CA2606218C

CA2606218C - In situ conversion process systems utilizing wellbores in at least two regions of a formation

Info

Publication number: CA2606218C
Application number: CA2606218A
Authority: CA
Inventors: Harold J. Vinegar; Chia-Fu Hsu
Original assignee: Shell Internationale Research Maatschappij BV
Current assignee: Shell Internationale Research Maatschappij BV
Priority date: 2005-04-22
Filing date: 2006-04-21
Publication date: 2014-04-15
Anticipated expiration: 2026-04-21
Also published as: EP1871986A1; AU2006239958A1; MA29468B1; EP1871985B1; AU2006239962A1; CN101163858B; CN101163854A; AU2006239962B2; EA012901B1; EA200702303A1; ATE435964T1; CA2606295A1; ZA200708090B; AU2006239997B2; NZ562240A; EA200702304A1; CA2605729C; AU2006239886B2; WO2006116095A1; AU2006239996A1

Abstract

A system for heating a subsurface formation is described. The system includes a plurality of elongated heaters (244) located in a plurality of openings in the formation. At least two of the heaters are substantially parallel to each other for at least a portion of the lengths of the heaters. At least two of the heaters have first end portions (234) in a first region of the formation and second end portions (238) in a second region of the formation. A source of time-varying current (254) is configured to apply time-varying current to at least two of the heaters. The first end portions of the heaters are configured to be applied with substantially the same voltage. The second portions of the heaters are configured to be applied with substantially the same voltage.

Description

IN SITU CONVERSION PROCESS SYSTEMS UTILIZING WELLBORES IN AT LEAST
TWO REGIONS OF A FORMATION
BACKGROUND
1. Field of the Invention The present invention relates generally to methods and systems for production of hydrocarbons, hydrogen, and/or other products from various subsurface formations such as hydrocarbon containing formations. In particular, certain embodiments relate to heating a selected portion or portions of the formation using temperature limited heaters placed in parallel wellbores in the formation.

2. Description of Related Art Hydrocarbons obtained from subterranean formations are often used as energy resources, as feedstocks, and as 'consumer products. Concerns over depletion of available hydrocarbon resources and concerns over declining overall quality of produced hydrocarbons have led to development of protesses for more efficient recovery, processing and/or use of available hydrocarbon resources. In situ processes may be used to remove hydrocarbon materials from subterranean formations. Chemical and/or physical properties of hydrocarbon material in a subterranean formation may need to be changed to allow hydrocarbon material to be more easily removed from the subterranean formation. The chemical and physical changes may include in situ reactions that produce removable fluids, composition changes, solubility changes, density changes, phase changes, and/or viscosity changes of the hydrocarbon material in the formation. A fluid may be, but is not limited to, a gas, a liquid, an emulsion, a slurry, and/or a stream of solid particles that has flow characteristics similar to liquid flow.
Heaters may be placed in wellbores to heat a formation during an in situ process. Examples of in situ processes utilizing downhole heaters are illustrated in U.S. Patent Nos.
2,634,961 to Ljungstrom; 2,732,195 to Ljungstrom; 2,780,450 to Ljungstrom; 2,789,805 to Ljungstrom; 2,923,535 to Ljungstrom; and 4,886,118 to Van Meurs et al.
Application of heat to oil shale formations is described in U.S. Patent Nos.
2,923,535 to Ljungstrom and 4,886,118 to Van Meurs et al. Heat may be applied to the oil shale formation to pyrolyze kerogen in the oil shale formation. The heat may also fracture the formation to increase permeability of the formation. The increased permeability may allow formation fluid to travel to a production well where the fluid is removed from the oil shale formation. In some processes disclosed by Ljungstrom, for example, an oxygen containing gaseous medium is introduced to a permeable stratum, preferably while still hot from a preheating step, to initiate combustion.
A heat source may be used to heat a subterranean formation. Electric heaters may be used to heat the subterranean formation by radiation and/or conduction. An electric heater may resistively heat an element. U.S.
Patent No. 2,548,360 to Germain describes an electric heating element placed in a viscous oil in a wellbore. The heater element heats and thins the oil to allow the oil to be pumped from the wellbore. U.S. Patent No. 4,716,960 to Eastlund et al. describes electrically heating tubing of a petroleum well by passing a relatively low voltage current through the tubing to prevent formation of solids. U.S. Patent No. 5,065,818 to Van Egmond describes an electric heating element that is cemented into a well borehole without a casing surrounding the heating element.
U.S. Patent No. 6,023,554 to Vinegar et al. describes an electric heating element that is positioned in a casing. The heating element generates radiant energy that heats the casing. A
granular solid fill material may be placed between the casing and the formation. The casing may conductively heat the fill material, which in turn conductively heats the formation.

Some formations may have thin hydrocarbon layers or thin rich layers in a thick hydrocarbon layer. It may be advantageous to use substantially parallel wellbores for heating and/or treating these types of formations. Using substantially parallel wellbores may also reduce the number of openings on the surface of the formation. Reducing the number of openings may be desirable to reduce capital costs and/or reduce the impact of drilling openings in the formation (for example, the environmental impact and/or surface topography modifications).
SUMMARY
Embodiments described herein generally relate to systems, methods, and heaters for treating a subsurface formation. Embodiments described herein also generally relate to heaters that have novel components therein. Such heaters can be obtained by using the systems and methods described herein.
In some embodiments, the invention provides a system for heating a subsurface formation, comprising: a plurality of elongated heaters located in a plurality of openings in the formation, at least two of the heaters being substantially parallel to each other for at least a portion of the lengths of the heaters; at least two of the heaters having first end portions in a first region of the formation, more especially in a first location on the surface of the formation, and second end portions in a second region of the formation, more especially in a second location on the surface of the formation; and a source of time-varying current configured to apply time-varying current to at least two of the heaters, wherein the first end portions of at least two heaters are configured to have substantially the same voltage applied to the first end portions, and the second portions of at least two heaters are configured to have substantially the same voltage applied to the second end portions, and wherein the system is configured to inhibit current leakage between heaters in the formation.
In an aspect of the invention there is provided a method for heating a subsurface formation using the system of the invention of the aforementioned embodiment, the method comprising: applying the substantially same voltage to the first end portions of the heaters; and applying the substantially same voltage to the second end portions of the heaters.
In some embodiments, the invention provides a system for heating a subsurface formation, comprising: a plurality of first elongated heaters located in a plurality of first openings in the formation, at least two of the first heaters being substantially parallel to each other for at least a portion of the lengths of the heaters; a plurality of second elongated heaters located in a plurality of second openings in the formation, at least two of the second heaters being substantially parallel to each other for at least a portion of the lengths of the heaters; at least two of the first heaters and at least two of the second heaters having first end portions in a first region of the formation and second end portions in a second region of the formation; and a source of time-varying current configured to apply time-varying current to at least two of the heaters; wherein the first end portions of the first heaters are configured to be applied with a first voltage that is opposite in polarity to a second voltage configured to be applied to the first end portions of the second heaters; and the second voltage is configured to be applied to the second end portions of the first heaters; and wherein the system is configured to inhibit current leakage between heaters in the formation.

In another aspect of the invention there is provided a method for heating a subsurface formation using the system of the latter embodiment of the invention, the method comprising:
applying the first voltage to the first end portions of the first heaters; applying the second voltage to the second end portions of the first heaters;
applying the second voltage to the first end portions of the second heaters;
and applying the first voltage to the second end portions of the second heaters until at least one of the heaters, or at least a portion of the formation, reaches a selected temperature.
In still another embodiment of the invention there is provided a system for heating a hydrocarbon containing formation, comprising: a plurality of openings in the formation, the openings having first end portions and second end portions; one or more heaters in the openings, the one or more heaters having first end portions and second end portions; and wherein the first end portions of the heaters are configured to be applied with a first voltage potential that is opposite in polarity to a second voltage potential, and wherein the system is configured to inhibit current leakage between heaters in the formation.
In further embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any of the other embodiments.
In further embodiments, treating a subsurface formation is performed using any of the methods, systems, or heaters described herein.
In further embodiments, additional features may be added to the specific embodiments described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description and upon reference to the accompanying drawings in which:
FIG. 1 depicts an illustration of stages of heating a hydrocarbon containing formation.
FIG. 2 shows a schematic view of an embodiment of a portion of an in situ conversion system for treating a hydrocarbon containing formation.
FIGS. 3, 4, and 5 depict cross-sectional representations of an embodiment of a temperature limited heater with an outer conductor having a ferromagnetic section and a non-ferromagnetic section.
2a FIGS. 6A and 6B depict cross-sectional representations of an embodiment of a temperature limited heater.
FIG. 7 depicts an embodiment of a temperature limited heater in which the support member provides a majority of the heat output below the Curie temperature of the ferromagnetic conductor.
FIGS. 8 and 9 depict embodiments of temperature limited heaters in which the jacket provides a majority of the heat output below the Curie temperature of the ferromagnetic conductor.
FIG. 10 depicts a side view representation of an embodiment of substantially u-shaped heaters.
FIG. 11 depicts a representational top view of an embodiment of a surface pattern of heaters depicted in FIG. 10.
FIG. 12 depicts a cross-section representation of substantially u-shaped heaters in a hydrocarbon layer.
FIG. 13 depicts a side view representation of an embodiment of substantially vertical heaters coupled to a substantially horizontal wellbore.
FIG. 14 depicts an embodiment of a substantially u-shaped heater that electrically isolates itself from the formation.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and may herein be described in detail. The drawings may not be to scale. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION
The following description generally relates to systems and methods for treating hydrocarbons in the formations. Such formations may be treated to yield hydrocarbon products, hydrogen, and other products.
"Hydrocarbons" are generally defined as molecules formed primarily by carbon and hydrogen atoms.
Hydrocarbons may also include other elements such as, but not limited to, halogens, metallic elements, nitrogen, oxygen, and/or sulfur. Hydrocarbons may be, but are not limited to, kerogen, bitumen, pyrobitumen, oils, natural mineral waxes, and asphaltites. Hydrocarbons may be located in or adjacent to mineral matrices in the earth.
Matrices may include, but are not limited to, sedimentary rock, sands, silicilytes, carbonates, diatomites, and other porous media. "Hydrocarbon fluids" are fluids that include hydrocarbons.
Hydrocarbon fluids may include, entrain, or be entrained in non-hydrocarbon fluids such as hydrogen, nitrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, water, and ammonia.
A "formation" includes one or more hydrocarbon containing layers, one or more non-hydrocarbon layers, an overburden, and/or an underburden. The "overburden" and/or the "underburden" include one or more different types of impermeable materials. For example, overburden and/or underburden may include rock, shale, mudstone, or wet/tight carbonate. In some embodiments of in situ conversion processes, the overburden and/or the underburden may include a hydrocarbon containing layer or hydrocarbon containing layers that are relatively impermeable and are not subjected to temperatures during in situ conversion processing that result in significant characteristic changes of the hydrocarbon containing layers of the overburden and/or the underburden. For example, the underburden may contain shale or mudstone, but the underburden is not allowed to heat to pyrolysis temperatures during the in situ conversion process. In some cases, the overburden and/or the underburden may be somewhat permeable.

"Formation fluids" and refer to fluids present in a formation and may include pyrolyzation fluid, synthesis gas, mobilized hydrocarbon, and water (steam). Formation fluids may include hydrocarbon fluids as well as non-hydrocarbon fluids. The term "mobilized fluid" refers to fluids in a hydrocarbon containing formation that are able to flow as a result of thermal treatment of the formation. "Produced fluids"
refer to formation fluids removed from the formation.
A "heat source" is any system for providing heat to at least a portion of a formation substantially by conductive and/or radiative heat transfer. For example, a heat source may include electric heaters such as an insulated conductor, an elongated member, and/or a conductor disposed in a conduit. A heat source may also include systems that generate heat by burning a fuel external to or in a formation. The systems may be surface burners, downhole gas burners, flameless distributed combustors, and natural distributed combustors. In some embodiments, heat provided to or generated in one or more heat sources may be supplied by other sources of energy.
The other sources of energy may directly heat a formation, or the energy may be applied to a transfer medium that directly or indirectly heats the formation. It is to be understood that one or more heat sources that are applying heat to a formation may use different sources of energy. Thus, for example, for a given formation some heat sources may supply heat from electric resistance heaters, some heat sources may provide heat from combustion, and some heat sources may provide heat from one or more other energy sources (for example, chemical reactions, solar energy, wind energy, biomass, or other sources of renewable energy). A chemical reaction may include an exothermic reaction (for example, an oxidation reaction). A heat source may also include a heater that provides heat to a zone proximate and/or surrounding a heating location such as a heater well.
A "heater" is any system or heat source for generating heat in a well or a near wellbore region. Heaters may be, but are not limited to, electric heaters, burners, combustors that react with material in or produced from a formation, and/or combinations thereof.
An "in situ conversion process" refers to a process of heating a hydrocarbon containing formation from heat sources to raise the temperature of at least a portion of the formation above a pyrolysis temperature so that pyrolyzation fluid is produced in the formation.
"Insulated conductor" refers to any elongated material that is able to conduct electricity and that is covered, in whole or in part, by an electrically insulating material.
An elongated member may be a bare metal heater or an exposed metal heater.
"Bare metal" and "exposed metal" refer to metals that do not include a layer of electrical insulation, such as mineral insulation, that is designed to provide electrical insulation for the metal throughout an operating temperature range of the elongated member.
Bare metal and exposed metal may encompass a metal that includes a corrosion inhibiter such as a naturally occurring oxidation layer, an applied oxidation layer, and/or a film. Bare metal and exposed metal include metals with polymeric or other types of electrical insulation that cannot retain electrical insulating properties at typical operating temperature of the elongated member. Such material may be placed on the metal and may be thermally degraded during use of the heater.
"Temperature limited heater" generally refers to a heater that regulates heat output (for example, reduces heat output) above a specified temperature without the use of external controls such as temperature controllers, power regulators, rectifiers, or other devices. Temperature limited heaters may be AC (alternating current) or modulated (for example, "chopped") DC (direct current) powered electrical resistance heaters.
"Curie temperature" is the temperature above which a ferromagnetic material loses all of its ferromagnetic properties. In addition to losing all of its ferromagnetic properties above the Curie temperature, the ferromagnetic material begins to lose its ferromagnetic properties when an increasing electrical current is passed through the ferromagnetic material.
"Time-varying current" refers to electrical current that produces skin effect electricity flow in a ferromagnetic conductor and has a magnitude that varies with time. Time-varying current includes both alternating current (AC) and modulated direct current (DC).
"Alternating current (AC)" refers to a time-varying current that reverses direction substantially sinusoidally.
AC produces skin effect electricity flow in a ferromagnetic conductor.
"Modulated direct current (DC)" refers to any substantially non-sinusoidal time-varying current that produces skin effect electricity flow in a ferromagnetic conductor.
"Turndown ratio" for the temperature limited heater is the ratio of the highest AC or modulated DC
resistance below the Curie temperature to the lowest resistance above the Curie temperature for a given current.
In the context of reduced heat output heating systems, apparatus, and methods, the term "automatically"
means such systems, apparatus, and methods function in a certain way without the use of external control (for example, external controllers such as a controller with a temperature sensor and a feedback loop, PID controller, or predictive controller).
"Nitride" refers to a compound of nitrogen and one or more other elements of the Periodic Table. Nitrides include, but are not limited to, silicon nitride, boron nitride, or alumina nitride.
The term "wellbore" refers to a hole in a formation made by drilling or insertion of a conduit into the formation. A wellbore may have a substantially circular cross section, or another cross-sectional shape. As used herein, the terms "well" and "opening," when referring to an opening in the formation may be used interchangeably with the term "wellbore."
A "u-shaped wellbore" refers to a wellbore that extends from a first opening in the formation, through at least a portion of the formation, and out through a second opening in the formation. In this context, the wellbore may be only roughly in the shape of a "v" or "u", with the understanding that the "legs" of the "u" do not need to be parallel to each other, or perpendicular to the "bottom" of the "u" for the wellbore to be considered "u-shaped".
"Orifices" refer to openings, such as openings in conduits, having a wide variety of sizes and cross-sectional shapes including, but not limited to, circles, ovals, squares, rectangles, triangles, slits, or other regular or irregular shapes.
"Pyrolysis" is the breaking of chemical bonds due to the application of heat.
For example, pyrolysis may include transforming a compound into one or more other substances by heat alone. Heat may be transferred to a section of the formation to cause pyrolysis. In some formations, portions of the formation and/or other materials in the formation may promote pyrolysis through catalytic activity.
"Pyrolyzation fluids" or "pyrolysis products" refers to fluid produced substantially during pyrolysis of hydrocarbons. Fluid produced by pyrolysis reactions may mix with other fluids in a formation. The mixture would be considered pyrolyzation fluid or pyrolyzation product. As used herein, "pyrolysis zone" refers to a volume of a formation (for example, a relatively permeable formation such as a tar sands formation) that is reacted or reacting to form a pyrolyzation fluid.
"Superposition of heat" refers to providing heat from two or more heat sources to a selected section of a formation such that the temperature of the formation at least at one location between the heat sources is influenced by the heat sources.

"Synthesis gas" is a mixture including hydrogen and carbon monoxide.
Additional components of synthesis gas may include water, carbon dioxide, nitrogen, methane, and other gases. Synthesis gas may be generated by a variety of processes and feedstocks. Synthesis gas may be used for synthesizing a wide range of compounds.
Hydrocarbons in formations may be treated in various ways to produce many different products. In certain embodiments, hydrocarbons in formations are treated in stages. FIG. 1 depicts an illustration of stages of heating the hydrocarbon containing formation. FIG. 1 also depicts an example of yield ("Y") in barrels of oil equivalent per ton (y axis) of formation fluids from the formation versus temperature ("T") of the heated formation in degrees Celsius (x axis).
Desorption of methane and vaporization of water occurs during stage 1 heating.
Heating of the formation through stage 1 may be performed as quickly as possible. When the hydrocarbon containing formation is initially heated, hydrocarbons in the formation desorb adsorbed methane. The desorbed methane may be produced from the formation. If the hydrocarbon containing formation is heated further, water in the hydrocarbon containing formation is vaporized. Water may occupy, in some hydrocarbon containing formations, between 10% and 50% of the pore volume in the formation. In other formations, water occupies larger or smaller portions of the pore volume. Water typically is vaporized in a formation between 160 C and 285 C at pressures of 600 kPa absolute to 7000 kPa absolute. In some embodiments, the vaporized water produces wettability changes in the formation and/or increased formation pressure. The wettability changes and/or increased pressure may affect pyrolysis reactions or other reactions in the formation. In certain embodiments, the vaporized water is produced from the formation. In other embodiments, the vaporized water is used for steam extraction and/or distillation in the formation or outside the formation. Removing the water from and increasing the pore volume in the formation increases the storage space for hydrocarbons in the pore volume.
In certain embodiments, after stage 1 heating, the formation is heated further, such that a temperature in the formation reaches (at least) an initial pyrolyzation temperature (such as a temperature at the lower end of the temperature range shown as stage 2). Hydrocarbons in the formation may be pyrolyzed throughout stage 2. A
pyrolysis temperature range varies depending on the types of hydrocarbons in the formation. The pyrolysis =
temperature range may include temperatures between 250 C and 900 C. The pyrolysis temperature range for producing desired products may extend through only a portion of the total pyrolysis temperature range. In some embodiments, the pyrolysis temperature range for producing desired products may include temperatures between 250 C and 400 C or temperatures between 270 C and 350 C. If a temperature of hydrocarbons in the formation is slowly raised through the temperature range from 250 C to 400 C, production of pyrolysis products may be substantially complete when the temperature approaches 400 C. Average temperature of the hydrocarbons may be raised at a rate of less than 5 C per day, less than 2 C per day, less than 1 C per day, or less than 0.5 C per day through the pyrolysis temperature range for producing desired products.
Heating the hydrocarbon containing formation with a plurality of heat sources may establish thermal gradients around the heat sources that slowly raise the temperature of hydrocarbons in the formation through the pyrolysis temperature range.
The rate of temperature increase through the pyrolysis temperature range for desired products may affect the quality and quantity of the formation fluids produced from the hydrocarbon containing formation. Raising the temperature slowly through the pyrolysis temperature range for desired products may inhibit mobilization of large chain molecules in the formation. Raising the temperature slowly through the pyrolysis temperature range for desired products may limit reactions between mobilized hydrocarbons that produce undesired products. Slowly raising the temperature of the formation through the pyrolysis temperature range for desired products may allow for the production of high quality, high API gravity hydrocarbons from the formation. Slowly raising the temperature of the formation through the pyrolysis temperature range for desired products may allow for the removal of a large amount of the hydrocarbons present in the formation as hydrocarbon product.
In some in situ conversion embodiments, a portion of the formation is heated to a desired temperature instead of slowly heating the temperature through a temperature range. In some embodiments, the desired temperature is 300 C, 325 C, or 350 C. Other temperatures may be selected as the desired temperature.
Superposition of heat from heat sources allows the desired temperature to be relatively quickly and efficiently established in the formation. Energy input into the formation from the heat sources may be adjusted to maintain the temperature in the formation substantially at the desired temperature. The heated portion of the formation is maintained substantially at the desired temperature until pyrolysis declines such that production of desired formation fluids from the formation becomes uneconomical. Parts of the formation that are subjected to pyrolysis may include regions brought into a pyrolysis temperature range by heat transfer from only one heat source.
In certain embodiments, formation fluids including pyrolyzation fluids are produced from the formation.
As the temperature of the formation increases, the amount of condensable hydrocarbons in the produced formation fluid may decrease. At high temperatures, the formation may produce mostly methane and/or hydrogen. If the hydrocarbon containing formation is heated throughout the entire pyrolysis range, the formation may produce only small amounts of hydrogen towards an upper limit of the pyrolysis range. After all of the available hydrogen is depleted, a minimal amount of fluid production from the formation will typically occur.
After pyrolysis of hydrocarbons, a large amount of carbon and some hydrogen may still be presentin the formation. A significant portion of carbon remaining in the formation can be produced from the formation in the form of synthesis gas. Synthesis gas generation may take place during stage 3 heating depicted in FIG. 1. Stage 3 may include heating a hydrocarbon containing formation to a temperature sufficient to allow synthesis gas generation. For example, synthesis gas may be produced in a temperature range from about 400 C to about 1200 C, about 500 C to about 1100 C, or about 550 C to about 1000 C. The temperature of the heated portion of the formation when the synthesis gas generating fluid is introduced to the formation determines the composition of synthesis gas produced in the formation. The generated synthesis gas may be removed from the formation through a production well or production wells.
Total energy content of fluids produced from the hydrocarbon containing formation may stay relatively constant throughout pyrolysis and synthesis gas generation. During pyrolysis at relatively low formation temperatures, a significant portion of the produced fluid may be condensable hydrocarbons that have a high energy content At higher pyrolysis temperatures, however, less of the formation fluid may include condensable hydrocarbons. More non-condensable formation fluids may be produced from the formation. Energy content per unit volume of the produced fluid may decline slightly during generation of predominantly non-condensable formation fluids. During synthesis gas generation, energy content per unit volume of produced synthesis gas declines significantly compared to energy content of pyrolyzation fluid. The volume of the produced synthesis gas, however, will in many instances increase substantially, thereby compensating for the decreased energy content.
FIG. 2 depicts a schematic view of an embodiment of a portion of the in situ conversion system for treating the hydrocarbon containing formation. The in situ conversion system may include barrier wells 200. Barrier wells are used to form a barrier around a treatment area. The barrier inhibits fluid flow into and/or out of the treatment area. Barrier wells include, but are not limited to, dewatering wells, vacuum wells, capture wells, injection wells, grout wells, freeze wells, or combinations thereof. In some embodiments, barrier wells 200 are dewatering wells.
Dewatering wells may remove liquid water and/or inhibit liquid water from entering a portion of the formation to be heated, or to the formation being heated. In the embodiment depicted in FIG.
2, the barrier wells 200 are shown extending only along one side of heat sources 202, but the barrier wells typically encircle all heat sources 202 used, or to be used, to heat a treatment area of the formation.
Heat sources 202 are placed in at least a portion of the formation. Heat sources 202 may include heaters such as insulated conductors, conductor-in-conduit heaters, surface burners, flameless distributed combustors, and/or natural distributed combustors. Heat sources 202 may also include other types of heaters. Heat sources 202 provide heat to at least a portion of the formation to heat hydrocarbons in the formation. Energy may be supplied to heat sources 202 through supply lines 204. Supply lines 204 may be structurally different depending on the type of heat source or heat sources used to heat the formation. Supply lines 204 for heat sources may transmit electricity for electric heaters, may transport fuel for combustors, or may transport heat exchange fluid that is circulated in the formation.
Production wells 206 are used to remove formation fluid from the formation. In some embodiments, production well 206 may include one or more heat sources. A heat source in the production well may heat one or more portions of the formation at or near the production well. A heat source in a production well may inhibit condensation and reflux of formation fluid being removed from the formation.
Formation fluid produced from production wells 206 may be transported through collection piping 208 to treatment facilities 210. Formation fluids may also be produced from heat sources 202. For example, fluid may be produced from heat sources 202 to control pressure in the formation adjacent to the heat sources. Fluid produced from heat sources 202 may be transported through tubing or piping to collection piping 208 or the produced fluid may be transported through tubing or piping directly to treatment facilities 210. Treatment facilities 210 may include separation units, reaction units, upgrading units, fuel cells, turbines, storage vessels, and/or other systems and units for processing produced formation fluids.
Temperature limited heaters may be in configurations and/or may include materials that provide automatic temperature limiting properties for the heater at certain temperatures. In certain embodiments, ferromagnetic materials are used in temperature limited heaters. Ferromagnetic material may self-limit temperature at or near the Curie temperature of the material to provide a reduced amount of heat at or near the Curie temperature when a time-varying current is applied to the material. In certain embodiments, the ferromagnetic material self-limits temperature of the temperature limited heater at a selected temperature that is approximately the Curie temperature. In certain embodiments, the selected temperature is within 35 C, within 25 C, within 20 C, or within 10 C of the Curie temperature. In certain embodiments, ferromagnetic materials are coupled with other materials (for example, highly conductive materials, high strength materials, corrosion resistant materials, or combinations thereof) to provide various electrical and/or mechanical properties. Some parts of the temperature limited heater may have a lower resistance (caused by different geometries and/or by using different ferromagnetic and/or non-ferromagnetic materials) than other parts of the temperature limited heater. Having parts of the temperature limited heater with various materials and/or dimensions allows for tailoring the desired heat output from each part of the heater.
Temperature limited heaters may be more reliable than other heaters.
Temperature limited heaters may be less apt to break down or fail due to hot spots in the formation. In some embodiments, temperature limited heaters allow for substantially uniform heating of the formation. In some embodiments, temperature limited heaters are able to heat the formation more efficiently by operating at a higher average heat output along the entire length of the heater. The temperature limited heater operates at the higher average heat output along the entire length of the heater because power to the heater does not have to be reduced to the entire heater, as is the case with typical constant wattage heaters, if a temperature along any point of the heater exceeds, or is to exceed, a maximum operating temperature of the heater. Heat output from portions of a temperature limited heater approaching a Curie temperature of the heater automatically reduces without controlled adjustment of the time-varying current applied to the heater. The heat output automatically reduces due to changes in electrical properties (for example, electrical resistance) of portions of the temperature limited heater. Thus, more power is supplied by the temperature limited heater during a greater portion of a heating process.
In certain embodiments, the system including temperature limited heaters initially provides a first heat output and then provides a reduced (second heat output) heat output, near, at, or above the Curie temperature of an electrically resistive portion of the heater when the temperature limited heater is energized by a time-varying current.
The first heat output is the heat output at temperatures below which the temperature limited heater begins to self-limit. In some embodiments, the first heat output is the heat output at a temperature 50 C, 75 C, 100 C, or 125 C
below the Curie temperature of the ferromagnetic material in the temperature limited heater.
The temperature limited heater may be energized by time-varying current (alternating current or modulated direct current) supplied at the wellhead. The wellhead may include a power source and other components (for example, modulation components, transformers, and/or capacitors)-used in supplying power to the temperature limited heater. The temperature limited heater may be one of irony heaters used to heat a portion of the formation.
In certain embodiments, the temperature limited heater includes a conductor that operates as a skin effect or proximity effect heater when time-varying current is applied to the Conductor.
The skin effect limits the depth of current penetration into the interior of the conductor. For ferromagnetic materials, the skin effect is dominated by the magnetic permeability of the conductor. The relative magnetic permeability of ferromagnetic materials is typically between 10 and 1000 (for example, the relative magnetic permeability of ferromagnetic materials is typically at least 10 and may be at least 50, 100, 500, 1000 or greater). As the temperature of the ferromagnetic material is raised above the Curie temperature and/or as the applied electrical current is increased, the magnetic permeability of the ferromagnetic material decreases substantially and the skin depth expands rapidly (for example, the skin depth expands as the inverse square root of the magnetic permeability). The reduction in magnetic permeability results in a decrease in the AC or modulated DC resistance of the conductor near, at, or above the Curie temperature and/or as the applied electrical current is increased. When the temperature limited heater is powered by a substantially constant current source, portions of the heater that approach, reach, or are above the Curie temperature may have reduced heat dissipation. Sections of the temperature limited heater that are not at or near the Curie temperature may be dominated by skin effect heating that allows the heater to have high heat dissipation due to a higher resistive load.
An advantage of using the temperature limited heater to heat hydrocarbons in the formation is that the conductor is chosen to have a Curie temperature in a desired range of temperature operation. Operation within the desired operating temperature range allows substantial heat injection into the formation while maintaining the temperature of the temperature limited heater, and other equipment, below design limit temperatures. Design limit temperatures are temperatures at which properties such as corrosion, creep, and/or deformation are adversely affected. The temperature limiting properties of the temperature limited heater inhibits overheating or burnout of the heater adjacent to low thermal conductivity "hot spots" in the formation. In some embodiments, the temperature limited heater is able to lower or control heat output and/or withstand heat at temperatures above 25 C, 37 C, 100 C, 250 C, 500 C, 700 C, 800 C, 900 C, or higher up to 1131 C, depending on the materials used in the heater.
The temperature limited heater allows for more heat injection into the formation than constant wattage heaters because the energy input into the temperature limited heater does not have to be limited to accommodate low thermal conductivity regions adjacent to the heater. For example, in Green River oil shale there is a difference of at least a factor of 3 in the thermal conductivity of the lowest richness oil shale layers and the highest richness oil shale layers. When heating such a formation, substantially more heat is transferred to the formation with the temperature limited heater than with the conventional heater that is limited by the temperature at low thermal conductivity layers.
The heat output along the entire length of the conventional heater needs to accommodate the low thermal conductivity layers so that the heater does not overheat at the low thermal conductivity layers and burn out. The heat output adjacent to the low thermal conductivity layers that are at high temperature will reduce for the temperature limited heater, but the remaining portions of the temperature limited heater that are not at high temperature will still provide high heat output. Because heaters for heating hydrocarbon formations typically have long lengths (for example, at least 10 m, 100 m, 300 m, at least 500 m, 1 km or more up to 10 km), the majority of the length of the temperature limited heater may be operating below the Curie temperature while only a few portions are at or near the Curie temperature of the temperature limited heater.
The use of temperature limited heaters allows for efficient transfer of heat to the formation. Efficient transfer of heat allows for reduction in time needed to heat the formation to a desired temperature. For example, in Green River oil shale, pyrolysis typically requires 9.5 years to 10 years of heating when using a 12 m heater well spacing with conventional constant wattage heaters. For the same heater spacing, temperature limited heaters may allow a larger average heat output while maintaining heater equipment temperatures below equipment design limit temperatures. Pyrolysis in the formation may occur at an earlier time with the larger average heat output provided by temperature limited heaters than the lower average heat output provided by constant wattage heaters. For example, in Green River oil shale, pyrolysis may occur in 5 years using temperature limited heaters with a 12 m heater well spacing. Temperature limited heaters counteract hot spots due to inaccurate well spacing or drilling where heater wells come too close together. In certain embodiments, temperature limited heaters allow for increased power output over time for heater wells that have been spaced too far apart, or limit power output for heater wells that are spaced too close together. Temperature limited heaters also supply more power in regions adjacent the overburden and underburden to compensate for temperature losses in these regions.
Temperature limited heaters may be advantageously used in many types of formations. For example, in tar sands formations or relatively permeable formations containing heavy hydrocarbons, temperature limited heaters may be used to provide a controllable low temperature output for reducing the viscosity of fluids, mobilizing fluids, and/or enhancing the radial flow of fluids at or near the wellbore or in the formation. Temperature limited heaters may be used to inhibit excess coke formation due to overheating of the near wellbore region of the formation.
The use of temperature limited heaters, in some embodiments, eliminates or reduces the need for expensive temperature control circuitry. For example, the use of temperature limited heaters eliminates or reduces the need to perform temperature logging and/or the need to use fixed thermocouples on the heaters to monitor potential overheating at hot spots.
In certain embodiments, the temperature limited heater is deformation tolerant. Localized movement of material in the wellbore may result in lateral stresses on the heater that could deform its shape. Locations along a length of the heater at which the wellbore approaches or closes on the heater may be hot spots where a standard heater overheats and has the potential to burn out. These hot spots may lower the yield strength and creep strength of the metal, allowing crushing or deformation of the heater. The temperature limited heater may be formed with S
curves (or other non-linear shapes) that accommodate deformation of the temperature limited heater without causing failure of the heater.
In some embodiments, temperature limited heaters are more economical to manufacture or make than standard heaters. Typical ferromagnetic materials include iron, carbon steel, or ferritic stainless steel. Such materials are inexpensive as compared to nickel-based heating alloys (such as nichrome, KanthalTM (Bulten-Kanthal AB, Sweden), and/or LOHMTm (Driver-Harris Company, Harrison, New Jersey, U.S.A.)) typically used in insulated conductor (mineral insulated cable) heaters. In one embodiment of the temperature limited heater, the temperature limited heater is manufactured in continuous lengths as an insulated conductor heater to lower costs and improve reliability.
In some embodiments, the temperature limited heater is placed in the heater well using a coiled tubing rig.
A heater that can be coiled on a spool may be manufactured by using metal such as ferritic stainless steel (for example, 409 stainless steel) that is welded using electrical resistance welding (ERW). To form a heater section, a metal strip from a roll is passed through a first former where it is shaped into a tubular and then longitudinally welded, using ERW. The tubular is passed through a second former where a conductive strip (for example, a copper strip) is applied, drawn down tightly on the tubular through a die, and longitudinally welded using ERW. A sheath may be formed by longitudinally welding a support material (for example, steel such as 347H or 34711H) over the conductive strip material. The support material may be a strip rolled over the conductive strip material. An overburden section of the heater may be formed in a similar manner. In certain embodiments, the overburden section uses a non-ferromagnetic material such as 304 stainless steel or 316 stainless steel instead of a ferromagnetic material. The heater section and overburden section may be coupled together using standard techniques such as butt welding using an orbital welder. In some embodiments, the overburden section material (the non-ferromagnetic material) may be pre-welded to the ferromagnetic material before rolling. The pre-welding may eliminate the need for a separate coupling step (for example, butt welding). In an embodiment, a flexible cable (for example, a furnace cable such as a MGT 1000 furnace cable) may be pulled through the center after forming the tubular heater. An end bushing on the flexible cable may be welded to the tubular heater to provide an electrical current return path. The tubular heater, including the flexible cable, may be coiled onto a spool before installation into a heater well. In an embodiment, the temperature limited heater is installed using the coiled tubing rig. The coiled tubing rig may place the temperature limited heater in a deformation resistant container in the formation. The deformation resistant container may be placed in the heater well using conventional methods.
The ferromagnetic alloy or ferromagnetic alloys used in the temperature limited heater determine the Curie temperature of the heater. Curie temperature data for various metals is listed in "American Institute of Physics Handbook," Second Edition, McGraw-Hill, pages 5-170 through 5-176.
Ferromagnetic conductors may include one or more of the ferromagnetic elements (iron, cobalt, and nickel) and/or alloys of these elements. In some embodiments, ferromagnetic conductors include iron-chromium (Fe-Cr) alloys that contain tungsten (W) (for example, HCM12A and SAVE12 (Sumitomo Metals Co., Japan) and/or iron alloys that contain chromium (for example, Fe-Cr alloys, Fe-Cr-W alloys, Fe-Cr-V (vanadium) alloys, Fe-Cr-Nb (Niobium) alloys). Of the three main ferromagnetic elements, iron has a Curie temperature of 770 C; cobalt (Co) has a Curie temperature of 1131 C; and nickel has a Curie temperature of approximately 358 C. An iron-cobalt alloy has a Curie temperature higher than the Curie temperature of iron. For example, iron-cobalt alloy with 2% by weight cobalt has a Curie temperature of 800 C; iron-cobalt alloy with 12% by weight cobalt has a Curie temperature of 900 C; and iron-cobalt alloy with 20% by weight cobalt has a Curie temperature of 950 C. Iron-nickel alloy has a Curie temperature lower than the Curie temperature of iron. For example, iron-nickel alloy with 20% by weight nickel has a Curie temperature of 720 C, and iron-nickel alloy with 60% by weight nickel has a Curie temperature of 560 C.
Some non-ferromagnetic elements used as alloys raise the Curie temperature of iron. For example, an iron-vanadium alloy with 5.9% by weight vanadium has a Curie temperature of approximately 815 C. Other non-ferromagnetic elements (for example, carbon, aluminum, copper, silicon, and/or chromium) may be alloyed with iron or other ferromagnetic materials to lower the Curie temperature. Non-ferromagnetic materials that raise the Curie temperature may be combined with non-ferromagnetic materials that lower the Curie temperature and alloyed with iron or other ferromagnetic materials to produce a material with a desired Curie temperature and other desired physical and/or chemical properties. In some embodiments, the Curie temperature material is a ferrite such as NiFe204. In other embodiments, the Curie temperature material is a binary compound such as FeNi3 or Fe3A1.
Certain embodiments of temperature limited heaters may include more than one ferromagnetic material.
Such embodiments are within the scope of embodiments described herein if any conditions described herein apply to at least one of the ferromagnetic materials in the temperature limited heater.
Ferromagnetic properties generally decay as the Curie temperature is approached. Thus, the self-limiting temperature may be somewhat below the actual Curie temperature of the ferromagnetic conductor. Skin depth generally defines an effective penetration depth of time-varying current into the conductive material. In general, current density decreases exponentially with distance from an outer surface to the center along the radius of the conductor. The depth at which the current density is approximately 1/e of the surface current density is called the skin depth. The skin depth for current flow in 1% carbon steel is 0.132 cm at room temperature and increases to 0.445 cm at 720 C. From 720 C to 730 C, the skin depth sharply increases to over 2.5 cm. Thus, a temperature limited heater embodiment using 1% carbon steel begins to self-limit between 650 C and 730 C.
For most metals, resistivity (p) increases with temperature. The relative magnetic permeability generally varies with temperature and with current. Additional equations may be used to assess the variance of magnetic permeability and/or skin depth on both temperature and/or current. The dependence of pt on current arises from the dependence of p on the magnetic field.
Materials used in the temperature limited heater may be selected to provide a desired turndown ratio.
Turndown ratios of at least 1.1:1, 2:1, 3:1, 4:1, 5:1, 10:1, 30:1, or 50:1 may be selected for temperature limited heaters. Larger turndown ratios may also be used. A selected turndown ratio may depend on a number of factors including, but not limited to, the type of formation in which the temperature limited heater is located (for example, a higher turndown ratio may be used for an oil shale formation with large variations in thermal conductivity between rich and lean oil shale layers) and/or a temperature limit of materials used in the wellbore (for example, temperature limits of heater materials). In some embodiments, the turndown ratio is increased by coupling additional copper or another good electrical conductor to the ferromagnetic material (for example, adding copper to lower the resistance above the Curie temperature).
The temperature limited heater may provide a minimum heat output (power output) below the Curie temperature of the heater. In certain embodiments, the minimum heat output is at least 400 W/m (Watts per meter), 600 W/m, 700 W/m, 800 W/m, or higher up to 2000 W/m. The temperature limited heater reduces the amount of heat output by a section of the heater when the temperature of the section of the heater approaches or is above the Curie temperature. The reduced amount of heat may be substantially less than the heat output below the Curie temperature. In some embodiments, the reduced amount of heat is at most 400 W/m, 200 W/m, 100 W/m or may approach 0 W/m.
In some embodiments, AC frequency is adjusted to change the skin depth of the ferromagnetic material.
For example, the skin depth of 1% carbon steel at room temperature is 0.132 cm at 60 Hz, 0.0762 cm at 180 Hz, and 0.046 cm at 440 Hz. Since heater diameter is typically larger than twice the skin depth, using a higher frequency (and thus a heater with a smaller diameter) reduces heater costs. For a fixed geometry, the higher frequency results in a higher turndown ratio. The turndown ratio at a higher frequency is calculated by multiplying the turndown ratio at a lower frequency by the square root of the higher frequency divided by the lower frequency. In some embodiments, a frequency between 100 Hz and 1000 Hz, between 140 Hz and 200 Hz, or between 400 Hz and 600 Hz is used (for example, 180 Hz, 540 Hz, or 720 Hz). In some embodiments, high frequencies may be used. The frequencies may be greater than 1000 Hz.
In certain embodiments, modulated DC (for example, chopped DC, waveform modulated DC, or cycled DC) may be used for providing electrical power to the temperature limited heater. A DC modulator or DC chopper may be coupled to a DC power supply to provide an output of modulated direct current. In some embodiments, the DC power supply may include means for modulating DC. One example of a DC
modulator is a DC-to-DC converter system. DC-to-DC converter systems are generally known in the art. DC is typically modulated or chopped into a desired waveform. Waveforms for DC modulation include, but are not limited to, square-wave, sinusoidal, deformed sinusoidal, deformed square-wave, triangular, and other regular or irregular waveforms.
The modulated DC waveform generally defines the frequency of the modulated DC.
Thus, the modulated DC waveform may be selected to provide a desired modulated DC frequency. The shape and/or the rate of modulation (such as the rate of chopping) of the modulated DC waveform may be varied to vary the modulated DC
frequency. DC may be modulated at frequencies that are higher than generally available AC frequencies. For example, modulated DC may be provided at frequencies of at least 1000 Hz.
Increasing the frequency of supplied current to higher values advantageously increases the turndown ratio of the temperature limited heater.
In certain embodiments, the modulated DC waveform is adjusted or altered to vary the modulated DC
frequency. The DC modulator may be able to adjust or alter the modulated DC
waveform at any time during use of the temperature limited heater and at high currents or voltages. Thus, modulated DC provided to the temperature limited heater is not limited to a single frequency or even a small set of frequency values. Waveform selection using - the DC modulator typically allows for a wide range of modulated DC
frequencies and for discrete control of the modulated DC frequency. Thus, the modulated DC frequency is more easily set at a distinct value whereas AC
frequency is generally limited to multiples of the line frequency. Discrete control of the modulated DC frequency allows for more selective control over the turndown ratio of the teinperature limited heater. Being able to selectively control the turndown ratio of the temperature limited heater allows for a broader range of materials to be used in designing and constructing the temperature limited heater.
In some embodiments, the modulated DC frequency or the AC frequency is adjusted to compensate for changes in properties (for example, subsurface conditions such as temperature or pressure) of the temperature limited heater during use. The modulated DC frequency or the AC frequency provided to the temperature limited heater is varied based on assessed downhole conditions. For example, as the temperature of the temperature limited heater in the wellbore increases, it may be advantageous to increase the frequency of the current provided to the heater, thus increasing the turndown ratio of the heater. In an embodiment, the downhole temperature of the temperature limited heater in the wellbore is assessed.

In certain embodiments, the modulated DC frequency, or the AC frequency, is varied to adjust the turndown ratio of the temperature limited heater. The turndown ratio may be adjusted to compensate for hot spots occurring along a length of the temperature limited heater. For example, the turndown ratio is increased because the temperature limited heater is getting too hot in certain locations. In some embodiments, the modulated DC
frequency, or the AC frequency, are varied to adjust a turndown ratio without assessing a subsurface condition.
In certain embodiments, an outermost layer of the temperature limited heater (for example, the outer conductor) is chosen for corrosion resistance, yield strength, and/or creep resistance. In one embodiment, austenitic (non-ferromagnetic) stainless steels such as 201, 304H, 347H, 347HH, 316H, 310H, 347HP, NF709 (Nippon Steel Corp., Japan) stainless steels, or combinations thereof may be used in the outer conductor. The outermost layer may also include a clad conductor. For example, a corrosion resistant alloy such as 800H or 347H stainless steel may be clad for corrosion protection over a ferromagnetic carbon steel tubular. If high temperature strength is not required, the outermost layer may be constructed from ferromagnetic metal with good corrosion resistance such as one of the ferritic stainless steels. In one embodiment, a ferritic alloy of 82.3% by weight iron with 17.7% by weight chromium (Curie temperature of 678 C) provides desired corrosion resistance.
= The Metals Handbook, vol. 8, page 291 (American Society of Materials (ASM)) includes a graph of Curie temperature of iron-chromium alloys versus the amount of chromium in the alloys. In some temperature limited heater embodiments, a separate support rod or tubular (made from 347H
stainless steel). is coupled to the temperature limited heater made from an iron-chromium alloy to provide yield strength and/or creep resistance. In certain embodiments, the support material and/or the ferromagnetic material is selected to provide a 100,000 hour creep-rupture strength of at least 20.7 MPa at 650 C. In some embodiments, the 100,000 hour creep-rupture strength is at least 13.8 MPa at 650 C or at least 6.9 MPa at 650 C. For example, 347H
steel has a favorable creep-rupture strength at or above 650 C. In some embodiments, the 100,000 hour creep-rupture strength ranges from 6.9 MPa to 41.3 MPa or more for longer heaters and/or higher earth or fluid stresses.
In certain embodiments, the temperature limited heater includes a composite conductor with a ferromagnetic tubular and a non-ferromagnetic, high electrical conductivity core. The non-ferromagnetic, high electrical conductivity core reduces a required diameter of the conductor. For example, the conductor may be composite 1.19 cm diameter conductor with a core of 0.575 cm diameter copper clad with a 0.298 cm thickness of ferritic stainless steel or carbon steel surrounding the core. The core or non-ferromagnetic conductor may be copper or copper alloy. The core or non-ferromagnetic conductor may also be made of other metals that exhibit low electrical resistivity and relative magnetic permeabilities near 1 (for example, substantially non-ferromagnetic materials such as aluminum and aluminum alloys, phosphor bronze, beryllium copper, and/or brass). A composite conductor allows the electrical resistance of the temperature limited heater to decrease more steeply near the Curie temperature. As the skin depth increases near the Curie temperature to include the copper core, the electrical resistance decreases very sharply.
The composite conductor may increase the conductivity of the temperature limited heater and/or allow the heater to operate at lower voltages. In an embodiment, the composite conductor exhibits a relatively flat resistance versus temperature profile at temperatures below a region near the Curie temperature of the ferromagnetic conductor of the composite conductor. In some embodiments, the temperature limited heater exhibits a relatively flat resistance versus temperature profile between 100 C and 750 C or between 300 C and 600 C. The relatively flat resistance versus temperature profile may also be exhibited in other temperature ranges by adjusting, for example, materials and/or the configuration of materials in the temperature limited heater. In certain embodiments, the relative thickness of each material in the composite conductor is selected to produce a desired resistivity versus temperature profile for the temperature limited heater.
A composite conductor (for example, a composite inner conductor or a composite outer conductor) may be manufactured by methods including, but not limited to, coextrusion, roll forming, tight fit tubing (for example, cooling the inner member and heating the outer member, then inserting the inner member in the outer member, followed by a drawing operation and/or allowing the system to cool), explosive or electromagnetic cladding, arc overlay welding, longitudinal strip welding, plasma powder welding, billet coextrusion, electroplating, drawing, sputtering, plasma deposition, coextrusion casting, magnetic forming, molten cylinder casting (of inner core material inside the outer or vice versa), insertion followed by welding or high temperature braising, shielded active gas welding (SAG), and/or insertion of an inner pipe in an outer pipe followed by mechanical expansion of the inner pipe by hydroforming or use of a pig to expand and swage the inner pipe against the outer pipe. In some embodiments, a ferromagnetic conductor is braided over a non-ferromagnetic conductor. In certain embodiments, composite conductors are formed using methods similar to those used for cladding (for example, cladding copper to steel). A metallurgical bond between copper cladding and base ferromagnetic material may be advantageous.
' Composite conductors produced by a coextrusion process that forms a good metallurgical bond (for example, a good bond between copper and 446 stainless steel) may be provided by Anomet Products, Inc. (Shrewsbury, Massachusetts, U.S.A.).
FIGS. 3-9 depict various embodiments of temperature limited heaters. One or more features of an embodiment of the temperature limited heater depicted in any of these figures may be combined with one or more features of other embodiments of temperature limited heaters depicted in these figures. In certain embodiments described herein, temperature limited heaters are dimensioned to operate at a frequency of 60 Hz AC. It is to be understood that dimensions of the temperature limited heater may be adjusted from those described herein in order for the temperature limited heater to operate in a similar manner at other AC
frequencies or with modulated DC
current.
FIG. 3 depicts a cross-sectional representation of an embodiment of the temperature limited heater with an outer conductor having a ferromagnetic section and a non-ferromagnetic section. FIGS. 4 and 5 depict transverse cross-sectional views of the embodiment shown in FIG. 3. In one embodiment, ferromagnetic section 212 is used to provide heat to hydrocarbon layers in the formation. Non-ferromagnetic section 214 is used in the overburden of the formation: Non-ferromagnetic section 214 provides little or no heat to the overburden, thus inhibiting heat losses in the overburden and improving heater efficiency. Ferromagnetic section 212 includes a ferromagnetic material such as 409 stainless steel or 410 stainless steel. Ferromagnetic section 212 has a thickness of 0.3 cm. Non-ferromagnetic section 214 is copper with a thickness of 0.3 cm. Inner conductor 216 is copper. Inner conductor 216 has a diameter of 0.9 cm. Electrical insulator 218 is silicon nitride, boron nitride, magnesium oxide powder, or another suitable insulator material. Electrical insulator 218 has a thickness of 0.1 cm to 0.3 cm.
FIG. 6A and FIG. 6B depict cross-sectional representations of an embodiment of a temperature limited heater with a ferromagnetic inner conductor and a non-ferromagnetic core.
Inner conductor 216 may be made of 446 stainless steel, 409 stainless steel, 410 stainless steel, carbon steel, Armco ingot iron, iron-cobalt alloys, or other ferromagnetic materials. Core 220 may be tightly bonded inside inner conductor 216. Core 220 is copper or other non-ferromagnetic material. In certain embodiments, core 220 is inserted as a tight fit inside inner conductor 216 before a drawing operation. In some embodiments, core 220 and inner conductor 216 are coextrusion bonded.
Outer conductor 222 is 347H stainless steel. A drawing or rolling operation to compact electrical insulator 218 (for example, compacted silicon nitride, boron nitride, or magnesium oxide powder) may ensure good electrical contact between inner conductor 216 and core 220. In this embodiment, heat is produced primarily in inner conductor 216 until the Curie temperature is approached. Resistance then decreases sharply as current penetrates core 220.
FIG. 7 depicts an embodiment of a temperature limited heater in which the support member provides a majority of the heat output below the Curie temperature of the ferromagnetic conductor. Core 220 is an inner conductor of the temperature limited heater. In certain embodiments, core 220 is a highly electrically conductive material such as copper or aluminum. In some embodiments, core 220 is a copper alloy that provides mechanical strength and good electrically conductivity such as a dispersion strengthened copper. In one embodiment, core 220 is Glidcop (SCM Metal Products, Inc., Research Triangle Park, North Carolina, U.S.A.). Ferromagnetic conductor 224 is a thin layer of ferromagnetic material between electrical conductor 226 and core 220. In certain embodiments, electrical conductor 226 is also support member 228. In certain embodiments, ferromagnetic conductor 224 is iron or an iron alloy. In some embodiments, ferromagnetic conductor 224 includes ferromagnetic material with a high relative magnetic permeability. For example, ferromagnetic conductor 224 may be purified iron such as Armco ingot iron (AK Steel Ltd., United Kingdom). Iron with some impurities typically has a relative magnetic permeability on the order of 400. Purifying the iron by annealing the iron in hydrogen gas (HJ at 1450 C
increases the relative magnetic permeability of the iron. Increasing the relative magnetic permeability of ferromagnetic conductor 224 allows the thickness of the ferromagnetic conductor to be reduced. For example, the thickness of unpurified iron may be approximately 4.5 mm while the thickness of the purified iron is approximately 0.76 mm.
In certain embodiments, electrical conductor 226 provides support for ferromagnetic conductor 224 and the temperature limited heater. Electrical conductor 226 may be made of a material that provides good mechanical strength at temperatures near or above the Curie temperature of ferromagnetic conductor 224. In certain embodiments, electrical conductor 226 is a corrosion resistant member.
Electrical conductor 226 (support member 228) may provide support for ferromagnetic conductor 224 and corrosion resistance. Electrical conductor 226 is made from a material that provides desired electrically resistive heat output at temperatures up to and/or above the Curie temperature of ferromagnetic conductor 224.
In an embodiment, electrical conductor 226 is 34711 stainless steel. In some embodiments, electrical conductor 226 is another electrically conductive, good mechanical strength, corrosion resistant material. For example, electrical conductor 226 may be 30411, 316H, 347HH, NF709, Incoloy 800H alloy (Inco Alloys International, Huntington, West Virginia, U.S.A.), Haynes HR120 alloy, or Inconel 617 alloy.
In some embodiments, electrical conductor 226 (support member 228) includes different alloys in different portions of the temperature limited heater. For example, a lower portion of electrical conductor 226 (support member 228) is 347H stainless steel and an upper portion of the electrical conductor (support member) is NF709. In certain embodiments, different alloys are used in different portions of the electrical conductor (support member) to increase the mechanical strength of the electrical conductor (support member) while maintaining desired heating properties for the temperature limited heater.
In some embodiments, ferromagnetic conductor 224 includes different ferromagnetic conductors in different portions of the temperature limited heater. Different ferromagnetic conductors may be used in different portions of the temperature limited heater to vary the Curie temperature and, thus, the maximum operating temperature in the different portions. In some embodiments, the Curie temperature in an upper portion of the temperature limited heater is lower than the Curie temperature in a lower portion of the heater. The lower Curie temperature in the upper portion increases the creep-rupture strength lifetime in the upper portion of the heater.
In the embodiment depicted in FIG. 7, ferromagnetic conductor 224, electrical conductor 226, and core 220 are dimensioned so that the skin depth of the ferromagnetic conductor limits the penetration depth of the majority of the flow of electrical current to the support member when the temperature is below the Curie temperature of the ferromagnetic conductor. Thus, electrical conductor 226 provides a majority of the electrically resistive heat output of the temperature limited heater at temperatures up to a temperature at or near the Curie temperature of ferromagnetic conductor 224. In certain embodiments, the temperature limited heater depicted in FIG. 7 is smaller (for example, an outside diameter of 3 cm, 2.9 cm, 2.5 cm, or less) than other temperature limited heaters that do not use electrical conductor 226 to provide the majority of electrically resistive heat output. The temperature limited heater depicted in FIG. 7 may be smaller because ferromagnetic conductor 224 is thin as compared to the size of the ferromagnetic conductor needed for a temperature limited heater in which the majority of the resistive heat output is provided by the ferromagnetic conductor.
In some embodiments, the support member and the corrosion resistant member are different members in the temperature limited heater. FIGS. 8 and 9 depict embodiments of temperature limited heaters in which the jacket provides a majority of the heat output below the Curie temperature of the ferromagnetic conductor. In these embodiments, electrical conductor 226 is jacket 230. Electrical conductor 226, ferromagnetic conductor 224, support member 228, and core 220 (in FIG. 8) or inner conductor 216 (in FIG.
9) are dimensioned so that the skin depth of the ferromagnetic conductor limits the penetration depth of the majority of the flow of electrical current to the thickness of the jacket. In certain embodiments, electrical conductor 226 is a material that is corrosion resistant and provides electrically resistive heat output below the Curie temperature of ferromagnetic conductor 224. For example, electrical conductor 226 is 825 stainless steel or 34711 stainless steel. In some embodiments, electrical conductor 226 has a small thickness (for example, on the order of 0.5 mm).
In FIG. 8, core 220 is highly electrically conductive material such as copper or aluminum. Support member 228 is 347H stainless steel or another material with good mechanical strength at or near the Curie temperature of ferromagnetic conductor 224.
In FIG. 9, support member 228 is the core of the temperature limited heater and is 347H stainless steel or another material with good mechanical strength at or near the Curie temperature of ferromagnetic conductor 224.
Inner conductor 216 is highly electrically conductive material such as copper or aluminum.
In certain embodiments, exposed metal heating elements are used in substantially horizontal sections of u-shaped wellbores. Substantially u-shaped wellbores may be used in tar sands formations, oil shale formation, or other formations with relatively thin hydrocarbon layers. Tar sands or thin oil shale formations may have thin shallow layers that are more easily and uniformly heated using heaters placed in substantially u-shaped wellbores.
Substantially u-shaped wellbores may also be used to process formations with thick hydrocarbon layers in formations. In some embodiments, substantially u-shaped wellbores are used to access rich layers in a thick hydrocarbon formation.
Heaters in substantially u-shaped wellbores may have long lengths compared to heaters in vertical wellbores because horizontal heating sections do not have problems with creep or hanging stress encountered with vertical heating elements. Substantially u-shaped wellbores may make use of natural seals in the formation and/or the limited thickness of the hydrocarbon layer. For example, the wellbores may be placed above or below natural seals in the formation without punching large numbers of holes in the natural seals, as would be needed with =

vertically oriented wellbores. Using substantially u-shaped wellbores instead of vertical wellbores may also reduce the number of wells needed to treat a surface footprint of the formation.
Using less wells reduces capital costs for equipment and reduces the environmental impact of treating the formation by reducing the amount of wellbores on the surface and the amount of equipment on the surface. Substantially u-shaped wellbores may also utilize a lower ratio of overburden section to heated section than vertical wellbores.
Substantially u-shaped wellbores may allow for flexible placement of opening of the wellbores on the surface. Openings to the wellbores may be placed according to the surface topology of the formation. In certain embodiments, the openings of wellbores are placed at geographically accessible locations such as topologic highs (for example, hills). For example, the wellbore may have a first opening on a first topologic high and a second opening on a second topologic high and the wellbore crosses beneath a topologic low (for example, a valley with alluvial fill) between the first and second topologic highs. This placement of the openings may avoid placing openings or equipment in topologic lows or other inaccessible locations. In addition, the water level may not be artesian in topologically high areas. Wellbores may be drilled so that the openings are not located near environmentally sensitive areas such as, but not limited to, streams, nesting areas, or animal refuges.
FIG. 10 depicts a side view representation of an embodiment of a heater with an exposed metal heating element placed in a substantially u-shaped wellbore. Heaters 232A, 232B, 232C
have first end portions at first location 234 on surface 236 of the formation and second end portions at second location 238 on the surface. Heaters 232A, 232B, 232C have sections 240 in overburden 242. Sections 240 are configured to provide little or no heat output. In certain embodiments, sections 240 include an insulated electrical conductor such as insulated copper.
Sections 240 are coupled to heating elements 244.
In certain embodiments, portions of heating elements 244 are substantially parallel in hydrocarbon layer 246. In certain embodiments, heating elements 244 are exposed metal heating elements. In certain embodiments, heating elements 244 are exposed metal temperature limited heating elements.
Heating elements 244 may include ferromagnetic materials such as 9% by weight to 13% by weight chromium stainless steel like 410 stainless steel, chromium stainless steels such as T/P91 or T/P92, 409 stainless steel, VM12 (Vallourec and Mannesmann Tubes, France) or iron-cobalt alloys for use as temperature limited heaters. In some embodiments, heating elements 244 are composite temperature limited heating elements such as 410 stainless steel and copper composite heating elements or 347H, iron, copper composite heating elements. Heating elements 244 may have lengths of at least about 100 m, at least about 500 m, or at least about 1000 m, up to lengths of about 6000 m.
Heating elements 244 may be solid rods or tubulars. In certain embodiments, solid rod heating elements have diameters several times the skin depth at the Curie temperature of the ferromagnetic material. Typically, the solid rod heating elements may have diameters of 1.91 cm or larger (for example, 2.5 cm, 3.2 cm, 3.81 cm, or 5.1 cm). In certain embodiments, tubular heating elements have wall thicknesses of at least twice the skin depth at the Curie temperature of the ferromagnetic material. Typically, the tubular heating elements have outside diameters of between about 2.5 cm and about 15.2 cm and wall thickness in range between about 0.13 cm and about 1.01 cm.
In certain embodiments, tubular heating elements 244 allow fluids to be convected through the tubular heating elements. Fluid flowing through the tubular heating elements may be used to preheat the tubular heating elements, to initially heat the formation, and/or to recover heat from the formation after heating is completed for the in situ conversion process. Fluids that may be flow through the tubular heating elements include, but are not limited to, air, water, steam, helium, carbon dioxide or other fluids. In some embodiments, a hot fluid, such as carbon dioxide or helium, flows through the tubular heating elements to provide heat to the formation. The hot fluid may be used to provide heat to the formation before electrical heating is used to provide heat to the formation. In some embodiments, the hot fluid is used to provide heat in addition to electrical heating. Using the hot fluid to provide heat to the formation in addition to providing electrical heating may be less expensive than using electrical heating alone to provide heat to the formation. In some embodiments, water and/or steam flows through the tubular heating element to recover heat from the formation. The heated water and/or steam may be used for solution mining and/or other processes.
Transition sections 248 may couple heating elements 244 to sections 240. In certain embodiments, transition sections 248 include material that has a high electrical conductivity but is corrosion resistant, such as 347 stainless steel over copper. In an embodiment, transition sections include a composite of stainless steel clad over copper. Transition sections 248 inhibit overheating of copper and/or insulation in sections 240.
FIG. 11 depicts a representational top view of an embodiment of a surface pattern of heaters depicted in FIG. 10. Heaters 232A-L may be arranged in a repeating triangular pattern on the surface of the formation, as shown in FIG. 11. A triangle may be formed by heaters 232A, 232B, and 232C and a triangle formed by heaters 232C, 232D, and 232E. In some embodiments, heaters 232A-L are arranged in a straight line on the surface of the formation. Heaters 232-A-L have first end portions at first location 234 on the surface and second end portions at second location 238 on the surface. Heaters 232A-L are arranged such that (a) the patterns at first location 234 and second location 238 correspond to each other, (b) the spacing between heaters is maintained at the two locations on the surface, and/or (c) the heaters all have substantially the same length (substantially the same horizontal distance between the end portions of the heaters on the surface as shown in the top view of FIG. 11).
As depicted in FIGS. 10 and 11, cables 250, 252 may be coupled to transformer 254 and one or more heater units, such as the heater unit including heaters 232A, 232B, 232C. Cables 250, 252 may carry a large amount of power. In certain embodiments, cables 250, 252 are capable of carrying high currents with low losses. For example, cables 250, 252 may be thick copper or aluminum conductors. The cables may also have thick insulation layers. In some embodiments, cable 250 and/or cable 252 may be superconducting cables.
The superconducting cables may be cooled by liquid nitrogen. Superconducting cables are available from Superpower, Inc. (Schenectady, New York, U.S.A). Superconducting cables may minimize power loss and reduce the size of the cables needed to couple transformer 254 to the heaters.
In certain embodiments, bus bar 255A is coupled to first end portions of heaters 232A-L and bus bar 255B
is coupled to second end portions of heaters 232A-L. Bus bars 255A,B
electrically couple heaters 232A-L to cables 250, 252 and transformer 254. Bus bars 255A,B distribute power to heaters 232A-L. In certain embodiments, bus bars 255A,B are capable of carrying high currents with low losses. In some embodiments, bus bars 255A,B are made of superconducting material such as the superconductor material used in cables 250, 252.
As shown in FIGS. 10 and 11, heaters 232A-L are coupled to a single transformer 254. In certain embodiments, transformer 254 is a source of time-varying current. In certain embodiments, transformer 254 is an electrically isolated, single-phase transformer. In certain embodiments, transformer 254 provides power to heaters 232A-L from an isolated secondary phase of the transformer. First end portions of heaters 232A-L may be coupled to one side of transformer 254 while second end portions of the heaters are coupled to the opposite side of the transformer. Transformer 254 provides a substantially common voltage to the first end portions of heaters 232A-L
and a substantially common voltage to the second end portions of heaters 232A-L. In certain embodiments, transformer 254 applies a voltage potential to the first end portions of heaters 232A-L that is opposite in polarity and substantially equal in magnitude to a voltage potential applied to the second end portions of the heaters. For example, a +660 V potential may be applied to the first end portions of heaters 232A-L and a -660 V potential applied to the second end portions of the heaters at a selected point on the wave of time-varying current (such as AC
or modulated DC). Thus, the voltages at the two end portion of the heaters may be equal in magnitude and opposite in polarity with an average voltage that is substantially at ground potential.
Applying the same voltage potentials to the end portions of all heaters 232A-L
produces voltage potentials along the lengths of the heaters that are substantially the same along the lengths of the heaters. FIG. 12 depicts a cross-section representation, along a vertical plane, such as the plane A-A
shown in FIG. 10, of substantially u-shaped heaters in a hydrocarbon layer. The voltage potential at the cross-sectional point shown in FIG. 12 along the length of heater 232A is substantially the same as the voltage potential at the corresponding cross-sectional points on heaters 232A-L shown in FIG. 12. At lines equidistant between heater wellheads, the voltage potential is approximately zero. Other wells, such as production wells or monitoring wells, may be located along these zero voltage potential lines, if desired. Production wells 206 located close to the overburden may be used to transport formation fluid that is initially in a vapor phase to the surface. Production wells located close to a bottom of the heated portion of the formation may be used to transport formation fluid that is initially in a liquid phase to the surface.
In certain embodiments, the voltage potential at the midpoint of heaters 232A-L is about zero. Having similar voltage potentials along the lengths of heaters 232A-L inhibits current leakage between the heaters. Thus, there is little or no current flow in the formation and the heaters may have long lengths as described above. Having the opposite polarity and substantially equal voltage potentials at the end portions of the heaters also halves the voltage applied at either end portion of the heater versus having one end portion of the heater grounded and one end portion at full potential. Reducing (halving) the voltage potential applied to an end portion of the heater generally reduces current leakage, reduces insulator requirements, and/or reduces arcing distances because of the lower voltage potential to ground applied at the end portions of the heaters.
In certain embodiments, substantially vertical heaters are used to provide heat to the formation. Opposite polarity and substantially equal voltage potentials, as described above, may be applied to the end portions of the substantially vertical heaters. FIG. 13 depicts a side view representation of substantially vertical heaters coupled to a substantially horizontal wellbore. Heaters 232A, 232B, 232C, 232D, 232E, 232F
are located substantially vertical in hydrocarbon layer 246. First end portions of heaters 232A, 232B, 232C, 232D, 232E, 232F are coupled to bus bar 255A on a surface of the formation. Second end portions of heaters 232A, 232B, 232C, 232D, 232E, 232F are coupled to bus bar 255B in contacting section 257.
Bus bar 255B may be a bus bar located in a substantially horizontal wellbore in contacting section 257.
Second end portions of heaters 232A, 232B, 232C, 232D, 232E, 232F may be coupled to bus bar 255B by any method described herein or any method known in the art. For example, containers with thermite powder are coupled to bus bar 255B (for example, by welding or brazing the containers to the bus bar), end portions of heaters 232A, 232B, 232C, 232D, 232E, 232F are placed inside the containers, and the thermite powder is activated to electrically couple the heaters to the bus bar. The containers may be coupled to bus bar 255B by, for example, placing the containers in holes or recesses in bus bar 255B or coupled to the outside of the bus bar and then brazing or welding the containers to the bus bar.
Bus bar 255A and bus bar 255B may be coupled to transformer 254 with cables 250, 252, as described above. Transformer 254 may provide voltages to bar 255A and bus bar 255B as described above for the embodiments depicted in FIGS. 10 and 11. For example, transformer 254 may apply a voltage potential to the first end portions of heaters 232A-F that is opposite in polarity and substantially equal in magnitude to a voltage potential applied to the second end portions of the heaters. Applying the same voltage potentials to the end portions of all heaters 232A-F may produce voltage potentials along the lengths of the heaters that are substantially the same along the lengths of the heaters. Applying the same voltage potentials to the end portions of all heaters 232A-F may inhibit current leakage between the heaters and/or into the formation.
In certain embodiments, it may be advantageous to allow some current leakage into the formation during early stages of heating to heat the formation at a faster rate. Current leakage from the heaters into the formation electrically heats the formation directly. The formation is heated by direct electrical heating in addition to conductive heat provided by the heaters. The formation (the hydrocarbon layer) may have an initial electrical resistance that averages at least 10 ohrnm. In some embodiments, the formation has an initial electrical resistance of at least 100 ohnrm or of at least 300 ohnrm. Direct electrical heating is achieved by having opposite potentials applied to adjacent heaters in the hydrocarbon layer. Current may be allowed to leak into the formation until a selected temperature is reached in the heaters or in the formation. The selected temperature may be below or near the temperature that water proximate one or more heaters boils off. After water boils off, the hydrocarbon layer is substantially electrically isolated from the heaters and direct heating of the formation is inefficient. After the selected temperature is reached, the voltage potential is applied in the opposite polarity and substantially equal magnitude manner described above for FIGS. 10 and 11 so that adjacent heaters will have the same voltage potential along their lengths.
Current is allowed to leak into the formation by reversing the polarity of one or more heaters shown in FIG.
11 so that a first group of heaters has a positive voltage potential at first location 234 and a second group of heaters has a negative voltage potential at the first location. The first end portions, at first location 234, of a first group of heaters (for example, heaters 232A, 232B, 232D, 232E, 232G, 232H, 232J, 232K, depicted in FIG. 11) are applied with a positive voltage potential that is substantially equal in magnitude to a negative voltage potential applied to the second end portions, at second location 238, of the first group of heaters.
The first end portions, at first location 234, of the second group of heaters (for example, heaters 232C, 232F, 2321, 232L) are applied with a negative voltage potential that is substantially equal in magnitude to the positive voltage potential applied to the first end portions of the first group of heaters. Similarly, the second end portions, at second location 238, of the second group of heaters are applied with a positive voltage potential substantially equal in magnitude to the negative potential applied to the second end portions of the first group of heaters. After the selected temperature is reached, the first end portions of both groups of heaters are applied with voltage potential that is opposite in polarity and substantially similar in magnitude to the voltage potential applied to the second end portions of both groups of heaters.
In certain embodiments, heating elements 244 are exposed to hydrocarbon layer 246 and fluids from the hydrocarbon layer. Thus, heating elements 244 are "bare metal" or "exposed metal" heating elements. Heating elements 244 may be made from a material that has an acceptable sulfidation rate at high temperatures used for pyrolyzing hydrocarbons. In certain embodiments, heating elements 244 are made from material that has a sulfidation rate that decreases with increasing temperature over at least a certain temperature range (for example, 530 C to 650 C), such as 410 stainless steel. Using such materials reduces corrosion problems due to sulfur-containing gases (such as H2S) from the formation. Heating elements 244 may also be substantially inert to galvanic corrosion.
In some embodiments, heating elements 244 have a thin electrically insulating layer such as aluminum oxide or thermal spray coated aluminum oxide. In some embodiments, the thin electrically insulating layer is an enamel coating of a ceramic composition. These enamel coatings include, but are not limited to, high temperature porcelain enamels. High temperature porcelain enamels may include silicon dioxide, boron oxide, alumina, and alkaline earth oxides (CaO or MgO), and minor amounts of alkali oxides (Na20, K20, Li0). The enamel coating may be applied as a finely ground slurry by dipping the heating element into the slurry or spray coating the heating element with the slurry. The coated heating element is then heated in a furnace until the glass transition temperature is reached so that the slurry spreads over the surface of the heating element and makes the porcelain enamel coating.
The porcelain enamel coating contracts when cooled below the glass transition temperature so that the coating is in compression. Thus, when the coating is heated during operation of the heater the coating is able to expand with the heater without cracking.
The thin electrically insulating layer has low thermal impedance allowing heat transfer from the heating element to the formation while inhibiting current leakage between heating elements in adjacent openings and current leakage into the formation. In certain embodiments, the thin electrically insulating layer is stable at temperatures above at least 350 C, above 500 C, or above 800 C. In certain embodiments, the thin electrically insulating layer has an emissivity of at least 0.7, at least 0.8, or at least 0.9. Using the thin electrically insulating layer may allow for long heater lengths in the formation with low current leakage.
In certain embodiments, a heater becomes electrically isolated from the formation because the heater has littleorno voltage potential on the outside of the heater. FIG. 14 depicts an embodiment of a substantially u-shaped heater that electrically isolates itself from the formation. Heater 232 has a first end portion at a first opening on surface 236 and a second end portion at a second opening on the surface. In some embodiments, heater 232 has only one end portion coupled to the surface.
Heater 232 includes heating element 244 located in hydrocarbon layer 246.
Heating element 244 is a ferromagnetic conduit heating element or ferromagnetic tubular heating element. In certain embodiments, heating element 244 is a temperature limited heater tubular heating element. In certain embodiments, heating element 244 is a 9% by weight to 13% by weight chromium stainless steel tubular such as a 410 stainless steel tubular, aT/P91 stainless steel tubular, or a T/P92 stainless steel tubular. Heating element 244 is coupled to sections 240. Sections 240 are located in overburden 242. Sections 240 include higher electrical conductivity materials such as copper or aluminum. In certain embodiments, sections 240 are copper clad inside carbon steel.
Center conductor 256 is located at or near a center of heating element 244. In one embodiment, center conductor 256 is an insulated conductor (such as a mineral insulated conductor with a copper core, magnesium oxide insulation, and a stainless steel sheath). In an alternative embodiment, center conductor 256 is a conductor separated from heating element 244 by one or more electrically-insulating centralizers so that the heater is in a conductor-in-conduit configuration. The centralizers may include silicon nitride or another electrically insulating material.
Center conductor 256 is electrically coupled to heating element 244 at an end portion of the center conductor and the heating element at surface 236 (as shown by coupling 258 in FIG. 14). Center conductor 256,is used as a return conductor for heating element 244 so that current in the center conductor flows in an opposite direction from current in the heating element The magnetic field generated by current flow in center conductor 256 substantially confines the flow of electrons and heat generation to the inside of heating element 244 below the Curie temperature of the ferromagnetic material in the heating element. Thus, the outside of heating element 244 is at substantially zero potential and the heating element is electrically isolated from the formation and any adjacent heater or heating element. In some embodiments, a fluid, such as carbon dioxide or another fluid with a high heat capacity, flows through heating element 244 to preheat the formation and/or to recover heat from the heating element.

In certain embodiments, portions of the wellbore that extend through the overburden include casings.
The casings may include materials that inhibit inductive effects in the casings. Inhibiting inductive effects in the casings may inhibit induced currents in the casing and/or reduce heat losses to the overburden. In some embodiments, the overburden casings may include non-metallic materials such as fiberglass, polyvinylchloride (PVC), chlorinated PVC (CPVC), or high-density polyethylene (HDPE). HDPEs with working temperatures in a usable range include HDPEs available from Dow Chemical Co., Inc. (Midland, Michigan, USA). In some embodiments, overburden casings may include non-magnetic metals such as aluminum or non-magnetic alloys such as manganese steels having at least 10% manganese, iron aluminum alloys with at least 18% aluminum, or austentitic stainless steels such as 304 stainless steel or 316 stainless steel. In some embodiments, overburden casings may include carbon steel or other ferromagnetic material coupled on the inside diameter to a highly conductive non-ferromagnetic metal (for example, copper or aluminum) to inhibit inductive effects or skin effects.
In certain embodiments, wellheads for the wellbores may be made of one or more non-ferromagnetic materials. The wellheads may include fiberglass, PVC, CPVC, HDPE, and/or non-magnetic alloys or metals.
Using non-ferromagnetic materials in the wellhead may inhibit undesired heating of components in the wellhead.
Ferromagnetic materials used in the wellhead may be electrically and/or thermally insulated from other components of the wellhead. In some embodiments, an inert gas (for example, nitrogen or argon) is purged inside the wellhead and/or inside of casings to inhibit reflux of heated gases into the wellhead and/or the casings.
In some embodiments, two or more substantially horizontal wellbores are branched off of a first substantially vertical wellbore drilled downwards from a first location on a surface of the formation. The substantially horizontal wellbores may be substantially parallel through a hydrocarbon layer. The substantially horizontal wellbores may reconnect at a second substantially vertical wellbore drilled downwards at a second location on the surface of the formation. Having multiple wellbores branching off of a single substantially vertical wellbore drilled downwards from the surface reduces the number of openings made at the surface of the formation.
Further modifications and alternative embodiments of various aspects of the invention may be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as the presently preferred embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. In addition, it is to be understood that features described herein independently may, in certain embodiments, be combined.

Claims

1. A system for heating a subsurface formation, comprising:
a plurality of elongated resistance heaters located in a plurality of openings in the formation, at least two of the heaters being substantially parallel to each other for at least a portion of the lengths of the heaters;
at least two of the heaters having first end portions in a first location on the surface of the formation and second end portions in a second location on the surface of the formation; and a source of time-varying current configured to apply time-varying current to at least two of the heaters, wherein the first end portions of at least two heaters are configured to have substantially the same voltage applied to the first end portions, and the second portions of at least two heaters are configured to have substantially the same voltage applied to the second end portions, and wherein the system is configured to inhibit current leakage between heaters in the formation.

2. The system of claim 1, wherein the first end portions of the heaters are configured to be applied with a first voltage and the second end portions of the heaters are configured to be applied with a second voltage, and wherein the first voltage is, at a selected point in time on the voltage versus time wave of the first voltage, opposite in polarity to the second voltage, at the selected point in time on the voltage versus time wave of the second voltage.

3. The system of claim 1 or 2, wherein the voltage configured to be applied to the first end portions of the heaters is substantially equal in magnitude to the voltage configured to be applied to the second end portions of the heaters.

4. The system of any one of claims 1-3, wherein the voltage at a selected distance along the length of a first heater of the one or more heaters is similar to or at substantially the same voltage potential as a corresponding point at the selected distance along the length of a second heater of the one or more heaters.

5. The system of any one of claims 1-4, wherein at least two heaters have substantially similar electrical resistivities along at least a portion of the length of the heaters.

6. The system of any one of claims 1-5, wherein at least one of the heaters has a substantially uniform electrical resistivity along a heated portion of the heater.

7. The system of any one of claims 1-6, further comprising at least one superconducting cable electrically coupled between the source of time-varying current and at least one of the heaters.

8. The system of any one of claims 1-7, further comprising at least one bus bar or at least one superconducting bus bar electrically coupled between the source of time-varying current and one or more of the heaters.

9. The system of any of one of claims 1-8, wherein the source of time-varying current comprises an electrically isolated, single-phase transformer.

10. The system of claim 9, wherein the first end portions of the heaters are electrically coupled to one side of the transformer, and the second end portions of the heaters are electrically coupled to the opposite side of the transformer.

11 . The system of any one of claims 1-10, wherein the first end portions of the heaters are configured to be applied with a first voltage and the second end portions of the heaters are configured to be applied with a second voltage, wherein the first voltage is equal in magnitude and opposite in polarity to the second voltage, with an average voltage that is substantially at ground potential.

12. The system of any one of claims 1-11, wherein the source of time-varying current is configured to apply voltage from the isolated secondary phase of the source.

13. The system of any one of claims 1-12, wherein the elongated heaters comprise heated portions that are substantially horizontal in at least a portion of the formation.

14. The system of any one of claims 1-12, wherein the elongated heaters comprise heated portions that are substantially vertical in at least a portion of the formation.

15. The system of any one of claims 1-12, wherein at least one opening comprises a u-shaped opening.

16. The system of any one of claims 1-15, wherein at least one elongated heater comprises a temperature limited heater, the temperature limited heater comprising a ferromagnetic conductor and is configured to provide, when a time varying current is applied to the temperature limited heater, and when the heater is below a selected temperature, an electrical resistance and, when the ferromagnetic conductor is at or above the selected temperature, the temperature limited heater automatically provides a reduced electrical resistance.

17. A method for heating a subsurface formation using the system in any one of claims 1-16, the method comprising:
applying the substantially same voltage to the first end portions of the heaters; and applying the substantially same voltage to the second end portions of the heaters.

18. The method of claim 17, wherein the first voltage potential is substantially equal in magnitude to the second voltage potential at the selected point in time.

19. The method of any one of claims 17 or 18, further comprising applying the voltages with an electrically isolated single-phase transformer.

20. The method of any one of claims 17-19, further comprising providing heat to at least a portion of a hydrocarbon layer in the formation using the heaters.

21. The method of claim 20, wherein the hydrocarbon layer has an initial electrical resistance of at least 10 ohm.m, at least 100 ohm.m, or of at least 300 ohm.m.

22. The method of any one of claims 17-21, further comprising providing heat to at least a portion of a hydrocarbon layer in the formation using the heaters such that at least some hydrocarbons in the layer are pyrolyzed.

23. The method as claimed in any one of claims 20-22, further comprising producing a fluid from the formation.

24. The method as claimed in any of claims 1 to 23, further comprising producing from the fluid a transportation fuel.

25. A system for heating a subsurface formation, comprising;
a plurality of first elongated heaters located in a plurality of first openings in the formation, at least two of the first heaters being substantially parallel to each other for at least a portion of the lengths of the heaters;
a plurality of second elongated heaters located in a plurality of second openings in the formation, at least two of the second heaters being substantially parallel to each other for at least a portion of the lengths of the heaters;
at least two of the first heaters and at least two of the second heaters having first end portions in a first region of the formation and second end portions in a second region of the formation; and a source of time-varying current configured to apply time-varying current to at least two of the heaters;
wherein the first end portions of the first heaters are configured to be applied with a first voltage that is opposite in polarity to a second voltage configured to be applied to the first end portions of the second heaters; and the second voltage is configured to be applied to the second end portions of the first heaters, and wherein the system is configured to inhibit current leakage between heaters in the formation.

26. The system of claim 25, wherein the first voltage is substantially equal in magnitude to the second voltage.

27. The system of any one of claims 25 or 26, wherein at least two heaters have substantially similar electrical resistivities along at least a portion of the length of the heaters.

28. The system of any one of claims 25-27, wherein at least one of the heaters has a substantially uniform electrical resistivity along a heated portion of the heater.

29. The system of any one of claims 25-28, further comprising at least one superconducting cable electrically coupled between the source of time-varying current and at least one of the heaters.

30. The system of any one of claims 25-29, further comprising at least one bus bar or at least one superconducting bus bar electrically coupled between the source of time-varying current and one or more of the heaters.

31. The system of any one of claims 25-30, wherein the source of time-varying current comprises an electrically isolated, single-phase transformer.

32. The system of any one of claims 25-31, wherein the elongated heaters comprise heated portions that are substantially horizontal in at least a portion of the formation.

33. The system of any one of claims 25-32, wherein the elongated heaters comprise heated portions that are substantially vertical in at least a portion of the formation.

34. The system of any one of claims 25-33, wherein at least one elongated heater comprises a temperature limited heater, the temperature limited heater comprising a ferromagnetic conductor and is configured to provide, when a time varying current is applied to the temperature limited heater, and when the heater is below a selected temperature, an electrical resistance and, when the ferromagnetic conductor is at or above the selected temperature, the temperature limited heater automatically provides a reduced electrical resistance.

35. The system of any one of claims 25-34, wherein the first voltage is configured to be applied to the second end portions of the second heaters.

36. The system of any one of claims 25-35, wherein the system is configured to allow current leakage between heaters in the formation.

37. A method for heating a subsurface formation using the system in any one of claims 25-36, the method comprising:
applying the first voltage to the first end portions of the first heaters;
applying the second voltage to the second end portions of the first heaters;
applying the second voltage to the first end portions of the second heaters;
and applying the first voltage to the second end portions of the second heaters until at least one of the heaters, or at least a portion of the formation, reaches a selected temperature.

38. The method of claim 37, wherein the second voltage is substantially equal in magnitude to the first voltage.

39. The method of any one of claims 37 or 38, wherein the selected temperature is at or near the boiling point of water at or near at least one of the heaters.

40. The method of any one of claims 37-39, further comprising, when at least one heater reaches the selected temperature, applying the first voltage to the first end portions of the first heaters and the first end portions of the second heaters, and applying the second voltage to the second end portions of the first heaters and the second end portions of the second heaters.

41. The method of any one of claims 37-40, further comprising providing heat to at least a portion of a hydrocarbon layer in the formation using the heaters.

42. The method of claim 41, wherein the hydrocarbon layer has an initial electrical resistance of at least 10 ohm.m, at least 100 ohm.m, or of at least 300 ohm.m.

43. The method of any one of claims 37-42, further comprising providing heat to at least a portion of a hydrocarbon layer in the formation using the heaters such that at least some hydrocarbons in the layer are pyrolyzed.

44. The method as claimed in any one of claims 37-43, further comprising producing a fluid from the formation.

45. The method as claimed in any one of claims 37-44, further comprising producing from the fluid a transportation fuel.

46. A system for heating a hydrocarbon containing formation, comprising:
a plurality of openings in the formation, the openings having first end portions and second end portions;
one or more heaters in the openings, the one or more heaters having first end portions and second end portions; and wherein the first end portions of the heaters are configured to be applied with a first voltage potential that is opposite in polarity to a second voltage potential, and wherein the system is configured to inhibit current leakage between heaters in the formation.