Temperature limited heater utilizing non-ferromagnetic conductor

• US 8,224,165 B2
• Filed: 04/21/2006
• Issued: 07/17/2012
• Est. Priority Date: 04/22/2005
• Status: Expired due to Fees

• Current Assignee: Shell Oil Company (Shell Plc)
• Original Assignee: Shell Oil Company (Shell Plc)
• Inventors: Vinegar, Harold J., Harris, Christopher Kelvin
• Primary Examiner(s): PAIK, SANG YEOP
• Application Number:
  US11/409,565
• Publication Number:
  US 20080217321A1
• Time in Patent Office: 2,279 Days
• Field of Search: 392301-306, 392/469, 166/60, 166/61, 166/302, 166/248, 219544-553
• US Class Current: 392/301
• CPC Class Codes: C07C 4/02 by cracking a single hydrocarbon or a mixture of individually defined hydrocarbons or a normally gaseous hydrocarbon fraction
• CPC Class Codes: C07C 9/04 Methane production by treatment of sewage C02F11/04; natural gas, synthetic natural gas C10L3/06
• CPC Class Codes: E21B 17/028 Electrical or electro-magnetic connections
• CPC Class Codes: E21B 36/001 Cooling arrangements
• CPC Class Codes: E21B 36/04 using electrical heaters
• CPC Class Codes: E21B 43/24 using heat, e.g. steam injection
• CPC Class Codes: E21B 43/243 Combustion in situ
• CPC Class Codes: Y10T 29/49179 by metal fusion bonding

Abstract

A heater is described. The heater includes a ferromagnetic conductor and an electrical conductor electrically coupled to the ferromagnetic conductor. The ferromagnetic conductor is positioned relative to the electrical conductor such that an electromagnetic field produced by time-varying current flow in the ferromagnetic conductor confines a majority of the flow of the electrical current to the electrical conductor at temperatures below or near a selected temperature.

Claims

1. A heater configured for heating a subsurface formation, comprising:

an inner electrical conductor comprising electrically conductive material;

a ferromagnetic conductor concentric with the inner electrical conductor, wherein the ferromagnetic conductor at least partially surrounds the inner electrical conductor and is electrically coupled to the inner electrical conductor; and

an electrical conductor concentric with the ferromagnetic conductor and the inner electrical conductor, wherein the electrical conductor at least partially surrounds the ferromagnetic conductor and is electrically coupled to the ferromagnetic conductor and the inner electrical conductor, the ferromagnetic conductor being positioned relative to the electrical conductor and having a thickness such that an electromagnetic field produced by time-varying current flow in the ferromagnetic conductor confines a majority of the flow of the electrical current to the electrical conductor at temperatures below a selected temperature;

wherein the heater is located in a wellbore in a hydrocarbon containing layer in the subsurface formation, the heater is at least about 10 m in length in the hydrocarbon containing layer, and the heater is configured to provide heat to at least a portion of the hydrocarbon containing layer surrounding the wellbore.

2. The heater of claim 1, wherein the inner electrical conductor is a substantially circular inner conductor.

3. The heater of claim 1, wherein the inner electrical conductor comprises copper.

4. The heater of claim 1, further comprising a support member located between the ferromagnetic conductor and the electrical conductor, the support member being concentric with the ferromagnetic conductor and the electrical conductor.

5. The heater of claim 1, further comprising a support member located inside the inner electrical conductor, the support member being concentric with the inner electrical conductor.

6. The heater of claim 1, further comprising a support member, wherein the support member is configured to provide the heater with a creep-rupture lifetime of at least about 30,000 hours at operating temperatures up to about 834°

C.

7. The heater of claim 1, wherein the heater has a creep-rupture lifetime of at least about 30,000 hours at operating temperatures up to about 770°

C.

8. The heater of claim 1, wherein the heater is at least about 100 m in length in the hydrocarbon containing layer.

9. The heater of claim 1, wherein the heater is at least about 300 m in length in the hydrocarbon containing layer.

10. The heater of claim 1, wherein the heater is configured to provide heat to at least a portion of the hydrocarbon containing layer surrounding the wellbore to mobilize hydrocarbons in the portion.

11. The heater of claim 1, wherein the heater is configured to provide heat to at least a portion of the hydrocarbon containing layer surrounding the wellbore to pyrolyze hydrocarbons in the portion.

12. The heater of claim 1, wherein the heater is substantially circular in shape.

13. The heater of claim 1, wherein the selected temperature is the Curie temperature of the ferromagnetic conductor.

14. The heater of claim 1, wherein a cross-sectional area of the electrical conductor is at least ½

of a cross-sectional area of the inner electrical conductor.

15. The heater of claim 1, wherein the electrical conductor provides a majority of a resistive heat output of the heater at temperatures up to approximately the selected temperature of the ferromagnetic conductor.

16. A heater configured for heating a subsurface formation, comprising:

an electrical conductor coupled to a ferromagnetic material and an inner electrical conductor, the heater being configured to provide electric resistance heating, and the heater having dimensions such that a majority of the electric resistance heat output is generated in the electrical conductor;

wherein the ferromagnetic material is configured to substantially concentrate time-varying electrical current flow to the electrical conductor at temperatures below a selected temperature;

wherein the electrical conductor at least partially surrounds the ferromagnetic material and the ferromagnetic material at least partially surrounds the inner electrical conductor, the inner electrical conductor being substantially circular and the ferromagnetic material and the electrical conductor being concentric with the inner electrical conductor; and

wherein the heater is located in a wellbore in a hydrocarbon containing layer in the subsurface formation, the heater is at least about 10 m in length in the hydrocarbon containing layer, and the heater is configured to provide heat to at least a portion of the hydrocarbon containing layer surrounding the wellbore.

17. The heater of claim 16, wherein the inner electrical conductor is a substantially circular inner conductor.

18. The heater of claim 16, wherein the inner electrical conductor comprises copper.

19. The heater of claim 16, further comprising a support member located between the ferromagnetic conductor and the electrical conductor, the support member being concentric with the ferromagnetic conductor and the electrical conductor.

20. The heater of claim 16, further comprising a support member located inside the inner electrical conductor, the support member being concentric with the inner electrical conductor.

21. The heather of claim 16, further comprising a support member, wherein the support member is configured to provide the heater with a creep-rupture lifetime of at least about 30,000 hours at operating temperatures up to about 834°

C.

22. The heater of claim 16, wherein the heater has a creep-rupture lifetime of at least about 30,000 hours at operating temperatures up to about 770°

C.

23. The heater of claim 16, wherein the heater is at least about 100 m in length in the hydrocarbon containing layer.

24. The heater of claim 16, wherein the heater is at least about 300 m in length in the hydrocarbon containing layer.

25. The heater of claim 16, wherein the heater is configured to provide heat to at least a portion of the hydrocarbon containing layer surrounding the wellbore to mobilize hydrocarbons in the portion.

26. The heater of claim 16, wherein the heater is configured to provide heat to at least a portion of the hydrocarbon containing layer surrounding the wellbore to pyrolyze hydrocarbons in the portion.

27. The heater of claim 16, wherein the heater is substantially circular in shape.

28. The heater of claim 16, wherein the selected temperature is the Curie temperature of the ferromagnetic conductor.

29. The heater of claim 16, wherein the ferromagnetic member and the electrical conductor are electrically coupled such that a power factor of the heater remains above 0.85 during use of the heater.

30. The heater of claim 16, wherein a cross-sectional area of the electrical conductor is at least ½

of a cross-sectional area of the inner electrical conductor.

31. The heater of claim 16, wherein the electrical conductor provides a majority of a resistive heat output of the heater at temperatures up to approximately the selected temperature of the ferromagnetic conductor.