System, method and apparatus for hydrogen-oxygen burner in downhole steam generator

• US 7,770,646 B2
• Filed: 10/08/2007
• Issued: 08/10/2010
• Est. Priority Date: 10/09/2006
• Status: Expired due to Fees

• Current Assignee: World Energy Systems, Inc.
• Original Assignee: World Energy Systems, Inc.
• Inventors: Klassen, Michael, Langdon, John E., Gokulakrishnan, Ponnuthurai, Fuller, Casey, Ware, Charles H., Hamer, Andrew
• Primary Examiner(s): Gay; Jennifer H
• Assistant Examiner(s): DiTrani; Angela M
• Application Number:
  US11/868,707
• Publication Number:
  US 20080083537A1
• Time in Patent Office: 1,037 Days
• Field of Search: 166/59, 166/256, 166/57, 166/302, 166/303, 431/350, 122/5.52, 60/395.7
• US Class Current: 166/303
• 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 a fuel and an oxidizer;

an injector coupled to the burner casing for injecting the fuel and the 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, 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, wherein the effusion cooling section has a first plurality of effusion holes disposed through a wall of the liner at an angle relative to the longitudinal axis of the wall and operable to inject small jets of steam through the wall to provide a layer of cooler gases to protect the wall of the liner, wherein the effusion cooling and jet mixing section has a second plurality of effusion holes disposed through the wall of the liner at an angle relative to the longitudinal axis of the wall and operable to inject small jets of steam through the wall to provide a layer of cooler gases to protect the wall of the liner and a plurality of mixing holes disposed through the wall of the liner at an angle perpendicular to the longitudinal axis of the wall and operable to inject steam farther toward the longitudinal axis of the liner, wherein the mixing holes are larger than the effusion holes.

2. The downhole burner according to claim 1, wherein the effusion holes extend through the liner at a 20°

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

3. The downhole burner according to claim 1, wherein the mixing holes are oriented at a 90°

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

4. The 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.

5. The downhole burner according to claim 4, 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.

6. The downhole burner according to claim 5, 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.

7. The downhole burner according to claim 4, 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.

8. The 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.

9. The 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.

10. 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; and

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 of the liner and an exterior of the injector for permitting steam to leak past and cool 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, 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 and having 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 degree angle relative to an internal surface of the liner to inject steam farther toward a longitudinal axis of the liner.

11. The system according to claim 10, 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.

12. The system according to claim 11, wherein the effusion holes extend through the liner at a 20°

angle relative to the 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.

13. The system according to claim 10, wherein approximately 37.5% of the steam provided through the steam channel is injected into the liner by the effusion cooling section.

14. The system according to claim 10, 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.

15. The system according to claim 14, wherein the steam arriving at the steam channel has a steam quality of about 50% to 90%.

16. The system according to claim 10, 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.

17. The system according to claim 10, 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.

18. The system according to claim 17, 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.

19. The system according to claim 10, wherein a nanocatalyst is injected into the well to promote converting and upgrading the hydrocarbons downhole.

20. The system according to claim 10, 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.

21. The system according to claim 10, 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.

22. The system according to claim 10, 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.

23. 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, wherein the liner comprises;

an effusion cooling section located adjacent to the injector and 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; and

an effusion cooling and jet mixing section located adjacent to the effusion cooling section and having a plurality of effusion holes and a plurality of mixing holes, the mixing holes being larger than the effusion holes and oriented at a 90 degree angle relative to an internal surface of the liner to inject steam farther toward a longitudinal axis of the liner;

(b) lowering the downhole burner into the well;

(c) delivering fuel, an oxidizer and steam from the 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 the steam quality of the steam, and 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; and

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

24. The method according to claim 23, wherein the effusion holes extend through the liner at a 20°

angle relative to the 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.

25. The method according to claim 23, further comprising injecting water into the downhole burner and cooling the liner with the water.

26. The method according to claim 23, 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.

27. The method according to claim 26, 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.

28. The method according to claim 23, 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.

29. The method according to claim 23, 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.

30. The method according to claim 29, 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.

31. The method according to claim 23, further comprising injecting a nanocatalyst into the oil-bearing formation to promote converting and upgrading the hydrocarbon downhole.

32. The method according to claim 23, 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.

33. The method according to claim 23, wherein the well comprises a wellbore configuration selected from the group consisting of vertical, horizontal, SAGD, and combinations thereof.

34. The method according to claim 23, 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.

35. The method of claim 23, further comprising delivering a coolant to the downhole burner and cooling at least one of the injector and the liner using the coolant, wherein the coolant includes one of a gaseous phase coolant and liquid water.

36. The method of claim 23, wherein the well into which the downhole burner is lowered includes one of a well located beneath tundra, a land-based well, and a well located beneath a sea.

37. The method of claim 23, wherein the fuel includes one of hydrogen, natural gas, syngas, and combinations thereof.

38. The method of claim 23, wherein the oxidizer includes one of oxygen, air, oxygen-rich air, and combinations thereof.

39. 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, wherein the liner includes an effusion cooling and jet mixing section having a plurality of effusion holes and a plurality of mixing holes, the mixing holes being larger than the effusion holes and oriented at a 90 degree angle relative to an internal surface of the liner to inject steam into the liner; and

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

40. The system according to claim 39, wherein the liner comprises an effusion cooling section located adjacent to the injector, and the effusion cooling and jet mixing section is located adjacent to the effusion cooling section.

41. The system according to claim 40, 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 degree angle relative to the 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.

42. The system according to claim 39, 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.

43. The system according to claim 42, 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.

44. The system according to claim 39, 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.

45. The system of claim 39, wherein the CO₂ is delivered in the same conduit as at least one of the fuel and the oxidizer.

46. A downhole burner for a well, comprising:

a burner casing;

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

an injector coupled to the liner for injecting the fuel and the oxidizer into the liner, wherein the injector comprises;

a cover plate having an oxidizer inlet;

an oxidizer distribution manifold plate having an oxidizer manifold and oxidizer holes in fluid communication with the oxidizer inlet;

a fuel distribution manifold plate having oxidizer holes in fluid communication with the oxidizer holes of the oxidizer distribution manifold plate, a fuel inlet, a fuel manifold for routing fuel from the fuel inlet through an interior of the fuel distribution manifold plate for cooling the fuel distribution manifold plate, and fuel holes in fluid communication with the fuel inlet; and

an injector face plate having oxidizer holes in fluid communication with the oxidizer holes of the fuel distribution manifold plate and fuel holes in fluid communication with the fuel holes of the fuel distribution manifold plate; and

a steam channel located inside the burner casing and surrounding the injector and the liner, wherein the liner includes a plurality of holes for communicating steam from the steam channel to an interior of the liner downstream from the injector.

47. The downhole burner of claim 46, wherein the cover plate is located on top of the oxidizer distribution manifold, wherein the oxidizer distribution manifold is located on top of the fuel distribution manifold plate, wherein the fuel distribution manifold plate is located on top of the injector face plate.

48. The downhole burner of claim 46, wherein the cover plate, the oxidizer distribution manifold plate, the fuel distribution manifold plate, and the injector face plate are in a stacked configuration.

49. The downhole burner of claim 46, wherein the injector is positioned at an upper end of the liner.

50. A system for producing hydrocarbons from a well, comprising:

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

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 the oxidizer into the well;

a liner coupled to the burner casing, wherein the fuel and the oxidizer are combusted within the liner; and

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

a first section having a plurality of holes disposed through the liner at a first angle for communicating steam from the steam channel to an interior of the liner; and

a second section having a second plurality of holes that are larger than the first plurality of holes and are disposed through the liner at a second angle different than the first angle for communicating steam from the steam channel to the interior of the liner and a third plurality of holes disposed through the liner at a third angle different than the second angle for communicating steam from the steam channel to the interior of the liner, wherein the first section is located above the second section and adjacent to the injector.