In situ thermal processing of a hydrocarbon containing formation to produce a hydrocarbon condensate

• US 6,688,387 B1
• Filed: 04/24/2001
• Issued: 02/10/2004
• Est. Priority Date: 04/24/2000
• Status: Expired due to Term

• Current Assignee: Salamander Solutions Inc.
• Original Assignee: Shell Oil Company (Shell Plc)
• Inventors: Karanikas, John Michael, de Rouffignac, Eric Pierre, Wellington, Scott Lee, Ryan, Robert Charles, Fowler, Thomas David, Stegemeier, George Leo, Berchenko, Ilya Emil, Zhang, Etuan, Shahin, Gordon Thomas Jr., Vinegar, Harold J.
• Primary Examiner(s): SUCHFIELD, GEORGE A
• Application Number:
  US09/841,432
• Publication Number:
  US 20040015023A1
• Time in Patent Office: 1,022 Days
• Field of Search: 166/57, 166/59, 166/60, 166/245, 166/251.1, 166/256, 166/261, 166/266, 166/267, 166/272.1, 166/302
• US Class Current: 166/245
• CPC Class Codes: C09K 8/592 Compositions used in combination with generated heat, e.g. by steam injection
• CPC Class Codes: E21B 36/001 Cooling arrangements
• CPC Class Codes: E21B 36/04 using electrical heaters
• CPC Class Codes: E21B 41/0057 Disposal of a fluid by injection into a subterranean formation
• CPC Class Codes: E21B 43/24 using heat, e.g. steam injection
• CPC Class Codes: E21B 43/2401 by means of electricity
• CPC Class Codes: E21B 43/243 Combustion in situ
• CPC Class Codes: E21B 43/247 in association with fracturing processes or crevice forming processes
• CPC Class Codes: E21B 43/30 Specific pattern of wells, e.g. optimising the spacing of wells
• CPC Class Codes: Y02C 20/40 of CO2
• CPC Class Codes: Y02P 20/582 Recycling of unreacted starting or intermediate materials
• CPC Class Codes: Y10S 48/06 Underground gasification of coal

Abstract

A hydrocarbon containing formation may be treated using an in situ thermal process. Hydrocarbons, H₂, and/or other formation fluids may be produced from the formation. Heat may be applied to the formation to raise a temperature of a portion of the formation to a pyrolysis temperature. Heat input into the formation may be controlled to raise a temperature of the formation at a selected rate.

Claims

1. A method of treating a hydrocarbon containing formation in situ, comprising:

providing heat from one or more heaters to at least a portion of the formation;

allowing the heat to transfer from at least the portion to a part of the formation substantially by conduction of heat;

pyrolyzing at least some hydrocarbons within the part of the formation;

controlling a pressure within the part of the formation, wherein the controlled pressure is at or above a selected value; and

producing a mixture from the formation.

2. The method of claim 1, wherein the one or more heaters comprise at least two heaters, and wherein controlled superposition of heat from at least the two heaters pyrolyzes at least some hydrocarbons within the part of the formation.

3. The method of claim 1, wherein at least one of the one or more heaters comprises an electrical heater.

4. The method of claim 1, wherein at least one of the one or more heaters comprises a surface burner.

5. The method of claim 1, wherein at least one of the one or more heaters comprises a flameless distributed combustor.

6. The method of claim 1, wherein at least one of the one or more heaters comprises a natural distributed combustor.

7. The method of claim 1, further comprising controlling a pressure and a temperature within at least a majority of the part of the formation, wherein the pressure is controlled as a function of temperature, or the temperature is controlled as a function of pressure.

8. The method of claim 1, further comprising controlling the heat such that an average heating rate of the part of the formation is less than about 1.0°

C. per day in a pyrolysis temperature range of about 270°

C. to about 400°

C.

9. The method of claim 1, wherein providing heat from the one or more heaters to at least the portion of the formation comprises:

heating a selected volume (V) of the hydrocarbon containing formation from the one or more heaters, wherein the formation has an average heat capacity (C_ν

), and wherein the heating pyrolyzes at least some hydrocarbons within the selected volume of the formation; and

wherein heating energy/day (Pwr) provided to the selected volume is equal to or less than h*V*C_ν

*ρ

_B, wherein ρ

_B is formation bulk density, and wherein an average heating rate (h) of the selected volume is about 10°

C./day.

10. The method of claim 1, wherein providing heat from the one or more heaters comprises heating the part of the formation such that a thermal conductivity of at least a portion of the part of the formation is greater than about 0.5 W/(m °

C.).

11. The method of claim 1, wherein the produced mixture comprises condensable hydrocarbons having an API gravity of at least about 25°

.

12. The method of claim 1, wherein the produced mixture comprises condensable hydrocarbons, and wherein about 0.1% by weight to about 15% by weight of the condensable hydrocarbons are olefins.

13. The method of claim 1, wherein the produced mixture comprises non-condensable hydrocarbons, and wherein a molar ratio of ethene to ethane in the non-condensable hydrocarbons ranges from about 0.001 to about 0.15.

14. The method of claim 1, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 1% by weight, when calculated on an atomic basis, of the condensable hydrocarbons is nitrogen.

15. The method of claim 1, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 1% by weight, when calculated on an atomic basis, of the condensable hydrocarbons is oxygen.

16. The method of claim 1, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 1% by weight, when calculated on an atomic basis, of the condensable hydrocarbons is sulfur.

17. The method of claim 1, wherein the produced mixture comprises condensable hydrocarbons, wherein about 5% by weight to about 30% by weight of the condensable hdrocarbons comprise oxygen containing compounds, and wherein the oxygen containing compounds comprise phenols.

18. The method of claim 1, wherein the produced mixture comprises condensable hydrocarbons, and wherein greater than about 20% by weight of the condensable hydrocarbons are aromatic compounds.

19. The method of claim 1, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 5% by weight of the condensable hydrocarbons comprises multi-ring aromatics with more than two rings.

20. The method of claim 1, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 0.3% by weight of the condensable hydrocarbons are asphaltenes.

21. The method of claim 1, wherein the produced mixture comprises condensable hydrocarbons, and wherein about 5% by weight to about 30% by weight of the condensable hydrocarbons are cycloalkanes.

22. The method of claim 1, wherein the produced mixture comprises a non-condensable component, wherein the non-condensable component comprises molecular hydrogen, wherein the molecular hydrogen is greater than about 10% by volume of the non-condensable component, and wherein the molecular hydrogen is less than about 80% by volume of the non-condensable component at 25°

C. and one atmosphere absolute pressure.

23. The method of claim 1, wherein the produced mixture comprises amnmonia, and wherein greater than about 0.05% by weight of the produced mixture is ammonia.

24. The method of claim 1, wherein the produced mixture comprises ammonia, and wherein the ammonia is used to produce fertilizer.

25. The method of claim 1, wherein the pressure is controlled within at least a majority of the part of the formation, wherein the controlled pressure is at least about 2.0 bar absolute.

26. The method of claim 1, further comprising controlling formation conditions to produce a mixture of condensable hydrocarbons and H₂, wherein a partial pressure of H₂ within the mixture is greater than about 0.5 bar.

27. The method of claim 1, wherein the partial pressure of H₂ is measured when the mixture is at a production well.

28. The method of claim 1, further comprising altering a pressure within the formation to inhibit production of hydrocarbons from the formation having carbon numbers greater than about 25.

29. The method of claim 1, further comprising controlling formation conditions, wherein controlling formation conditions comprises recirculating a portion of hydrogen from the mixture into the formation.

30. The method of claim 1, further comprising:

providing hydrogen (H₂) to the part of the formation to hydrogenate hydrocarbons within the part of the formation; and

heating a portion of the part of the formation with heat from hydrogenation.

31. The method of claim 1, wherein the produced mixture comprises hydrogen and condensable hydrocarbons, the method further comprising hydrogenating a portion of the produced condensable hydrocarbons with at least a portion of the produced hydrogen.

32. The method of claim 1, wherein allowing the heat to transfer comprises increasing a permeability of a majority of the part of the formation to greater than about 100 millidarcy.

33. The method of claim 1, wherein allowing the heat to transfer comprises increasing a permeability of a majority of,the part of the formation such that the permeability of the majority of the part of the formation is substantially uniform.

34. The method of claim 1, further comprising controlling the heat to yield greater than about 60% by weight of condensable hydrocarbons, as measured by the Fischer Assay.

35. The method of claim 1, wherein producing the mixture comprises producing the mixture in a production well, and wherein at least about 7 heaters are disposed in the formation for each production well.

36. The method of claim 1, further comprising providing heat from three or more eaters to at least a portion of the formation, wherein three or more of the heaters are located in the formation in a unit of heaters, and wherein the unit of heaters comprises a triangular pattern.

37. The method of claim 1, further comprising providing heat from three or more heaters to at least a portion of the formation, wherein three or more of the heaters are located in the formation in a unit of heaters, wherein the unit of heaters comprises a triangular pattern, and wherein a plurality of the units are repeated over an area of the formation to form a repetitive pattern of units.

38. The method of claim 1, wherein at least about 20 heaters are disposed in the formation for each production well.

39. The method of claim 1, wherein the selected pressure is about 2.0 bar absolute.

40. The method of claim 1, wherein the mixture produced from the formation comprises hydrocarbons produced by pyrolyzing at least some hydrocarbons within the part of the formation.

41. A method of treating a hydrocarbon containing formation in situ, comprising:

providing heat from one or more heaters to at least a portion of the formation;

allowing the heat to transfer from at least the portion to a selected section of the formation substantially by conduction of heat;

pyrolyzing at least some hydrocarbons within the selected section of the formation;

controlling a pressure within the selected section of the formation, wherein the controlled pressure is at or above a selected value; and

producing a mixture from the formation.

42. The method of claim 41, wherein the one or more heaters comprise at least two heaters, and wherein controlled superposition of heat from at least the two heaters pyrolyzes at least some hydrocarbons within the selected section of the formation.

43. The method of claim 41, wherein at least one of the one or more heaters comprises a natural distributed combustor.

44. The method of claim 41, further comprising controlling a pressure and a temperature within at least a majority of the selected section of the formation, wherein the pressure is controlled as a function of temperature, or the temperature is controlled as a function of pressure.

45. The method of claim 41, further comprising controlling the heat such that an average heating rate of the selected section is less than about 1.0°

C. per day in a pyrolysis temperature range of about 270°

C. to about 00°

C.

46. The method of claim 41, wherein providing heat from one or more of the heaters to at least the portion of the formation comprises:

heating a selected volume (V) of the hydrocarbon containing formation from one or more of the heaters, wherein the formation has an average heat capacity (C_ν

), and wherein the heating pyrolyzes at least some hydrocarbons within the selected volume of the formation; and

wherein heating energy/day (Pwr) provided to the selected volume is equal to or less than h*V*C_ν

*ρ

_B, wherein ρ

_B is formation bulk density, and wherein an average heating rate (h) of the selected volume is about 10°

C./day.

47. The method of claim 41, wherein providing heat from the one or more heaters comprises heating the selected section such that a thermal conductivity of at least a portion of the selected section is greater than about 0.5 W/(m °

C.).

48. The method of claim 41, wherein the produced mixture comprises condensable hydrocarbons having an API gravity of at least about 25°

.

49. The method of claim 41, wherein the produced mixture comprises condensable hydrocarbons, and wherein about 0.1% by weight to about 15% by weight of the condensable hydrocarbons are olefins.

50. The method of claim 41, wherein the produced mixture comprises non-condensable hydrocarbons, and wherein a molar ratio of ethene to ethane in the non-condensable hydrocarbons ranges from about 0.001 to about 0.15.

51. The method of claim 41, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 1% by weight, when calculated on an atomic basis, of the condensable hydrocarbons is nitrogen.

52. The method of claim 41, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 1% by weight, when calculated on an atomic basis, of the condensable hydrocarbons is oxygen.

53. The method of claim 41, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 1% by weight, when calculated on an atomic basis, of the ndensable hydrocarbons is sulfur.

54. The method of claim 41, wherein the produced mixture comprises condensable hydrocarbons, wherein about 5% by weight to about 30% by weight of the condensable hydrocarbons comprise oxygen containing compounds, and wherein the oxygen containing compounds comprise phenols.

55. The method of claim 41, wherein the produced mixture comprises condensable hydrocarbons, and wherein greater than about 20% by weight of the condensable hydrocarbons are aromatic compounds.

56. The method of claim 41, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 5% by weight of the condensable hydrocarbons comprises multi-ring aromatics with more than two rings.

57. The method of claim 41, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 0.3% by weight of the condensable hydrocarbons are asphaltenes.

58. The method of claim 41, wherein the produced mixture comprises condensable hydrocarbons, and wherein about 5% by weight to about 30% by weight of the condensable hydrocarbons are cycloalkanes.

59. The method of claim 41, wherein the produced mixture comprises a non-condensable component, wherein the non-condensable component comprises molecular hydrogen, wherein the molecular hydrogen is greater than about 10% by volume of the non-condensable component, and wherein the molecular hydrogen is less than about 80% by volume of the non-condensable component at 25°

C. and one atmosphere absolute pressure.

60. The method of claim 41, wherein the produced mixture comprises ammonia, and wherein greater than about 0.05% by weight of the produced mixture is ammonia.

61. The method of claim 41, wherein the produced mixture comprises ammonia, and wherein the ammonia is used to produce fertilizer.

62. The method of claim 41, wherein the pressure is controlled within at least a majority of the selected section of the formation, wherein the controlled pressure is at least about 2.0 bar absolute.

63. The method of claim 41, further comprising controlling formation conditions to produce a mixture of condensable hydrocarbons and H₂, wherein a partial pressure of H₂ within the mixture is greater than about 0.5 bar.

64. The method of claim 41, wherein at least about 20 heaters are disposed in the formation for each production well.

65. The method of claim 63, wherein the partial pressure of H₂ is measured when the mixture is at a production well.

66. The method of claim 63, wherein controlling formation conditions comprises recirculating a portion of hydrogen from the mixture into the formation.

67. The method of claim 41, further comprising altering a pressure within the formation to inhibit production of hydrocarbons from the formation having carbon numbers greater than about 25.

68. The method of claim 41, further comprising:

providing hydrogen (H₂) to the selected section to hydrogenate hydrocarbons within the selected section; and

heating a portion of the selected section with heat from hydrogenation.

69. The method of claim 41, wherein the produced mixture comprises hydrogen and condensable hydrocarbons, the method further comprising hydrogenating a portion of the produced condensable hydrocarbons with at least a portion of the produced hydrogen.

70. Themethod of claim 41, wherein allowing the heat to transfer comprises increasing a permeability of a majority of the selected section to greater than about 100 millidarcy.

71. The method of claim 41, wherein allowing the heat to transfer comprises uniformly increasing a permeability of a majority of the selected section of the formation such that the permeability of the majority of the selected section of the formation is substantially uniform.

72. The method of claim 41, further comprising controlling the heat to yield greater than about 60% by weight of condensable hydrocarbons, as measured by the Fischer Assay.

73. The method of claim 41, wherein producing the mixture comprises producing the mixture in a production well, and wherein at least about 7 heaters are disposed in the formation for each production well.

74. The method of claim 41, further comprising providing heat from three or more heaters to at least a portion of the formation, wherein three or more of the heaters are located in the formation in a unit of heaters, and wherein the unit of heaters comprises a triangular pattern.

75. The method of claim 41, further comprising providing heat from three or more heaters to at least a portion of the formation, wherein three or more of the heaters are located in the formation in a unit of heaters, wherein the unit of heaters comprises a triangular pattern, and wherein a plurality of the units are repeated over an area of the formation to form a repetitive pattern of units.

76. A method of treating a hydrocarbon containing formation in situ, compnisig:

providing heat from one or more heaters to at least a portion of the formation, wherein the one orntore heaters c onprise at least two heaters;

allowing the heat to transfer from at least the portion to a part of the formation substantially by conduction of heat;

pyrolyzing at least some hydrocarbons within the part of the formation, wherein controlled superposition of heat from at least the two heaters pyrolyzes at least some hydrocarbons within the part of the formation;

controlling a pressure within at least a majority of the part of the formation, wherein the controlled pressure is at or about a selected value; and

producing a mixture from the formation.

77. The method of claim 76, wherein at least one of the one or more heaters comprises a natural distributed combustor.

78. The method of claim 76, further comprising controlling a pressure and a temperature within at least a majority of the part of the formation, wherein the pressure is controlled as a function of temperature, or the temperature is controlled as a function of pressure.

79. The method of claim 76, further comprising controlling the heat such that an average heating rate of the part is less than about 1.0°

C. per day in a pyrolysis temperature range of about 270°

C. to about 400°

C.

80. The method of claim 76, wherein providing heat from the one or more heat sources to at least the portion of the formation comprises:

heating a selected volume (V) of the hydrocarbon containing formation from one or more of the heat sources, wherein the formation has an average heat capacity (C_ν

), and wherein the heating pyrolyzes at least some hydrocarbons within the selected volume of the formation; and

wherein heating energy/day (Pwr) provided to the selected volume is equal to or less than h*V*C_ν

*ρ

_B, wherein ρ

_B is formation bulk density, and wherein an average heating rate (h) of the selected volume is about 10°

C./day.

81. The method of claim 76, wherein providing heat from the one or more heaters comprises heating the part such that a thermal conductivity of at least a portion of the part is greater than about 0.5 W/(m °

C.).

82. The method of claim 76, wherein the produced mixture comprises condensable hydrocarbons having an API gravity of at least about 25°

.

83. The method of claim 76, wherein the produced mixture comprises condensable hydrocarbons, and wherein about 0.1% by weight to about 15% by weight of the condensable hydrocarbons are olefins.

84. The method of claim 76, wherein the produced mixture comprises non-condensable hydrocarbons, and wherein a molar ratio of ethene to ethane in the non-condensable hydrocarbons ranges from about 0.001 to about 0.15.

85. The method of claim 76, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 1% by weight, when calculated on an atomic basis, of the condensable hydrocarbons is nitrogen.

86. The method of claim 76, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 1% by weight, when calculated on an atomic basis, of the condensable hydrocarbons is oxygen.

87. The method of claim 76, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 1% by weight, when calculated on an atomic basis, of the condensable hydrocarbons is sulfur.

88. The method of claim 76, wherein the produced mixture comprises condensable hydrocarbons, wherein about 5% by weight to about 30% by weight of the condensable

89. The method of claim 76, wherein the produced mixture comprises condensable hydrocarbons, and wherein greater tan about 20% by weight of the condensable hydrocarbons are aromatic compounds.

90. The method of claim 76, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 5% by weight of the condensable hydrocarbons comprises multi-ring aromatics with more than two rings.

91. The method of claim 76, wherein the produced mixture comprises condensable hydrocarbons, and wherein less than about 0.3% by weight of the condensable hydrocarbons are asphaltenes.

92. The method of claim 76, wherein the produced mixture comprises condensable hydrocarbons, and wherein about 5% by weight to about 30% by weight of the condensable hydrocarbons are cycloalkanes.

93. The method of claim 76, wherein the produced mixture comprises a non-condensable component, wherein the non-condensable component comprises molecular hydrogen, wherein the molecular hydrogen is greater than about 10% by volume of the non-condensable component, and wherein the molecular hydrogen is less than about 80% by volume of the non-condensable component at 25°

C. and one atmosphere absolute pressure.

94. The method of claim 76, wherein the produced mixture comprises ammonia, and wherein greater than about 0.05% by weight of the produced mixture is ammonia.

95. The method of claim 76, wherein the produced mixture comprises ammonia, and wherein the ammonia is used to produce fertilizer.

96. The method of claim 76, wherein the pressure is controlled within at least a majority of the part of the formation, wherein the controlled pressure is at least about 2.0 bar absolute.

97. The method of claim 76, further comprising controlling formation conditions to produce a mixture of condensable hydrocarbons and H₂, wherein a partial pressure of H₂ within the mixture is greater than about 0.5 bar.

98. The method of claim 97, wherein the partial pressure of H₂ is measured when the mixture is at a production well.

99. The method of claim 97, wherein controlling formation conditions comprises recirculating a portion of hydrogen from the mixture into the formation.

100. The method of claim 76, further comprising altering a pressure within the formation to inhibit production of hydrocarbons from the formation having carbon numbers greater than about 25.

101. The method of claim 76, further comprising:

providing hydrogen (H₂) to the part of the formation to hydrogenate hydrocarbons within the part of the formation; and

heating a portion of the part of the formation with heat from hydrogenation.

102. The method of claim 76, wherein the produced mixture comprises hydrogen and condensable hydrocarbons, the method further comprising hydrogenating a portion of the produced condensable hydrocarbons with at least a portion of the produced hydrogen.

103. The method of claim 76, wherein allowing the heat to transfer comprises increasing a permeability of a majority of the part of the formation to greater than about 100 millidarcy.

104. The method of claim 76, wherein allowing the heat to transfer comprises increasing a permeability of a majority of the part of the formation such that the permeability of the majority of the part of the formation is substantially uniform.

105. The method of claim 76, further comprising controlling the heat to yield greater than about 60% by weight of condensable hydrocarbons, as measured by the Fischer Assay.

106. The method of claim 76, wherein producing the mixture comprises producing the mixture in a production well, and wherein at least about 7 heaters are disposed in the formation for each production well.

107. The method of claim 76, further comprising providing heat from three or more heaters to at least a portion of the formation, wherein three or more of the heaters are located in the formation in a unit of heaters, and wherein the unit of heaters comprises a triangular pattern.

108. The method of claim 76, wherein at least about 20 heaters are disposed in the formation for each production well.

109. The method of claim 76, further comprising providing heat from three or more heaters to at least a portion of the formation, wherein three or more of the heaters are located in the formation in a unit of heaters, wherein the unit of heaters comprises a triangular pattern, and wherein a plurality of the units are repeated over an area of the formation to form a repetitive pattern of units.