Subsurface heaters with low sulfidation rates

• US 8,606,091 B2
• Filed: 10/20/2006
• Issued: 12/10/2013
• Est. Priority Date: 10/24/2005
• Status: Expired due to Fees

• Current Assignee: Shell Oil Company (Shell Plc)
• Original Assignee: Shell Oil Company (Shell Plc)
• Inventors: John, Randy Carl, Vinegar, Harold J.
• Primary Examiner(s): PAIK, SANG YEOP
• Application Number:
  US11/584,801
• Publication Number:
  US 20070127897A1
• Time in Patent Office: 2,608 Days
• Field of Search: 392301-306, 392/469, 166 60- 61, 166/302, 219/553
• US Class Current: 392/301
• CPC Class Codes: C10G 1/002 in combination with oil conversion- or refining processes
• CPC Class Codes: C10G 1/02 by distillation
• CPC Class Codes: C10G 2300/308 Gravity, density, e.g. API
• CPC Class Codes: C10G 9/24 by heating with electrical means
• 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 43/281 using heat
• CPC Class Codes: E21B 43/34 Arrangements for separating materials produced by the well
• CPC Class Codes: Y02E 20/14 Combined heat and power generation [CHP]

Abstract

A system for heating a hydrocarbon containing formation includes a heater having an elongated ferromagnetic metal heater section. The heater is located in an opening in a formation. The heater section is configured to heat the hydrocarbon containing formation. The exposed ferromagnetic metal has a sulfidation rate that goes down with increasing temperature of the heater, when the heater is in a selected temperature range.

Claims

1. A system for heating a hydrocarbon containing formation, comprising:

a heater comprising an elongated ferromagnetic metal heater section, wherein a portion of the ferromagnetic metal heater section has at least 2% by weight cobalt, wherein the heater is located in an opening in the formation and at least a part of the portion of the ferromagnetic metal heater section is exposed to the formation, wherein the portion of the ferromagnetic metal heater section is configured to be heated to at least 500°

C., and, when a temperature of the portion is increased into the range of about 500°

C. to about 650°

C., a sulfidation rate of the ferromagnetic metal heater section decreases, and wherein the heater section is configured to heat the hydrocarbon containing formation.

2. The system of claim 1, wherein the heater section is 410 stainless steel.

3. The system of claim 1, wherein the portion of the ferromagnetic metal heater section comprises iron, chromium, and the weight percentage of chromium is at least about 9%.

4. The system of claim 1, wherein the heater section is substantially inert to galvanic corrosion.

5. The system of claim 1, wherein the heater is a temperature limited heater.

6. The system of claim 1, wherein the heater section is substantially the only electrical path in the heater configured to carry current into and out of the formation.

7. The system of claim 1, wherein the temperature of the portion ranges between about 530°

C. and about 650°

C.

8. The system of claim 1, wherein the portion of the ferromagnetic metal heater section comprises at least 5% by weight cobalt.

9. The system of claim 1, wherein the portion of the ferromagnetic metal heater section comprises at most 10% by weight cobalt.

10. The system of claim 1, wherein the heater section is an electrical resistance heater section.

11. A heater having a metal section comprising:

ferromagnetic stainless steel having at least 2.0% cobalt by weight; and

wherein the metal section is configured to be heated to at least 500°

C. under a sulfidation atmosphere, and, when a temperature of the metal section is increased into the range of about 500°

C. to about 650°

C., a sulfidation rate of the metal section decreases, and wherein the composition of the metal section, when exposed to the sulfidation atmosphere, is such that the sulfidation rate of the metal section is at most about 25 mils per year at a temperature between about 800°

C. and about 880°

C.

12. The heater of claim 11, wherein at least a part of the portion of the ferromagnetic metal heater section is exposed to a subsurface formation.

13. The heater of claim 11, wherein the stainless steel is at most 10% by weight cobalt.

14. The heater of claim 11, wherein the stainless steel comprises iron and chromium.

15. The heater of claim 11, wherein the stainless steel comprises at most about 22% chromium by weight.

16. The heater of claim 11, wherein the stainless steel is 410 stainless steel.

17. The heater of claim 11, wherein the metal section is substantially inert to galvanic corrosion.

18. The heater of claim 11, wherein the metal section comprises a temperature limited heater section.

19. The heater of claim 11, wherein the metal section is substantially the only electrical path in the heater configured to carry current into and out of a subsurface formation.

20. The heater of claim 11, wherein the metal section is an electrical resistance heater section.

21. A method for heating a subsurface formation, comprising:

heating using a heater comprising an elongated ferromagnetic metal heater section, the ferromagnetic metal heater section having at least 2% by weight cobalt, wherein at least a portion of the ferromagnetic metal heater section is exposed to the formation; and

heating such that a part of the portion of the ferromagnetic metal heater section is at a temperature of at least 500°

C., and, when a temperature of the portion is increased into the range of about 500°

C. to about 650°

C., a sulfidation rate of the ferromagnetic metal heater section decreases.

22. The method of claim 21, wherein the temperature range is increased into a range between about 530°

C. and 650°

C.

23. The method of claim 21, wherein the heater section is 410 stainless steel.

24. The method of claim 21, wherein the heater section is substantially inert to galvanic corrosion.

25. The method of claim 21, wherein the heater section comprises a temperature limited heater section.

26. The method of claim 21, wherein the heater section is substantially the only electrical path in the heater configured to carry current into and out of the formation.

27. The method of claim 21, further comprising applying current to the heater section such that the heater section heats as a result of the electrical resistance of the heater section.

28. The method of claim 21, wherein the subsurface formation comprises hydrocarbons, the method further comprising allowing the heat to transfer to the formation such that at least some hydrocarbons are pyrolyzed in the formation.

29. The method of claim 21, further comprising producing a fluid from the formation.

30. The method of claim 21, further comprising producing a fluid from the formation, and producing a transportation fuel from the produced fluid.

31. A method for heating a subsurface formation using a heater comprising an elongated ferromagnetic metal heater section comprising stainless steel having at least 2.0% cobalt by weight, wherein a portion of the ferromagnetic metal heater section is exposed to the formation, and heating such that the exposed portion of the ferromagnetic metal heater section is at a temperature of at least 500°

C., and, when a temperature of the portion is increased into the range of about 500°

C. to about 650°

C., a sulfidation rate of the ferromagnetic metal heater section decreases, and wherein the composition of the heater section is such that the sulfidation rate of the heater section is less than about 25 mils per year at a temperature between about 800°

C. to about 880°

C.

32. The method of claim 31, wherein the stainless steel is at most 10% by weight cobalt.

33. The method of claim 31, wherein the stainless steel comprises at most about 15% chromium by weight.

34. The method of claim 31, wherein the heater section is substantially inert to galvanic corrosion.

35. The method of claim 31, wherein the heater section is substantially the only electrical path in the heater configured to carry current into and out of a subsurface formation.

36. The method of claim 31, further comprising applying current to the heater section such that the heater section heats as a result of the electrical resistance of the heater section.

37. The method of claim 31, wherein the subsurface formation comprises hydrocarbons, the method further comprising allowing the heat to transfer to the formation such that at least some hydrocarbons are mobilized and/or pyrolyzed in the formation.

38. The method of claim 31, further comprising producing a fluid from the formation.

39. The method of claim 31, further comprising producing a fluid from the formation, and producing a transportation fuel from the produced fluid.