High voltage temperature limited heaters

• US 8,238,730 B2
• Filed: 10/24/2003
• Issued: 08/07/2012
• Est. Priority Date: 10/24/2002
• Status: Active Grant

• Current Assignee: Shell Oil Company (Shell Plc)
• Original Assignee: Shell Oil Company (Shell Plc)
• Inventors: Sandberg, Chester Ledlie, Vinegar, Harold J., Harris, Christopher Kelvin, Son, Jaime Santos, Carl, Fredrick Gordon Jr.
• Primary Examiner(s): PAIK, SANG YEOP
• Application Number:
  US10/693,820
• Publication Number:
  US 20040144540A1
• Time in Patent Office: 3,210 Days
• Field of Search: 392301-306, 392/469, 166 60- 61, 166/302, 219/553
• US Class Current: 392/301
• CPC Class Codes: E21B 36/008 using chemical heat generating means
• CPC Class Codes: E21B 36/02 using burners
• 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 43/2401 by means of electricity
• CPC Class Codes: H05B 2214/03 Heating of hydrocarbons

Abstract

A heater system may include an alternating current supply and an electrical conductor. An alternating current may be applied to one or more electrical conductors at a voltage above about 200 volts. The electrical conductors may be located in a formation. The electrical conductors may provide an electrically resistive heat output upon application of the alternating electrical current. At least one of the electrical conductors may include an electrically resistive ferromagnetic material. An electrical conductor may provide a reduced amount of heat above or near a selected temperature. Heat may be allowed to transfer from an electrical conductor to a part of the formation.

Claims

1. A system configured to heat a hydrocarbon containing formation, comprising:

a heater well extending from a surface of the earth through an overburden of the formation and into a hydrocarbon containing layer in the formation;

an AC supply configured to provide AC at a voltage above about 200 volts; and

one or more electrical conductors located in the heater well and extending from the surface into the hydrocarbon containing layer, the electrical conductors being electrically coupled to the AC supply;

at least one electrical conductor comprising one or more ferromagnetic sections, and being configured to provide an electrically resistive heat output during application of AC to the electrical conductor such that heat transfers from the electrical conductor to hydrocarbons in the hydrocarbon containing layer to at least mobilize some hydrocarbons in the layer;

wherein one or more of the ferromagnetic sections provides a reduced amount of heat above or near a selected temperature during use, wherein the selected temperature is at or about the Curie temperature of the ferromagnetic section.

2. The system of claim 1, further comprising at least one production well extending into the hydrocarbon containing layer and configured to produce at least some of the mobilized hydrocarbons from the hydrocarbon containing layer.

3. The system of claim 1, wherein at least one electrical conductor transfers heat during use to hydrocarbons in the hydrocarbon containing layer to at least mobilize some hydrocarbons in the layer.

4. The system of claim 1, wherein at least one electrical conductor transfers heat during use to hydrocarbons in the hydrocarbon containing layer to pyrolyze at least some hydrocarbons in the layer.

5. The system of claim 1, wherein at least one of the ferromagnetic sections heats during use to a temperature of at least about 650°

C.

6. The system of claim 1, wherein the AC supply is configured to provide AC at a voltage below about 2500 volts.

7. The system of claim 1, wherein the system comprises three or more electrical conductors, and wherein at least three of the electrical conductors are coupled in a three-phase electrical configuration.

8. The system of claim 1, wherein at least one of the ferromagnetic sections comprises iron, nickel, chromium, cobalt, tungsten, or a mixture thereof.

9. The system of claim 1, wherein at least one of the ferromagnetic sections has a thickness of at least about ¾

of a skin depth of the AC at the Curie temperature of such ferromagnetic sections.

10. The system of claim 1, wherein the heat output below the selected temperature is greater than about 400 watts per meter of electrical conductor.

11. The system of claim 1, wherein at least a portion of the electrical conductor is longer than about 10 m.

12. The system of claim 1, wherein one or more of the ferromagnetic sections are configured to sharply reduce the heat output at or near the selected temperature.

13. The system of claim 1, wherein the heat output from at least a portion of the ferromagnetic sections decreases at or near the selected temperature due to the Curie effect.

14. The system of claim 1, wherein the AC resistance of the electrical conductor increases with an increase in temperature up to the selected temperature, and wherein the AC resistance of the electrical conductor decreases with an increase in temperature above the selected temperature.

15. The system of claim 1, wherein the AC supply provides an electrical current of at least about 70 amps to the electrical conductor.

16. The system of claim 1, wherein at least one of the electrical conductors comprises a turndown ratio of at least about 2 to 1.

17. The system of claim 1, wherein the AC supply applies AC at about 180 Hz.

18. The system of claim 1, wherein the system withstands operating temperatures of about 250°

C. or above.

19. The system of claim 1, wherein the electrical conductor automatically provides the reduced amount of heat above or near the selected temperature.

55. The system of claim 1, wherein the heater well extends at least about 10 m into the hydrocarbon containing layer.

56. The system of claim 1, wherein the hydrocarbon containing layer comprises hydrocarbons configured to be treated and produced from the formation using an in situ conversion process.

20. A system configured to heat a hydrocarbon containing formation, comprising:

a heater well extending from a surface of the earth through an overburden of the formation and into a hydrocarbon containing layer in the formation;

an AC supply configured to provide AC at a voltage above about 200 volts; and

one or more electrical conductors located in the heater well and extending from the surface into the hydrocarbon containing layer, the electrical conductors being electrically coupled to the AC supply;

at least one electrical conductor comprising one or more ferromagnetic sections, and being configured to provide an electrically resistive heat output during application of AC to the electrical conductor such that heat transfers from the electrical conductor to hydrocarbons in the hydrocarbon containing layer to at least mobilize some hydrocarbons in the layer;

wherein one or more of the ferromagnetic sections provides a reduced amount of heat above or near a selected temperature that is about 20% or less of the heat output at about 50°

C. below the selected temperature during use, wherein the selected temperature is at or about the Curie temperature of the ferromagnetic section.

21. The system of claim 20, further comprising at least one production well extending into the hydrocarbon containing layer and configured to produce at least some of the mobilized hydrocarbons from the hydrocarbon containing layer.

22. The system of claim 20, wherein at least one electrical conductor transfers heat during use to hydrocarbons in the hydrocarbon containing layer to at least mobilize some hydrocarbons in the layer.

23. The system of claim 20, wherein at least one electrical conductor transfers heat during use to hydrocarbons in the hydrocarbon containing layer to pyrolyze at least some hydrocarbons in the layer.

24. The system of claim 20, wherein at least one of the ferromagnetic sections heats during use to a temperature of at least about 650°

C.

25. The system of claim 20, wherein the AC supply is configured to provide AC at a voltage below about 2500 volts.

26. The system of claim 20, wherein the system comprises three or more electrical conductors, and wherein at least three of the electrical conductors are coupled in a three-phase electrical configuration.

27. The system of claim 20, wherein at least one of the ferromagnetic sections comprises iron, nickel, chromium, cobalt, tungsten, or a mixture thereof.

28. The system of claim 20, wherein at least one of the ferromagnetic sections has a thickness of at least about ¾

of a skin depth of the AC at the Curie temperature of such ferromagnetic sections.

29. The system of claim 20, wherein the heat output below the selected temperature is greater than about 400 watts per meter of electrical conductor.

30. The system of claim 20, wherein at least a portion of the electrical conductor is longer than about 10 m.

31. The system of claim 20, wherein one or more of the ferromagnetic sections are configured to sharply reduce the heat output at or near the selected temperature.

32. The system of claim 20, wherein the heat output from at least a portion of the ferromagnetic sections decreases at or near the selected temperature due to the Curie effect.

33. The system of claim 20, wherein the AC resistance of the electrical conductor increases with an increase in temperature up to the selected temperature, and wherein the AC resistance of the electrical conductor decreases with an increase in temperature above the selected temperature.

34. The system of claim 20, wherein the AC supply provides an electrical current of at least about 70 amps to the electrical conductor.

35. The system of claim 20, wherein at least one of the electrical conductors comprises a turndown ratio of at least about 2 to 1.

36. The system of claim 20, wherein the AC supply applies AC at about 180 Hz.

37. The system of claim 20, wherein the system withstands operating temperatures of about 250°

C. or above.

38. The system of claim 20, wherein the electrical conductor automatically provides the reduced amount of heat above or near the selected temperature.

57. The system of claim 20, wherein the heater well extends at least about 10 m into the hydrocarbon containing layer.

58. The system of claim 20, wherein the hydrocarbon containing layer comprises hydrocarbons configured to be treated and produced from the formation using an in situ conversion process.

39. A method of heating a hydrocarbon containing formation, comprising:

providing AC at a voltage above about 200 volts to one or more electrical conductors located in a heater well extending from a surface of the earth through an overburden of the formation and into a hydrocarbon containing layer in the formation, wherein providing the AC produces an electrically resistive heat output from the electrical conductors, at least one of the electrical conductors comprising one or more ferromagnetic sections; and

wherein one or more of the ferromagnetic sections are configured to provide a reduced amount of heat above or near a selected temperature during use, wherein the selected temperature is at or about the Curie temperature of the ferromagnetic section; and

allowing heat to transfer from the electrical conductors to hydrocarbons in the hydrocarbon containing layer to at least mobilize some hydrocarbons in the layer.

40. The method of claim 39, further comprising producing at least some of the mobilized hydrocarbons from the layer through a production well extending into the hydrocarbon containing layer.

41. The method of claim 39, wherein the transferred heat pyrolyzes at least some hydrocarbons in the hydrocarbon containing layer.

42. The method of claim 41, further comprising producing at least some of the pyrolyzed hydrocarbons from the layer through a production well extending into the hydrocarbon containing layer.

43. The method of claim 39, wherein at least one of the ferromagnetic sections heats to a temperature of at least about 650°

C.

44. The method of claim 39, further comprising providing the AC at a voltage below about 2500 volts.

45. The method of claim 39, further comprising providing the AC to at least one of the electrical conductors at or above the selected temperature.

46. The method of claim 39, further comprising providing the AC at a frequency of about 180 Hz.

47. The method of claim 39, further comprising providing an initial electrically resistive heat output when the electrical conductor providing the heat output is at least about 50°

C. below the selected temperature, and automatically providing the reduced amount of heat above or near the selected temperature.

48. The method of claim 39, wherein an AC resistance of at least one of the ferromagnetic sections decreases above the selected temperature to provide the reduced amount of heat.

49. The method of claim 39, wherein at least one of the ferromagnetic sections has a thickness of at least about ¾

of a skin depth of AC at the Curie temperature of the ferromagnetic material.

50. The method of claim 39, wherein the reduced amount of heat is less than about 400 watts per meter of length of electrical conductor.

51. The method of claim 39, further comprising controlling a skin depth in at least one of the ferromagnetic sections by controlling a frequency of the applied AC.

52. The method of claim 39, further comprising applying additional current to at least one of the ferromagnetic sections as the temperature of such ferromagnetic sections increases until the temperature is at or near the selected temperature.

53. The method of claim 39, further comprising controlling an amount of heat provided by at least one of the ferromagnetic sections by controlling an amount of current applied to at least one of the electrical conductors.

54. The method of claim 39, further comprising applying current of at least about 70 amps to at least one of the electrical conductors.

59. The method of claim 39, wherein the heater well extends at least about 10 m into the hydrocarbon containing layer.

60. The method of claim 39, wherein the hydrocarbon containing layer comprises hydrocarbons configured to be treated and produced from the formation using an in situ conversion process.