SYSTEM, METHOD AND APPARATUS FOR HYDROGEN-OXYGEN BURNER IN DOWNHOLE STEAM GENERATOR

• US 20080083537A1
• Filed: 10/08/2007
• Published: 04/10/2008
• Est. Priority Date: 10/09/2006
• Status: Active Grant

• Current Assignee: World Energy Systems, Inc.
• Original Assignee: World Energy Systems, Inc.
• Inventors: Gokulakrishan, Ponnuthurai, Ware, Charles H., Klassen, Michael, Langdon, John E., Hamer, Andrew, Fuller, Casey
• Granted Patent: US 7,770,646 B2
• Time in Patent Office: Days
• US Class Current: 166/302
• CPC Class Codes: E21B 43/164 Injecting CO2 or carbonated water in combination with organic material C09K8/594
• CPC Class Codes: E21B 43/24 using heat, e.g. steam injection
• CPC Class Codes: E21B 43/243 Combustion in situ

Abstract

A downhole burner for a steam generator includes an injector and a cooling liner. Steam enters the burner through holes in the cooling liner. Combustion occurring within the cooling liner heats the steam and increases its quality and may superheat it. The heated, high-quality steam and combustion products exit the burner and enter an oil-bearing formation to upgrade and improve the mobility of heavy crude oils held in the formation. The injector includes a face plate, a cover plate, an oxidizer distribution manifold plate, and a fuel distribution manifold plate. The cooling liner has an effusion cooling section and effusion cooling and jet mixing section. The effusion cooling section includes effusion holes for injecting steam along the cooling liner surface to protect the liner. The effusion cooling and jet mixing section has both effusion holes and mixing holes for injecting steam further toward central portions of the burner.

Claims

1. A downhole burner for a well, comprising:

a burner casing;

a liner coupled to the burner casing for combusting the fuel and oxidizer;

an injector coupled to the burner casing for injecting a fuel and an oxidizer into the liner;

a steam channel located inside the burner casing and surrounding exterior surfaces of the injector and the liner; and

the liner having a plurality of holes for communicating steam from the steam channel to an interior of the liner downstream from the injector, such that the steam is superheated by combustion of the fuel and oxidizer to increase a steam quality of the steam, the combusted fuel and oxidizer and the superheated steam exiting the liner to enter an oil-bearing formation to upgrade and improve a mobility of heavy crude oils held in the oil-bearing formation.

2. A downhole burner according to claim 1, wherein the liner comprises an effusion cooling section located adjacent to the injector, and an effusion cooling and jet mixing section located adjacent to the effusion cooling section.

3. A downhole burner according to claim 2, wherein the effusion cooling section has a plurality of effusion holes that inject small jets of steam through the liner to provide a layer of cooler gases to protect the liner.

4. A downhole burner according to claim 3, wherein the effusion holes extend through the liner at a 20°

angle relative to a longitudinal axis of the liner and are oriented to inject steam downstream of the injector, for moving the injected steam along an interior wall of the liner to lower a temperature thereof.

5. A downhole burner according to claim 2, wherein the effusion cooling and jet mixing section has a plurality of effusion holes and a plurality of mixing holes, the mixing holes being larger than the effusion holes, and the mixing holes being oriented at a 90°

angle relative to an internal surface of the liner to inject steam further toward a longitudinal axis of the liner.

6. A downhole burner according to claim 1, wherein the injector comprises an injector face plate having a plurality of injection holes for injecting the fuel and oxidizer into the burner, the injector face plate also having an igniter for igniting the fuel and oxidizer injected into the burner.

7. A downhole burner according to claim 6, wherein a gap is formed between an outer diameter of the injector face plate and an inner diameter of the liner so that steam can leak past and cool the injector face plate.

8. A downhole burner according to claim 7, wherein the burner casing and the liner each have a wall thickness of about 0.125 inches, the steam channel has an annular width between the liner and the burner casing of about 0.375 inches, and the gap has a width of about 0.050 inches.

9. A downhole burner according to claim 6, wherein the injector face plate has fuel holes and oxidizer holes, each of which is arranged in concentric rings to produce a shower head stream pattern of fuel and oxidizer to move streams of the fuel and oxidizer away from the injector face plate, such that a stand-off distance is provided between a flame of the combusted fuel and oxidizer and the injector face plate to reduce a temperature of the injector face plate.

10. A downhole burner according to claim 1, wherein the injector comprises (a) a cover plate having an oxidizer inlet, (b) an oxidizer distribution manifold plate having an oxidizer manifold and oxidizer holes coupled to the oxidizer inlet, and (c) a fuel distribution manifold plate having oxidizer holes, a fuel inlet, a fuel manifold for routing fuel through an interior of the fuel distribution manifold plate for cooling the fuel distribution plate, and fuel holes.

11. A downhole burner according to claim 1, wherein the injector comprises a cover plate on top of an oxidizer distribution manifold plate, the oxidizer distribution manifold plate is on top of a fuel distribution manifold plate, and the fuel distribution manifold plate is on top of an injector face plate.

13. A system according to claim 1, wherein the liner comprises an effusion cooling section located adjacent to the injector, and an effusion cooling and jet mixing section located adjacent to the effusion cooling section.

14. A system according to claim 13, wherein the effusion cooling section has a plurality of effusion holes that inject small jets of steam through the liner to provide a layer of cooler gases to protect the liner, and the gap has a width of about 0.050 inches.

15. A system according to claim 14, wherein the effusion holes extend through the liner at a 20°

angle relative to a longitudinal axis of the liner and are oriented to inject steam downstream of the injector, such that the injected steam moves along an interior wall of the liner to lower a temperature thereof.

16. A system according to claim 13, wherein approximately 37.5% of the steam provided through the steam channel is injected into the liner by the effusion cooling section.

17. A system according to claim 13, wherein the effusion cooling and jet mixing section has a plurality of effusion holes and a plurality of mixing holes, the mixing holes being larger than the effusion holes, and the mixing holes being oriented at a 90°

angle relative to an internal surface of the liner to inject steam further toward a longitudinal axis of the liner.

12. A system for producing viscous hydrocarbons from a well having a casing, comprising:

a plurality of conduits for delivering fuel, an oxidizer and steam from a surface down through the casing;

a downhole burner secured to the plurality of conduits, the downhole burner comprising;

a burner casing;

an injector coupled to the plurality of conduits for injecting the fuel and oxidizer into the well;

a liner coupled to the burner casing located below the injector for combusting the fuel and oxidizer, the liner having an interior that defines a gap between the interior and an exterior of the injector for permitting steam to leak past and cools the injector;

a steam channel located inside the burner casing and surrounding exterior surfaces of the injector and the liner; and

the liner having a plurality of holes for communicating steam from the steam channel to an interior of the liner downstream from the injector, such that the steam is superheated by combustion of the fuel and oxidizer to increase a steam quality of the steam, the combusted fuel and oxidizer and the superheated steam exiting the liner to enter an oil-bearing formation to upgrade and improve a mobility of heavy crude oils held in the oil-bearing formation.

18. A system according to claim 12, wherein the steam has a steam quality of approximately 80% to 100% formed at the surface of the well that is fluidly communicated to the steam channel at a pressure of about 1600 psi.

19. A system according to claim 18, wherein the steam arriving at the steam channel has a steam quality of about 50% to 90%.

20. A system according to claim 12, wherein the downhole burner has a power output of approximately 13 MMBtu/hr for producing about 3200 bpd of superheated steam with an outlet temperature of about 700°

F. at full load.

21. A system according to claim 12, wherein the injector comprises an injector face plate having a plurality of injection holes for injecting the fuel and oxidizer into the burner, the injector face plate also having an igniter for igniting the fuel and oxidizer injected into the burner.

22. A system according to claim 12, wherein a nanocatalyst is injected into the oil-bearing formation to promote converting and upgrading the hydrocarbon downhole.

23. A system according to claim 21, wherein the injector face plate has fuel holes and oxidizer holes, each of which is arranged in concentric rings to produce a shower head stream pattern of fuel and oxidizer to move streams of the fuel and oxidizer away from the injector face plate, such that a stand-off distance is provided between a flame of the combusted fuel and oxidizer and the injector face plate to reduce a temperature of the injector face plate.

24. A system according to claim 12, wherein the injector comprises (a) a cover plate having an oxidizer inlet, (b) an oxidizer distribution manifold plate having an oxidizer manifold and oxidizer holes coupled to the oxidizer inlet, and (c) a fuel distribution manifold plate having oxidizer holes, a fuel inlet, a fuel manifold for routing fuel through an interior of the fuel distribution manifold plate for cooling the fuel distribution plate, and fuel holes.

25. A system according to claim 12, wherein the injector comprises a cover plate on top of an oxidizer distribution manifold plate, the oxidizer distribution manifold plate is on top of a fuel distribution manifold plate, and the fuel distribution manifold plate is on top of an injector face plate.

26. A system according to claim 12, further comprising a separate CO₂ conduit for injecting CO₂ into at least one location of the downhole burner, including the injector, a head end of the liner, through the liner, and at an exit of the liner prior to a packer in the casing.

27. A method of producing viscous hydrocarbons from a well having a casing, comprising:

(a) providing a downhole burner having a burner casing, an injector, and a liner;

(b) lowering the downhole burner into the well;

(c) delivering fuel, an oxidizer and steam from a surface down through the casing to the downhole burner;

(d) injecting the fuel and oxidizer into the downhole burner with the injector;

(e) combusting the fuel and oxidizer with the liner;

(f) delivering steam through a steam channel located between the burner casing and the injector and liner;

(g) injecting steam from the steam channel, through holes in the liner, to an interior of the liner to superheat the steam with the combusted fuel and oxidizer to increase a steam quality of the steam; and

(h) releasing the combusted fuel and oxidizer and the superheated steam from the liner into an oil-bearing formation to upgrade and improve a mobility of heavy crude oils held in the oil-bearing formation.

28. A method according to claim 27, wherein step (g) further comprises leaking steam past the injector and cooling the injector with a gap located between an interior of the liner and an exterior of the injector.

29. A method according to claim 27, wherein the liner comprises an effusion cooling section located adjacent to the injector, and an effusion cooling and jet mixing section located adjacent to the effusion cooling section, the effusion cooling section having a plurality of effusion holes that inject small jets of steam through the liner to provide a layer of cooler gases to protect the liner.

30. A method according to claim 29, wherein the effusion holes extend through the liner at a 20°

angle relative to a longitudinal axis of the liner and are oriented to inject steam downstream of the injector, such that the injected steam moves along an interior wall of the liner to lower a temperature thereof.

31. A method according to claim 29, further comprising injecting water into the downhole burner and cooling the liner with the water.

32. A method according to claim 29, wherein the effusion cooling and jet mixing section has a plurality of effusion holes and a plurality of mixing holes, the mixing holes being larger than the effusion holes, and the mixing holes being oriented at a 90°

angle relative to an internal surface of the liner to inject steam further toward a longitudinal axis of the liner.

33. A method according to claim 27, wherein the steam has a steam quality of approximately 80% to 100% formed at the surface of the well that is fluidly communicated to the steam channel at a pressure of about 1600 psi.

34. A method according to claim 33, wherein the steam arriving at the steam channel has a steam quality of about 70% to 90%, and wherein approximately 37.5% of the steam provided through the steam channel is injected into the liner by the effusion cooling section.

35. A method according to claim 27, wherein the downhole burner has a power output of approximately 13 MMBtu/hr for producing about 3200 bpd of superheated steam with an outlet temperature of about 700°

F.

36. A method according to claim 27, wherein the injector comprises an injector face plate having a plurality of injection holes for injecting the fuel and oxidizer into the burner, the injector face plate also having an igniter for igniting the fuel and oxidizer injected into the burner.

37. A method according to claim 27, further comprising injecting a nanocatalyst into the oil-bearing formation to promote converting and upgrading the hydrocarbon downhole.

38. A method according to claim 36, wherein the injector face plate has fuel holes and oxidizer holes, each of which is arranged in concentric rings to produce a shower head stream pattern of fuel and oxidizer to move streams of the fuel and oxidizer away from the injector face plate, such that a stand-off distance is provided between a flame of the combusted fuel and oxidizer and the injector face plate to reduce a temperature of the injector face plate.

39. A method according to claim 27, wherein the injector comprises (a) a cover plate having an oxidizer inlet, (b) an oxidizer distribution manifold plate having an oxidizer manifold and oxidizer holes coupled to the oxidizer inlet, and (c) a fuel distribution manifold plate having oxidizer holes, a fuel inlet, a fuel manifold for routing fuel through an interior of the fuel distribution manifold plate for cooling the fuel distribution plate, and fuel holes.

40. A method according to claim 27, wherein the well comprises a wellbore configuration selected from the group consisting of vertical, horizontal, SAGD, and combinations thereof.

41. A method according to claim 27, further comprising a separate CO₂ conduit for injecting CO₂ into at least one location of the downhole burner, including the injector, a head end of the liner, through the liner, and at an exit of the liner prior to a packer in the casing.

42. A system for producing viscous hydrocarbons from a well having a casing, comprising:

a plurality of conduits for delivering fuel, an oxidizer, CO₂ and steam from a surface down through the casing;

a downhole burner secured to the plurality of conduits, the downhole burner comprising;

a burner casing;

an injector coupled to the plurality of conduits for injecting the fuel, oxidizer and CO₂ into the well;

a liner coupled to the burner casing located below the injector for combusting the fuel and oxidizer and releasing exhaust gases including the CO₂, the liner having an interior that defines a gap between the interior and an exterior of the injector for permitting steam to leak past and cools the injector;

a steam channel located inside the burner casing and surrounding exterior surfaces of the injector and the liner;

the liner having a plurality of holes for communicating steam from the steam channel to an interior of the liner downstream from the injector, such that the exhaust gases and the steam cool the liner, and the steam is superheated by the combusted fuel and oxidizer to increase a steam quality of the steam; and

the exhaust gases and the superheated steam exiting the liner to enter an oil-bearing formation to upgrade and improve a mobility of heavy crude oils held in the oil-bearing formation.

43. A system according to claim 42, wherein the liner comprises an effusion cooling section located adjacent to the injector, and an effusion cooling and jet mixing section located adjacent to the effusion cooling section.

44. A system according to claim 43, wherein the effusion cooling section has a plurality of effusion holes that inject small jets of steam through the liner to provide a layer of cooler gases to protect the liner, and the effusion holes extend through the liner at a 20°

angle relative to a longitudinal axis of the liner and are oriented to inject steam downstream of the injector, such that the injected steam moves along an interior wall of the liner to lower a temperature thereof.

45. A system according to claim 43, wherein the effusion cooling and jet mixing section has a plurality of effusion holes and a plurality of mixing holes, the mixing holes being larger than the effusion holes, and the mixing holes being oriented at a 90°

angle relative to an internal surface of the liner to inject steam further toward a longitudinal axis of the liner.

46. A system according to claim 42, wherein the injector comprises an injector face plate having a plurality of injection holes for injecting the fuel and oxidizer into the burner, the injector face plate also having an igniter for igniting the fuel and oxidizer injected into the burner, the burner casing and the liner each have a wall thickness of about 0.125 inches, the steam channel has an annular width between the liner and the burner casing of about 0.375 inches, and the gap has a width of about 0.050 inches.

47. A system according to claim 46, wherein the injector face plate has fuel holes and oxidizer holes, each of which is arranged in concentric rings to produce a shower head stream pattern of fuel and oxidizer to move streams of the fuel and oxidizer away from the injector face plate, such that a stand-off distance is provided between a flame of the combusted fuel and oxidizer and the injector face plate to reduce a temperature of the injector face plate.

48. A system according to claim 42, wherein the injector comprises (a) a cover plate having an oxidizer inlet, the cover plate is located on (b) an oxidizer distribution manifold plate having an oxidizer manifold and oxidizer holes coupled to the oxidizer inlet, and the oxidizer distribution manifold plate is on top of (c) a fuel distribution manifold plate having oxidizer holes, a fuel inlet, a fuel manifold for routing fuel through an interior of the fuel distribution manifold plate for cooling the fuel distribution plate, and fuel holes, and the fuel distribution manifold plate is located on top of (d) an injector face plate.