- the system is simple and sturdy in construction, is efficient and provides reliable operation over a range of operating conditions.
- a downhole recovery system for burning a mixture of hydrogen and oxygen to produce steam, carbon dioxide and hydrogen.
- the system in accordance with the invention in contrast, provides a system in which a mixture of atomized liquid fuel and air is completely combusted in an elongated hot wall combustion zone; together with a water injection stage immediately downstream from the combustion zone through which essentially particulate free high temperature combustion products flow and into which water is sprayed. The resulting mixture of steam and particulate free combustion products is injected into an (oil) formation.
- the single drawing figure shows water injection ports upstream from the burner orifice so that water is injected directly against the burner housing.
- this burner does not have an elongated hot wall combustion zone for the substantially complete combustion of the air fuel mixture.
- Fig. 17 shows the water sprays directly impinging on the combustion process so that the process would tend to be quenched prior to complete combustion, which the resulting materials discharged through nozzle 49.
- apparatus claim 1 and process claim 15 is directed to thermal enhancement of hydrocarbon material recovery from downhole geologic formations, and in the disclosed embodiment, an essentially particulate free mixture of steam and exhaust gases is generated at high pressure from liquid fuel oil for discharge into the geologic formation to be treated, with markedly reduced risk of plugging and/or degrading the natural porosity of the formation.
- the burner apparatus that is the subject of claim 9 is useful in other applications as well as the downhole thermal enhancement system of claims 1 and 15, and includes a tubular combustion chamber housed within a tubular coolant jacket assembly in an arrangement which controls and limits radial expansion of the refractory combustion chamber liner such that the burner system can be operated at high temperatures (in the order of 1400°C, for example) without subjecting the combustion liner to excessive compression forces at its inner surface which would cause a spalling type of failure.
- the inner surface of the combustion chamber unit is spaced from the inner surface of a coolant jacket assembly such that an air gap is provided in standby condition between the inner surface of the coolant jacket assembly and the outer surface of the combustion chamber unit.
- Thermal expansion of the monolithic tube during burner apparatus operation causes the outer surface of the combustion chamber unit to engage the inner surface of the coolant jacket assembly such that the reinforcing sleeve and the containing action of the coolant jacket assembly maintains the refractory material in compression during burner apparatus operation.
- the system shown in Fig. 1 includes an injection well 10 that extends downwardly from the surface 12 of the ground to an oil reservoir 14 or other similar subsurface geologic formation.
- a producing well 16 extends upwardly from reservoir 14 to processing equipment that includes such apparatus as oil/water separation unit 20, and flotation separation unit 22.
- Steam generator support equipment includes air compressor 24 and fuel tank 26. Supplies including liquid fuel (such as No. 2 fuel oil, No. 6 fuel oil, or preprocessed crude oil), air, and water are fed from the surface equipment through injection well 10 to thermal stimulation system 30 at the base of well 10.
- Thermal stimulation products including steam and C0 2 produced by system 30 are released into reservoir 14, and stimulate flow of hydrocarbon materials from reservoir 14 through producing well 16 to surface treatment equipment 20, 22 for pumping to a refinery over lines 28.
- That stimulation system is supported with a 17 3/4 centimeters diameter steel casing 32 by a tubing string 34 and includes a conventional packer body 36, a conventional slip assembly 38, a high temperature sealing module 40 and a steam generation unit 50.
- the tubing string 34 includes jointed pipe sections 42 (air supply) and 44 (water supply); a small diameter continuous tubing fuel line 46, and a small diameter continuous tubing hydraulic fluid line 48 for the packer.
- Tubing lines 46 and 48 are strung alongside the jointed pipe sections 42, 44 and restrained at regular intervals by tube clamps 52 that both support the continuous tubing lines 46, 48 and center the bundle within the casing 32.
- Slip assembly 38 and seal module 40 are hydraulically set.
- the high temperature seal module 40 includes a pair of dies through which metal sealing rings 54, 56 are hydraulically extruded into the annulus between packer 40 and the well casing 32.
- hydraulic fluid from the surface (at 1050 kp/cm 2 ) first causes the slips to deploy and then extrudes the sealing rings 54, 56.
- Further details of seal module 40 may be had with reference to copending PCT application Serial No. PCT/US81/00216 filed 23 Feb 1981, entitled PACKER which disclosure is incorporated herein by reference.
- the assembly is retrieved in conventional manner by pulling upward on the tubing string 34, thus causing the slips to release and the sealing rings to loosen.
- That generator unit is secured to flanged nipple 60 which is attached to the lower end of packer module 40.
- the upper flange 62 of coupling 64 is secured to nipple 60 by bolts 66 which pass through bolt holes 68.
- bolts 70 pass through bolt holes 72 in the lower flange 74 of adaptor 64 to secure the upper end of the steam generator unit 50 against flange 74.
- That steam generator unit includes axially aligned combustion section 76 and vaporizer section 78.
- Combustor section 76 includes a tubular refractory lined combustion chamber 80 that has a length of about ninety centimeters and an internal diameter of about 7 1/2 centimeters.
- Vaporizer section 78 has an axially aligned tubular chamber 82 that is about 90 centimeters in length and has an inner diameter of about 11 1/2 centimeters.
- a series of circumferentially extending arrays of jet nozzles 84 extends axially along the length of vaporizer chamber 82, the number of nozzles 84 in each circumferential array being greatest at the inlet end of vaporizer chamber 82 and decreasing towards outlet port 86.
- adaptor coupling 64 As indicated in Figs. 4 and 5, a number of passages extend through adaptor coupling 64, including fuel passage 100, electronics passage 102, two air passages 104A and 104B, and four water passages 106.
- Coupling 64 is bolted to nozzle housing 110, as indicated in Figs. 4 and 6, so that fuel passage 100 communicates with inclined groove 112 that extends to central chamber 114 in nozzle housing 110.
- Chamber 114 has an internal threaded bore 116 and an outlet port 120 which is surrounded by conical surface 118 on which atomizing nozzle unit 122 is seated.
- Nozzle unit 122 may be of the hollow cone type with a nominal spray angle of 75 degrees (measured at 40 psi), an orifice diameter of 1.6 millimeter and a core that imparts swirling motion to the liquid fuel.
- Nozzle 122 is threaded into adaptor 124 which has a central through passage 126 and which in turn is threaded into the bore of central chamber 114, so that the conical outer surface of the nozzle 122 is firmly seated at port 120.
- air passages 130A, 130B (which are aligned with corresponding passages 104A, 104B in adaptor 64) extend through nozzle housing 110 on either side of central chamber 114.
- the lower ends of passages 130 terminate at an annular recess 132 (Figs. 4 and 7) at the lower periphery of housing 110.
- Formed in the cylindrical wall of housing 110 above recess 132 are a stepped series of annular surfaces 134, 136, 138; and formed in the lower surface of nozzle housing 110 is a conical surface 140 that extends outwardly from port 120 to an annular ridge 142 in which are formed an array of eight slots 144.
- outer sleeve 150 a stainless steel tube of .95 centimeter wall thickness, 200 centimeters in length, and 15 1/4 centimeters in diameter
- inner combustor housing sleeve 152 a stainless steel tube of 0.6 centimeter wall thickness, 96 centimeters in length, and 12.7 centimeters in diameter
- Four water supply passages 156 (Fig. 6) in nozzle housing 110 extend from passage 106 in adaptor 64 (to the upper end of annular passage 154 at points immediately below surface 136.
- the upper end of sleeve 152 has a counterbore 158 in which flame stabilizer throat member 160 is received.
- the planar upper surface 162 of throat 160 is seated on the planar end surface of ridge 142 and forms the lower boundary of air supply plenum 132.
- Air supplied through passages 104A, 104B and 130A, 130B to annular plenum 132 flows inwardly through swirl channels 144 into an ignition zone 164 bounded on its upper side by conical nozzle holder surface 140 and on its lower side by conical surface 166 of flame stabilizer member 160.
- Convergent surface 166 of throat member 160 extends to five centimeters diameter throat orifice 168 and divergent surface 170 defines an expansion transition to lined combustion chamber 80.
- Flame and temperature sensors monitor ignition zone 164 and transmit signals over conductors that extend through passages 128 and 102.
- a cast aluminum oxide (AI 2 0 3 ) refractory sleeve 172 Received within combustor housing sleeve 152 and seated on the lower surface of throat member 160 is a cast aluminum oxide (AI 2 0 3 ) refractory sleeve 172 of of 0.95 centimeter thickness, and an array of arcuate aluminum oxide (AI 2 0 3 ) refractory segments 174, each 0.95 centimeters in thickness and 120 degrees in angular extent.
- the inner surfaces of arcuate segments 174 define the inner wall of combustion chamber 80 as indicated in Fig. 8.
- Sleeve 172 and the array of arcuate segments 174 are secured within sleeve 152 by a transition ring 176 that is welded to lower end of sleeve 152.
- Transition ring 176 has a cylindrical surface 178 of ten centimeters diameter and a lower surface 180 that diverges at an angle of 35 degrees to the system axis. Extending through ring 176 from annular passage 154 to surface 180 are an array of eight jet spray passages 182, each 0.76 millimeter in diameter.
- vaporizer chamber sleeve 184 (a stainless steel tube of 0.63 centimeter wall thickness, 96 centimeters in length, and 12.7 centimeters in diameter) which defines vaporization zone 82.
- a series of ten circumferential arrays 186 of jet nozzles 84 are secured in bores through the wall of sleeve 184, there being three circumferential arrays (186-1-3) of eight nozzles each (axially spaced about five centimeters apart) (Fig.
- Each jet nozzle 84 is of the hollow cone type and has an 0.76 millimeter diameter orifice.
- Spacer ring 188 is welded to the end surfaces of sleeves 150 and 184 and defines the lower end of annular water supply chamber 154. A cross-sectional view of vaporizer zone 82 is shown in Fig. 10.
- Unit 50' has tubular coupling adaptor 64' welded to end plate 200.
- the upper ends of outer sleeve 150' (a stainless steel tube of about 1 1/4 centimeter wall thickness, about fifteen centimeters in outer diameter, and 200 centimeters in length) and inner transition sleeve 202 (a stainless steel tube of about 0.6 centimeter wall thickness and about 12.5 centimeters in outer diameter) are also welded to end plate 200 so that an annular passage 204 is defined between those sleeves into which water is introduced from conduit 44'.
- flange 206 of ignition zone member 208 is Carried by member 208 is adaptor 124' to which nozzle 122' is threadedly received and to which fuel oil is supplied through conduit 46'. Air flow through coupling adaptor 64' and port 210 in end plate 200 flows into the chamber 212. A portion of that air flows through passage 214 into the nozzle region for exit through orifice 120' in a coaxial sheath that surrounds the spray of atomized fuel droplets from nozzle 122' into the ignition zone 164'. Air also flows from chamber 212 through swirl passages 144' into the periphery of ignition zone 164'.
- Ignition zone member has a convergent surface 166' to a five centimeter diameter throat orifice 168' and a lower divergent surface 170'. Signals from temperature sensor 216 are transmitted over conductor 218 to surface located monitoring equipment. Welded to the lower side of flange 206 is the upper end of sleeve 152' (a stainless steel tube of about 0.63 centimeter wall thickness, 96 centimeters in length, and 12.7 centimeters in outer diameter). A helical channel 154', 7.6 centimeters in width and 0.15 centimeter deep is formed in its outer surface and provides with 0.63 centimeter wide helical ridge 220 a helical coolant flow path.
- sleeve 152' a stainless steel tube of about 0.63 centimeter wall thickness, 96 centimeters in length, and 12.7 centimeters in outer diameter.
- a helical channel 154', 7.6 centimeters in width and 0.15 centimeter deep is formed
- Outer sleeve 150' is press or shrunk fitted over inner sleeve 152', and water flows from conduit 44' through a passage in end plate 200 to the annular passage 204 between sleeves 150' and 202 and through the helical path defined between the sleeves 150' and 152' along the length of the combustion zone 80'.
- transition ring 176' Welded to the lower end of sleeve 152' is transition ring 176', and seated on transition ring 176' is support ring 222. Housed within sleeve 152' and supported on support ring 222 is a refractory wall assembly 224 whose upper end 226 extends into the recess defined by outer surface 228 of ignition zone member 208.
- Assembly 224 includes stainless steel sleeve 230 (a tube of about 0.32 centimeter wall thickness and an outer diameter of about 11 centimeters) with a sprayed zirconia coating 232 on its outer surface; an inner sleeve 234 of cast high purity silicon carbide that has an inner surface 236 of 7.6 centimeters diameter and a 1 1/4 centimeter wall thickness; and an intermediate region 238 (about 0.32 centimeter in thickness) filled with cast aluminum oxide cement.
- stainless steel sleeve 230 a tube of about 0.32 centimeter wall thickness and an outer diameter of about 11 centimeters
- an inner sleeve 234 of cast high purity silicon carbide that has an inner surface 236 of 7.6 centimeters diameter and a 1 1/4 centimeter wall thickness
- an intermediate region 238 (about 0.32 centimeter in thickness) filled with cast aluminum oxide cement.
- sleeves 230 and 234 are concentrically located within a mold, and the refractory cement mixture (2200 parts Alumdun, 340 parts Melment plasticizer and 200 parts water) is poured into the space 238 while the mold is being vibrated so that the cement mixture fills the entire space.
- the assembly is dried at room temperature for 24 hours and then fired: 80°C for six hours; the temperature then increased at the rate of 24°C per hour to 496°C and held for four hours; and then cooled at a rate of 38°C per hour to room temperature.
- the cement securely bonds sleeves 230 and 234 together.
- the outer surface of sleeve 230 has a zirconia coating 232 (0.12 millimeter thickness) to provide an outer diameter of assembly 224 of about 11.38 centimeters.
- Assembly 102 is then inserted into water jacket sleeve, there being an annular gap (see Fig. 14) of about 0.25 millimeter between the outer surface 122 of the liner unit and the inner surface 124 of the coolant jacket structure at ambient temperature.
- transition ring 176' Welded to the lower surface of transition ring 176' is sleeve 184' (a length of about 84 centimeters) that carries an array of spray nozzles 84'. Spacer ring 188' is welded to the lower ends of sleeves 150' and 184' and defines the lower end of annular water chamber 154', as well as outlet port 86'.
- steam generation system 30 is secured to tubing string 34 and lowered into the bore hole casing 32.
- packer slips 38 and seal 40 are hydraulically set, as indicated above, to provide a sealed pressure zone in communication with reservoir 14 in which system 30 is disposed.
- Liquid fuel is then flowed through line 46 (46') to nozzle 122 (122') for atomization and spraying into ignition zone 164 (164') as indicated in Fig. 15.
- Simultaneously air is supplied in stoichiometric ratio through passages 104 and 130 (port 210) to annular plenum 132 (chamber 212) and flows through swirl passages 144 (144') into ignition zone 164 (164') to form a forced vortex flow 250, and through port 214 into nozzle chamber for flow through orifice 120 (120') in a sheath 252 about the jet 254 of atomized fuel droplets from nozzle 122 (122').
- Fuel ignition is by means of hypergolic liquid (for example, triethylborane) flowed through fuel line 46 (46') in advance of the liquid fuel.
- the hypergolic liquid ignites in ignition zone 164 (164') in the presence of the sheath and swirl air flows and ignites the fuel-air mixture.
- the temperature of surface 236 of the monolithic silicon carbide tube 234 increases, producing both axial and radial expansion of liner unit 224 until outer surface 240 of liner unit 224 seats against inner surface 242 of the coolant jacket assembly.
- the expanding silicon carbide is in compression and those compressive forces are stabilized at about one-half the safe compression stress of tube 234 by the containing action of the coolant jacket assembly.
- the combustion process temperature in zone 80' is in the order of 2040°C and the temperature of surface 236 of the silicon carbide liner is in the order of 1425°C.
- a coolant flow rate of thirty liters per minute is employed maintaining the temperature of the inner surface 242 of the water jacket in the order of 205°C or less.
- a thermal gradient diagrammatically indicated in Fig. 14, is established across the liner components, the thermal gradient for coating material 232 being about twice that of bonding material 238, so that major temperature drops are taken across the aluminum oxide bonding material 238 and the thin zirconia layer 232.
- silicon carbide sleeve 234 remains in compression as the system cools down so that it is not subjected to tension forces which would produce fracturing of the refractory material.
- This liner unit provides a physically stable combustion chamber surface 236 that provides an elongated high temperature wall combustion zone 80' in which stoichiometric air-fuel mixtures are completely burned so that the combustion product streams from combustion zone 80' are essentially particulate free and oxygen free and that may be repeatedly cycled through burner operation (start up and cool down) cycles.
- the water flow through coolant jacket passage 154 limits the temperature rise of the refractory liner assembly with the thermal gradient being adjusted by material selection including those of coating 232 and bonding agent 238.
- the coolant water discharged from the combustion chamber coolant jacket flows into the vaporization zone channel and is sprayed in jets 260 through nozzles 84 into stream of combustion products in vaporization zone 82 (Figs. 10 and 15) and flashed to steam with the resulting mixture of steam and combustion products being discharged through outlet port 86 (86') for flow into the oil reservoir 14.
- a range of characteristics of this steam generator system are set out in the following table:
- the system delivers 80 percent quality steam at reservoir pressures of up to 210 kg/cm 2 in quantities of up to 223 000 kg per day.
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Abstract
Description
- This invention relates to processes and apparatus for thermal treatment of subterranean geologic formations for enhancing recovery of geologic resources.
- Thermal treatment of subterranean geologic formations is frequently useful in enhancing the recovery of geologic resources. For example, some petroleum materials, the so-called "heavy crudes", have viscosity and gravity characteristics such that those materials do not flow readily through the porous earth formations, and hence their recovery is exceedingly difficult. Recovery of such petroleum materials may be enhanced by flowing heating materials into the subterranean reservoir for viscosity reduction, mobility enhancement, and like purposes. In other recovery systems, thermal treatment apparatus may be used to promote chemical reactions, to initiate in situ combustion or retorting and the like. While thermal treatment systems have been proposed for downhole use, their operation has not been entirely satisfactory, due in part to the nature of the remote, relatively inaccessible and frequently harsh environment. Simple and sturdy constructions as well as simple and reliable controls are desirable for effective operation. It is also frequently desirable that the system not introduce either particulate material or excess oxygen into the geologic formation being treated.
- In accordance with an aspect of the invention, there is provided thermal treatment apparatus for downhole deployment that includes a combustion stage with structure for intensely hot wall operation that defines a fuel-oxidant mixture combustion and retention zone, and ignition zone structure immediately upstream from the combustion zone in which a mixture of atomized liquid fuel and oxidant is ignited; together with a liquid injection stage immediately downstream from the combustion zone through which the stream of essentially particulate free, high temperature combustion products flows from the combustion zone and into which liquid to be vaporized is sprayed. The length of the chamber structure defining the hot wall combustion zone is preferably at least five times its width dimension and the zone is defined by a refractory wall whose surface is maintained at elevated temperature in excess of 1100°C in an arrangement in which the burning fuel-oxidant mixture is retained within the combustion zone until combustion is completed so that an essentially particulate free stream of combustion products is discharged from the combustion zone into the geologic formation to be treated. The liquid injection stage preferably has an elongated chamber of dimensions similar to and axially aligned with the hot wall combustion zone chamber.
- A thermal enhancement process in accordance with the invention for recovering hydrocarbon materials and the like from subterranean geologic formations includes the steps of positioning combustion chamber structure downhole adjacent the geologic formation to be treated, flowing an oxidant liquid fuel mixture at or below stoichiometric ratio into an ignition zone of the combustion chamber structure and igniting the mixture, flowing the burning mixture into a combustion zone defined by wall structure surface maintained at a temperature in excess of 1100°C retaining the burning oxidant-fuel mixture in the combustion zone sufficiently long to insure substantially complete combustion, and then discharging the resulting essentially particulate free, oxygen free product mixture into the subterranean formation to be treated. The invention provides reduced risk of plugging and/or degrading the natural porosity of the formation into which the mixture is discharged. In a preferred embodiment, the resulting stream of essentially particulate free combustion products is flowed through a vaporization zone while injecting water into the flowing combustion products stream, and a mixture of steam and combustion products including carbon dioxide is injected into an oil bearing formation for producing chemical and thermal stimulation interactions to enhance the speed and effectiveness of reservoir response.
- In a particular embodiment, the thermal treatment apparatus includes an elongated cylindrical body about fifteen centimeters in outer diameter which is disposed downhole in a conventional oil well casing. A high temperature seal module is provided for deployment immediately above or below the thermal treatment apparatus for sealing the casing adjacent the geologic formation to be treated. That high temperature seal module includes annular die structure and metal sealing rings which are hydraulically extruded through the dies into the annulus between packer and the well casing. Other types of high temperature packers can also be used. The combustion and liquid injection stages are housed in axial alignment within a common elongated sleeve that fits within the well casing with an annular cooling jacket chamber that extends the length of both the combustion and liquid injection stages through which the liquid to be vaporized is flowed. The combustion stage includes structure that defines a fuel injection zone with an atomizing nozzle that introduces a well atomized spray of fuel into the ignition zone in a coaxial sheath of air, and a refractory lined combustion chamber whose surface is maintained at an intensely hot temperature. Air flowed into the ignition zone through swirk passage structure establishes a forced vortex flow which maximizes aerodynamic shear and fuel-air mixing rates in a highly stirred zone with moderate temperature rise that provides stable ignition and enhanced fuel evaporation in the toroidal vortex. The downstream boundary of the forced vortex ignition zone is defined by fixed flame stabilizer structure that includes convergent-divergent throat structure with an extensively and highly stirred reverse flow zone immediately downstream from the throat structure that maximizes the combustion rate in the upstream end of the hot wall combustion zone. Downstream from the reverse flow zone and continuing through the hot wall combustion zone is a region of free vortex plug flow in which combustion is completed. The system provides flame stabilization in two separate but interconnected regions, a first region serving as an ignition zone and the second region providing a hot gas recirculation pattern that provides flame stability in a zone of high swirl and intensely back mixed flow which promotes efficient combustion. The hot refractory wall surface maximizes combustion of any remaining unburned materials and the thermal lag of that surface provides a ready ignition source for relight and helps smooth out variations in heat release rate due to process fluctuations.
- A particularly vulnerable component of burner systems is the combustion chamber liner which is subjected to severe thermal stresses both during operation of the system and start up and cool down sequences, and frequently fail. In accordance with another aspect of the invention the tubular combustion chamber unit housed within the tubular coolant jacket assembly includes a monolithic tube of refractory material whose inner surface defines the combustion zone. A metal reinforcing sleeve surrounds and extends the length of the refractory tube. The inner surface of the coolant jacket assembly and outer surface of the combustion chamber unit are dimensioned so that those surfaces are close to one another (less than one millimeter spacing) in standby or cool condition so that the combustion chamber unit has limited freedom to expand with that expansion being stabilized by the coolant jacket assembly so that compression forces in the refractory tube preferably do not exceed about one-half the safe compressive stress of the material; and the materials of the combustion chamber unit are selected to establish thermal gradient parameters across the combustion chamber unit to maintain the refractory tube in compression so that it is not subjected to tension forces that would produce fracturing of the refractory material during combustion system start up and cool down sequences, as well as during normal operation.
- While a variety of materials may be used in the combustion chamber unit, silicon compounds are preferred refractory tube materials, and high temperature metal alloys such as 304 stainless steel, Hasteloy, and Incoloy are preferred for the reinforcing sleeve. Refractory bonding material between the reinforcing sleeve and the refractory tube provides a thermal transition region and the gradient of that region may be adjusted as desired, for example with the addition of thermally conductive particles in the bonding material. A thermal adjusting coating also may be applied to the outer surface of the metal sleeve.
- In a particular embodiment designed for downhole deployment, the coolant jacket assembly is an elongated cylindrical structure about 15 centimeters in outer diameter and about 11 centimeters in inner diameter. The combustion chamber unit disposed within the coolant jacket assembly includes a tube of cast silicon carbide that defines a combustion chamber about 7 1/2 centimeters in diameter and about 92 centimeters in length. A stainless steel reinforcing sleeve has an outer diameter of slightly less than 11.5 centimeters so that there is an annular space of about 0.25 millimeter between the outer surface of the liner unit and the inner surface of the coolant jacket assembly. A transition region between the stainless steel sleeve and the silicon carbide tube is filled with an aluminum oxide bonding agent that has a substantially greater thermal gradient than either the silicon carbide tube or the stainless steel sleeve. In addition a thin coating of zirconia is provided on the outer surface of the metal reinforcing sleeve. The burner system includes ignition zone structure at one end of the combustion chamber unit for flowing an ignited fuel-oxidant mixture into the combustion chamber unit and a liquid injection stage immediately downstream from the combustion chamber unit through which a stream of essentially particulate free high temperature combustion products flows and into which liquid from the coolant jacket assembly is sprayed for vaporization.
- The system provides a burner system that is capable of operation for extended periods of time on an unsupervised basis in remote and inaccessible environments while maintaining stability and with minimal degradation, the refractory tube being maintained in compression without subjecting other system components to excessive stress.
- The downstream elongated liquid injection stage includes a tubular sleeve that supports an array of axially and circumferentially spaced spray nozzles through which water is injected at a controlled rate to generate steam and/or to control the temperature of the discharged mixture of combustion products and vaporized liquid.
- Liquid fuels are efficiently burned in downhole environments with processes and apparatus in accordance with the invention with complete combustion so that the resulting stream of combustion products is essentially particulate free. The system is simple and sturdy in construction, is efficient and provides reliable operation over a range of operating conditions.
- The following prior art has become known:
- US-A-4 078 613:
- A downhole recovery system for burning a mixture of hydrogen and oxygen to produce steam, carbon dioxide and hydrogen.
- The system in accordance with the invention, in contrast, provides a system in which a mixture of atomized liquid fuel and air is completely combusted in an elongated hot wall combustion zone; together with a water injection stage immediately downstream from the combustion zone through which essentially particulate free high temperature combustion products flow and into which water is sprayed. The resulting mixture of steam and particulate free combustion products is injected into an (oil) formation.
- US-A-3 456 721:
- A downhole burner with a perforated refractory lined combustion chamber through which water is injected into
quench zone 10 immediately downstream fromburner 5. The single drawing figure shows water injection ports upstream from the burner orifice so that water is injected directly against the burner housing. - Thus, this burner does not have an elongated hot wall combustion zone for the substantially complete combustion of the air fuel mixture.
- US-A-3 982 591:
- A system similar to that shown in US-A-4 078 613 in which hydrogen and oxygen are fed into primary combustion zone 67 and water is sprayed through apertures 63.
- The embodiment shown in Fig. 17 shows the water sprays directly impinging on the combustion process so that the process would tend to be quenched prior to complete combustion, which the resulting materials discharged through nozzle 49.
- Prior art systems of the type discussed above for thermally enhancing the recovery of hydrocarbon materials from downhole geologic formations typically generated significant quantities of soot (particulates) which tended to clog geologic formations.
- The system in accordance with the invention,
- -in contrast with those prior art systems which resorted to catalysts or gaseous fuels,
- -provides a long, hot combustion chamber defined by a combustion liner of refractory material which defines a high temperature zone (maintained at temperatures in excess of 1100°C) in a high pressure environment; combustion of the fuel is maximized by that long hot walled zone (even though the zone is at high pressure which produces poor fuel atomization) so that the resulting combustion product stream is essentially particulate free;
- -downstream from the long hot combustion zone is a vaporization zone into which the particulate free combustion product stream flows directly (without a nozzle throat or other flow restriction) for vaporizing liquid injected thereinto.
- The subject matter of
apparatus claim 1 andprocess claim 15 is directed to thermal enhancement of hydrocarbon material recovery from downhole geologic formations, and in the disclosed embodiment, an essentially particulate free mixture of steam and exhaust gases is generated at high pressure from liquid fuel oil for discharge into the geologic formation to be treated, with markedly reduced risk of plugging and/or degrading the natural porosity of the formation. - The burner apparatus that is the subject of claim 9 is useful in other applications as well as the downhole thermal enhancement system of
claims - In that burner apparatus, the inner surface of the combustion chamber unit is spaced from the inner surface of a coolant jacket assembly such that an air gap is provided in standby condition between the inner surface of the coolant jacket assembly and the outer surface of the combustion chamber unit.
- Thermal expansion of the monolithic tube during burner apparatus operation causes the outer surface of the combustion chamber unit to engage the inner surface of the coolant jacket assembly such that the reinforcing sleeve and the containing action of the coolant jacket assembly maintains the refractory material in compression during burner apparatus operation.
- There is no suggestion in the prior art of the apparatus as defined in claim 9, namely:
- a balanced combustion burner chamber system which allows moderate but not excessive expansion of the refractory tube while not subjecting that tube to either excessive compression or expansion stresses at burner operating conditions.
- Other features and advantages of the invention will be seen as the following description of particular embodiments progresses, in conjunction with the drawings, in which:
- Fig. 1 is a diagram of a thermal recovery system in accordance with the invention;
- Fig. 2 is an enlarged view of a portion of the injection well of Fig. 1;
- Fig. 3 is a sectional view of the thermal stimulation unit taken along the line 3-3 of Fig. 2;
- Fig. 4 is a sectional view, on an enlarged scale, of portions of the thermal stimulation unit taken along the line 4-4 of Fig. 3;
- Figs. 5-9 are sectional views taken along the lines 5-5, 6―6, 7-7, 8-8, and 9-9 respectively of Fig. 4;
- Fig. 10 is a sectional view taken along the line 10-10 of Fig. 2;
- Fig. 11 is a sectional view of portions of another thermal stimulation unit in accordance with the invention;
- Figs. 12 and 13 are sectional views taken along the lines 12-12 and 13-13 respectively of Fig. 11;
- Fig. 14 is an enlarged sectional view of a portion of the unit shown in Fig. 11; and
- Fig. 15 is a diagram indicating aerodynamic flow conditions in the thermal stimulation units shown in Figs. 4 and 11.
- The system shown in Fig. 1 includes an injection well 10 that extends downwardly from the
surface 12 of the ground to anoil reservoir 14 or other similar subsurface geologic formation. A producing well 16 extends upwardly fromreservoir 14 to processing equipment that includes such apparatus as oil/water separation unit 20, andflotation separation unit 22. Steam generator support equipment includesair compressor 24 andfuel tank 26. Supplies including liquid fuel (such as No. 2 fuel oil, No. 6 fuel oil, or preprocessed crude oil), air, and water are fed from the surface equipment through injection well 10 tothermal stimulation system 30 at the base ofwell 10. Thermal stimulation products including steam and C02 produced bysystem 30 are released intoreservoir 14, and stimulate flow of hydrocarbon materials fromreservoir 14 through producing well 16 to surfacetreatment equipment lines 28. - Further details of the downhole
thermal stimulation system 30 may be seen with reference to Fig. 2. That stimulation system is supported with a 17 3/4 centimetersdiameter steel casing 32 by atubing string 34 and includes aconventional packer body 36, aconventional slip assembly 38, a hightemperature sealing module 40 and asteam generation unit 50. Thetubing string 34 includes jointed pipe sections 42 (air supply) and 44 (water supply); a small diameter continuoustubing fuel line 46, and a small diameter continuous tubinghydraulic fluid line 48 for the packer.Tubing lines pipe sections 42, 44 and restrained at regular intervals by tube clamps 52 that both support thecontinuous tubing lines casing 32.Slip assembly 38 andseal module 40 are hydraulically set. The hightemperature seal module 40 includes a pair of dies through which metal sealing rings 54, 56 are hydraulically extruded into the annulus betweenpacker 40 and thewell casing 32. To setseal module 40, hydraulic fluid from the surface (at 1050 kp/cm2) first causes the slips to deploy and then extrudes the sealing rings 54, 56. Further details ofseal module 40 may be had with reference to copending PCT application Serial No. PCT/US81/00216 filed 23 Feb 1981, entitled PACKER which disclosure is incorporated herein by reference. The assembly is retrieved in conventional manner by pulling upward on thetubing string 34, thus causing the slips to release and the sealing rings to loosen. - Further details of the
steam generator unit 50 may be had with reference to Figs. 3 and 4. That generator unit is secured toflanged nipple 60 which is attached to the lower end ofpacker module 40. Theupper flange 62 ofcoupling 64 is secured to nipple 60 by bolts 66 which pass through bolt holes 68. Insimilar manner bolts 70 pass through bolt holes 72 in thelower flange 74 ofadaptor 64 to secure the upper end of thesteam generator unit 50 againstflange 74. - That steam generator unit includes axially aligned
combustion section 76 andvaporizer section 78.Combustor section 76 includes a tubular refractory linedcombustion chamber 80 that has a length of about ninety centimeters and an internal diameter of about 7 1/2 centimeters.Vaporizer section 78 has an axially alignedtubular chamber 82 that is about 90 centimeters in length and has an inner diameter of about 11 1/2 centimeters. A series of circumferentially extending arrays ofjet nozzles 84 extends axially along the length ofvaporizer chamber 82, the number ofnozzles 84 in each circumferential array being greatest at the inlet end ofvaporizer chamber 82 and decreasing towardsoutlet port 86. - As indicated in Figs. 4 and 5, a number of passages extend through
adaptor coupling 64, includingfuel passage 100,electronics passage 102, two air passages 104A and 104B, and fourwater passages 106.Coupling 64 is bolted tonozzle housing 110, as indicated in Figs. 4 and 6, so thatfuel passage 100 communicates withinclined groove 112 that extends tocentral chamber 114 innozzle housing 110.Chamber 114 has an internal threadedbore 116 and anoutlet port 120 which is surrounded byconical surface 118 on whichatomizing nozzle unit 122 is seated.Nozzle unit 122 may be of the hollow cone type with a nominal spray angle of 75 degrees (measured at 40 psi), an orifice diameter of 1.6 millimeter and a core that imparts swirling motion to the liquid fuel.Nozzle 122 is threaded intoadaptor 124 which has a central throughpassage 126 and which in turn is threaded into the bore ofcentral chamber 114, so that the conical outer surface of thenozzle 122 is firmly seated atport 120. - As shown in Figs. 4 and 6,
air passages nozzle housing 110 on either side ofcentral chamber 114. The lower ends of passages 130 terminate at an annular recess 132 (Figs. 4 and 7) at the lower periphery ofhousing 110. Formed in the cylindrical wall ofhousing 110 aboverecess 132 are a stepped series ofannular surfaces nozzle housing 110 is aconical surface 140 that extends outwardly fromport 120 to anannular ridge 142 in which are formed an array of eightslots 144. - Seated on
surface 138 is the upper end of outer sleeve 150 (a stainless steel tube of .95 centimeter wall thickness, 200 centimeters in length, and 15 1/4 centimeters in diameter); and seated onsurface 134 is an inner combustor housing sleeve 152 (a stainless steel tube of 0.6 centimeter wall thickness, 96 centimeters in length, and 12.7 centimeters in diameter) such that an elongatedannular passage 154 defined betweensleeves nozzle housing 110 extend frompassage 106 in adaptor 64 (to the upper end ofannular passage 154 at points immediately belowsurface 136. - The upper end of
sleeve 152 has acounterbore 158 in which flamestabilizer throat member 160 is received. The planarupper surface 162 ofthroat 160 is seated on the planar end surface ofridge 142 and forms the lower boundary ofair supply plenum 132. Air supplied throughpassages annular plenum 132 flows inwardly throughswirl channels 144 into anignition zone 164 bounded on its upper side by conicalnozzle holder surface 140 and on its lower side byconical surface 166 offlame stabilizer member 160.Convergent surface 166 ofthroat member 160 extends to five centimetersdiameter throat orifice 168 anddivergent surface 170 defines an expansion transition to linedcombustion chamber 80. Flame and temperature sensors monitorignition zone 164 and transmit signals over conductors that extend throughpassages - Received within
combustor housing sleeve 152 and seated on the lower surface ofthroat member 160 is a cast aluminum oxide (AI203)refractory sleeve 172 of of 0.95 centimeter thickness, and an array of arcuate aluminum oxide (AI203)refractory segments 174, each 0.95 centimeters in thickness and 120 degrees in angular extent. The inner surfaces ofarcuate segments 174 define the inner wall ofcombustion chamber 80 as indicated in Fig. 8.Sleeve 172 and the array ofarcuate segments 174 are secured withinsleeve 152 by atransition ring 176 that is welded to lower end ofsleeve 152.Transition ring 176 has acylindrical surface 178 of ten centimeters diameter and alower surface 180 that diverges at an angle of 35 degrees to the system axis. Extending throughring 176 fromannular passage 154 to surface 180 are an array of eightjet spray passages 182, each 0.76 millimeter in diameter. - Welded in similar manner to the lower end of
transition ring 176 is vaporizer chamber sleeve 184 (a stainless steel tube of 0.63 centimeter wall thickness, 96 centimeters in length, and 12.7 centimeters in diameter) which definesvaporization zone 82. A series of ten circumferential arrays 186 ofjet nozzles 84 are secured in bores through the wall ofsleeve 184, there being three circumferential arrays (186-1-3) of eight nozzles each (axially spaced about five centimeters apart) (Fig. 9), three circumferential arrays (186-4-6) of six nozzles each (axially spaced about five centimeters apart), and four circumferential arrays (187-7-10) of four nozzles each, (axially spaced about ten centimeters apart) along the axial length ofvaporization zone 82. Eachjet nozzle 84 is of the hollow cone type and has an 0.76 millimeter diameter orifice.Spacer ring 188 is welded to the end surfaces ofsleeves water supply chamber 154. A cross-sectional view ofvaporizer zone 82 is shown in Fig. 10. - Details of another thermal enhancement unit 50' may be had with reference to Figs. 11-14, in which elements corresponding to those of
generator unit 50 are identified with a primed reference numeral. Unit 50' has tubular coupling adaptor 64' welded toend plate 200. The upper ends of outer sleeve 150' (a stainless steel tube of about 1 1/4 centimeter wall thickness, about fifteen centimeters in outer diameter, and 200 centimeters in length) and inner transition sleeve 202 (a stainless steel tube of about 0.6 centimeter wall thickness and about 12.5 centimeters in outer diameter) are also welded toend plate 200 so that anannular passage 204 is defined between those sleeves into which water is introduced from conduit 44'. - Welded to the lower end of
transition sleeve 202 is flange 206 ofignition zone member 208. Carried bymember 208 is adaptor 124' to which nozzle 122' is threadedly received and to which fuel oil is supplied through conduit 46'. Air flow through coupling adaptor 64' andport 210 inend plate 200 flows into thechamber 212. A portion of that air flows throughpassage 214 into the nozzle region for exit through orifice 120' in a coaxial sheath that surrounds the spray of atomized fuel droplets from nozzle 122' into the ignition zone 164'. Air also flows fromchamber 212 through swirl passages 144' into the periphery of ignition zone 164'. Ignition zone member has a convergent surface 166' to a five centimeter diameter throat orifice 168' and a lower divergent surface 170'. Signals fromtemperature sensor 216 are transmitted overconductor 218 to surface located monitoring equipment. Welded to the lower side offlange 206 is the upper end ofsleeve 152' (a stainless steel tube of about 0.63 centimeter wall thickness, 96 centimeters in length, and 12.7 centimeters in outer diameter). Ahelical channel 154', 7.6 centimeters in width and 0.15 centimeter deep is formed in its outer surface and provides with 0.63 centimeter wide helical ridge 220 a helical coolant flow path. Outer sleeve 150' is press or shrunk fitted overinner sleeve 152', and water flows from conduit 44' through a passage inend plate 200 to theannular passage 204 betweensleeves 150' and 202 and through the helical path defined between thesleeves 150' and 152' along the length of the combustion zone 80'. - Welded to the lower end of
sleeve 152' is transition ring 176', and seated on transition ring 176' issupport ring 222. Housed withinsleeve 152' and supported onsupport ring 222 is arefractory wall assembly 224 whoseupper end 226 extends into the recess defined byouter surface 228 ofignition zone member 208.Assembly 224 includes stainless steel sleeve 230 (a tube of about 0.32 centimeter wall thickness and an outer diameter of about 11 centimeters) with a sprayedzirconia coating 232 on its outer surface; aninner sleeve 234 of cast high purity silicon carbide that has aninner surface 236 of 7.6 centimeters diameter and a 1 1/4 centimeter wall thickness; and an intermediate region 238 (about 0.32 centimeter in thickness) filled with cast aluminum oxide cement. - In the manufacture of
liner assembly 224,sleeves space 238 while the mold is being vibrated so that the cement mixture fills the entire space. The assembly is dried at room temperature for 24 hours and then fired: 80°C for six hours; the temperature then increased at the rate of 24°C per hour to 496°C and held for four hours; and then cooled at a rate of 38°C per hour to room temperature. The cement securely bondssleeves sleeve 230 has a zirconia coating 232 (0.12 millimeter thickness) to provide an outer diameter ofassembly 224 of about 11.38 centimeters. -
Assembly 102 is then inserted into water jacket sleeve, there being an annular gap (see Fig. 14) of about 0.25 millimeter between theouter surface 122 of the liner unit and theinner surface 124 of the coolant jacket structure at ambient temperature. - Welded to the lower surface of transition ring 176' is sleeve 184' (a length of about 84 centimeters) that carries an array of spray nozzles 84'. Spacer ring 188' is welded to the lower ends of sleeves 150' and 184' and defines the lower end of
annular water chamber 154', as well as outlet port 86'. - In use,
steam generation system 30 is secured totubing string 34 and lowered into thebore hole casing 32. After thesteam generation system 30 is positioned in the bore hole adjacent the subterranean formation to be treated, as indicated in Figs. 1 and 2, packer slips 38 andseal 40 are hydraulically set, as indicated above, to provide a sealed pressure zone in communication withreservoir 14 in whichsystem 30 is disposed. Liquid fuel is then flowed through line 46 (46') to nozzle 122 (122') for atomization and spraying into ignition zone 164 (164') as indicated in Fig. 15. Simultaneously air is supplied in stoichiometric ratio throughpassages 104 and 130 (port 210) to annular plenum 132 (chamber 212) and flows through swirl passages 144 (144') into ignition zone 164 (164') to form a forcedvortex flow 250, and throughport 214 into nozzle chamber for flow through orifice 120 (120') in asheath 252 about thejet 254 of atomized fuel droplets from nozzle 122 (122'). Fuel ignition is by means of hypergolic liquid (for example, triethylborane) flowed through fuel line 46 (46') in advance of the liquid fuel. The hypergolic liquid ignites in ignition zone 164 (164') in the presence of the sheath and swirl air flows and ignites the fuel-air mixture. - As the ignited fuel-air mixture burns, it flows through throat 168 (168') into highly stirred reverse flow zone 256 (at the upper end of refractory liner sleeve 172 (232)) which maximizes the combustion rate at the upper end of
combustion zone 80 and then flows downstream fromreverse flow zone 256 throughzone 258 of free vortex plug flow in which combustion is completed. - As combustion commences, the temperature of
surface 236 of the monolithicsilicon carbide tube 234 increases, producing both axial and radial expansion ofliner unit 224 untilouter surface 240 ofliner unit 224 seats againstinner surface 242 of the coolant jacket assembly. The expanding silicon carbide is in compression and those compressive forces are stabilized at about one-half the safe compression stress oftube 234 by the containing action of the coolant jacket assembly. With stoichiometric ratio of air and No. 2 fuel oil, the combustion process temperature in zone 80' is in the order of 2040°C and the temperature ofsurface 236 of the silicon carbide liner is in the order of 1425°C. At a five million BTU per hour firing rate a coolant flow rate of thirty liters per minute is employed maintaining the temperature of theinner surface 242 of the water jacket in the order of 205°C or less. With theliner unit 224 stabilized by the coolant jacket, a thermal gradient, diagrammatically indicated in Fig. 14, is established across the liner components, the thermal gradient forcoating material 232 being about twice that ofbonding material 238, so that major temperature drops are taken across the aluminumoxide bonding material 238 and thethin zirconia layer 232. When combustion is terminated,silicon carbide sleeve 234 remains in compression as the system cools down so that it is not subjected to tension forces which would produce fracturing of the refractory material. This liner unit provides a physically stablecombustion chamber surface 236 that provides an elongated high temperature wall combustion zone 80' in which stoichiometric air-fuel mixtures are completely burned so that the combustion product streams from combustion zone 80' are essentially particulate free and oxygen free and that may be repeatedly cycled through burner operation (start up and cool down) cycles. - The water flow through
coolant jacket passage 154 limits the temperature rise of the refractory liner assembly with the thermal gradient being adjusted by material selection including those ofcoating 232 andbonding agent 238. The coolant water discharged from the combustion chamber coolant jacket flows into the vaporization zone channel and is sprayed injets 260 throughnozzles 84 into stream of combustion products in vaporization zone 82 (Figs. 10 and 15) and flashed to steam with the resulting mixture of steam and combustion products being discharged through outlet port 86 (86') for flow into theoil reservoir 14. -
- In one test run of the system shown in Figs. 11-13 of 80 hours duration at firing rates from 1-5 million BTU* per hour, using a Delavan Type A hollow cone pressure atomizing 80 degree 54 I gallon per hour nozzle, No. 2 fuel oil and air stoichiometric ratio were flowed through the system with steam generation at pressures of 7-35 kp/cm2. In another test run at atmospheric pressure with emulsified No. 6 fuel oil using a Delavan Type SNA air atomizing nozzle and stoichiometric air-fuel ratios the system operated at firing rates of 128,000-180,000 BTU* per hour. In each run the output stream from the system contained less than 1/2 percent oxygen and was essentially particulate free (on the average, the output streams contained less than five parts per million particles greater than two microns in size).
- Improved downhole thermal treatment processes and apparatus of the invention are capable of prolonged operation over a wide range of firing rates and reservoir pressures; the apparatus is of compact construction and suitable for use in connection with conventional oil field equipment; and the invention offers significant time and cost savings over surface generated steam for heavy oil recovery from deep reservoirs as well as other processes for recovery of resources from subterranean geologic formations.
*=0,454 kg
Claims (21)
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Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US19482080A | 1980-10-07 | 1980-10-07 | |
US194820 | 1980-10-07 | ||
US296321 | 1981-08-28 | ||
US06/296,321 US4456068A (en) | 1980-10-07 | 1981-08-28 | Process and apparatus for thermal enhancement |
US296322 | 1981-08-28 | ||
US06/296,322 US4459101A (en) | 1981-08-28 | 1981-08-28 | Burner systems |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP86105864A Division EP0200195A3 (en) | 1980-10-07 | 1981-10-05 | Thermal enhancement |
EP86105864.2 Division-Into | 1986-04-30 |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0061494A1 EP0061494A1 (en) | 1982-10-06 |
EP0061494A4 EP0061494A4 (en) | 1984-09-28 |
EP0061494B1 true EP0061494B1 (en) | 1988-01-20 |
Family
ID=27393371
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP81902877A Expired EP0061494B1 (en) | 1980-10-07 | 1981-10-05 | Thermal enhancement |
EP86105864A Withdrawn EP0200195A3 (en) | 1980-10-07 | 1981-10-05 | Thermal enhancement |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP86105864A Withdrawn EP0200195A3 (en) | 1980-10-07 | 1981-10-05 | Thermal enhancement |
Country Status (6)
Country | Link |
---|---|
EP (2) | EP0061494B1 (en) |
JP (1) | JPS57501537A (en) |
DE (1) | DE3176623D1 (en) |
FR (1) | FR2491542A1 (en) |
NO (1) | NO821883L (en) |
WO (1) | WO1982001214A1 (en) |
Families Citing this family (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
AU3710697A (en) * | 1997-07-01 | 1999-01-25 | Alexandr Petrovich Linetsky | Method for exploiting gas and oil fields and for increasing gas and crude oil output |
GB2475812B (en) * | 2005-08-17 | 2011-08-24 | Halliburton Energy Serv Inc | Communicated fluids with a heated-fluid generation system |
CA2690105C (en) * | 2009-01-16 | 2014-08-19 | Resource Innovations Inc. | Apparatus and method for downhole steam generation and enhanced oil recovery |
DE102013000303A1 (en) | 2013-01-10 | 2014-07-10 | Linde Aktiengesellschaft | Method for producing water vapor-gas mixture for use in oil recovery enhancing method, involves executing oxy-fuel combustion partly inside water body and producing water vapor with combustion exhaust gas of oxyfuel combustion |
US10273790B2 (en) | 2014-01-14 | 2019-04-30 | Precision Combustion, Inc. | System and method of producing oil |
CN104785392B (en) * | 2015-03-26 | 2018-03-06 | 成都来宝石油设备有限公司 | Gas reservoir exploitation drive nozzle |
CA2972203C (en) | 2017-06-29 | 2018-07-17 | Exxonmobil Upstream Research Company | Chasing solvent for enhanced recovery processes |
CA2974712C (en) | 2017-07-27 | 2018-09-25 | Imperial Oil Resources Limited | Enhanced methods for recovering viscous hydrocarbons from a subterranean formation as a follow-up to thermal recovery processes |
CA2978157C (en) | 2017-08-31 | 2018-10-16 | Exxonmobil Upstream Research Company | Thermal recovery methods for recovering viscous hydrocarbons from a subterranean formation |
CA2983541C (en) | 2017-10-24 | 2019-01-22 | Exxonmobil Upstream Research Company | Systems and methods for dynamic liquid level monitoring and control |
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US2734578A (en) * | 1956-02-14 | Walter | ||
US1803282A (en) * | 1928-10-15 | 1931-04-28 | Doherty Res Co | High-temperature electric heating furnace |
US2210854A (en) * | 1938-04-08 | 1940-08-06 | Philadelphia & Reading Coal & | Heating apparatus |
FR963507A (en) * | 1947-03-21 | 1950-07-17 | ||
US2916535A (en) * | 1948-05-01 | 1959-12-08 | Westinghouse Electric Corp | Ultra-high-temperature furnace |
US2584606A (en) * | 1948-07-02 | 1952-02-05 | Edmund S Merriam | Thermal drive method for recovery of oil |
US2712351A (en) * | 1949-02-23 | 1955-07-05 | Union Carbide & Carbon Corp | Method of operating an internal combustion blowtorch |
US2706382A (en) * | 1949-07-09 | 1955-04-19 | Carborundum Co | Devices for confinement and release of high velocity, hot gases |
US2658332A (en) * | 1951-03-21 | 1953-11-10 | Carborundum Co | Fluid cooled, refractory, ceramic lined rocket structure |
US2770097A (en) * | 1952-02-14 | 1956-11-13 | William C Walker | Cooling systems for engines that utilize heat |
FR1097553A (en) * | 1953-04-22 | 1955-07-07 | Gewerk Keramchemie | Refractory lining, heat insulating and corrosion resistant, for boilers, vessels and other devices |
US2897649A (en) * | 1956-07-03 | 1959-08-04 | Reddy Robert | Igniter |
US3254721A (en) * | 1963-12-20 | 1966-06-07 | Gulf Research Development Co | Down-hole fluid fuel burner |
US3321922A (en) * | 1964-10-29 | 1967-05-30 | Jr William T Latto | Small rocket engine |
US3338286A (en) * | 1966-09-12 | 1967-08-29 | Pan American Petroleum Corp | Heat shield for bottom hole igniter |
US3410347A (en) * | 1967-01-26 | 1968-11-12 | George R Garrison | Heater apparatus for use in wells |
US3456721A (en) * | 1967-12-19 | 1969-07-22 | Phillips Petroleum Co | Downhole-burner apparatus |
GB1240009A (en) * | 1968-07-27 | 1971-07-21 | Leyland Gas Turbines Ltd | Flame tube |
GB1254452A (en) * | 1968-09-16 | 1971-11-24 | British Petroleum Co | Geological formation heating |
US3595316A (en) * | 1969-05-19 | 1971-07-27 | Walter A Myrick | Aggregate process for petroleum production |
US3669079A (en) * | 1970-08-06 | 1972-06-13 | Robert B Black | Water heater |
US3724447A (en) * | 1971-10-27 | 1973-04-03 | Aluminum Co Of America | Immersion heater |
US3918255A (en) * | 1973-07-06 | 1975-11-11 | Westinghouse Electric Corp | Ceramic-lined combustion chamber and means for support of a liner with combustion air penetrations |
US3916047A (en) * | 1973-08-21 | 1975-10-28 | Raymond J Niesen | Coated steel form for use in a coreless induction furnace |
US3982591A (en) * | 1974-12-20 | 1976-09-28 | World Energy Systems | Downhole recovery system |
US4007001A (en) * | 1975-04-14 | 1977-02-08 | Phillips Petroleum Company | Combustors and methods of operating same |
US4078613A (en) * | 1975-08-07 | 1978-03-14 | World Energy Systems | Downhole recovery system |
US4079784A (en) * | 1976-03-22 | 1978-03-21 | Texaco Inc. | Method for in situ combustion for enhanced thermal recovery of hydrocarbons from a well and ignition system therefor |
MX145676A (en) * | 1976-09-27 | 1982-03-19 | World Energy System | IMPROVEMENTS IN A SYSTEM THAT INCLUDES A GAS GENERATOR FROM PROBING WELLS FOR THE RECOVERY OF OIL |
DE2808690C2 (en) * | 1978-03-01 | 1983-11-17 | Messerschmitt-Bölkow-Blohm GmbH, 8000 München | Device for generating superheated steam for the extraction of petroleum |
GB2020403A (en) * | 1978-04-19 | 1979-11-14 | Heenan Environmental Systems | Combustion furnace and method of operating same |
-
1981
- 1981-10-05 EP EP81902877A patent/EP0061494B1/en not_active Expired
- 1981-10-05 JP JP56503463A patent/JPS57501537A/ja active Pending
- 1981-10-05 DE DE8181902877T patent/DE3176623D1/en not_active Expired
- 1981-10-05 EP EP86105864A patent/EP0200195A3/en not_active Withdrawn
- 1981-10-05 WO PCT/US1981/001331 patent/WO1982001214A1/en active IP Right Grant
- 1981-10-07 FR FR8118892A patent/FR2491542A1/en not_active Withdrawn
-
1982
- 1982-06-04 NO NO821883A patent/NO821883L/en unknown
Also Published As
Publication number | Publication date |
---|---|
EP0061494A4 (en) | 1984-09-28 |
NO821883L (en) | 1982-06-04 |
JPS57501537A (en) | 1982-08-26 |
WO1982001214A1 (en) | 1982-04-15 |
DE3176623D1 (en) | 1988-02-25 |
FR2491542A1 (en) | 1982-04-09 |
EP0200195A3 (en) | 1987-02-04 |
EP0061494A1 (en) | 1982-10-06 |
EP0200195A2 (en) | 1986-11-05 |
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