Method and Apparatus for Thermal Fluid Generation for Use in Enhanced Oil Recovery
20220195855 · 2022-06-23
Inventors
Cpc classification
E21B43/166
FIXED CONSTRUCTIONS
International classification
Abstract
A thermal fluid generator utilizes a plasma energy heat source to generate steam, and combine the steam with nitrogen gas. Combined flow streams of steam and heated nitrogen are injected downhole into subterranean reservoir to thermally stimulate the flow of hydrocarbons (such as, for example, residual oil) from a reservoir, while also increasing fluid pressure in the reservoir. The thermal fluid generator can be located at the earth's surface, or positioned downhole within a wellbore.
Claims
1. A thermal fluid generator assembly for generating heated fluid for injection into subterranean strata comprising: a) a shroud member defining a central opening; b) a plasma torch configured to generate a plasma jet stream extending through said central opening; c) at least one nozzle configured to spray water at said plasma jet stream, wherein said water is heated by said plasma jet stream to create steam; d) at least one copper coil disposed around said at least one nozzle; and e) at least one outlet port extending through said shroud member to deliver a second gas to mix with said steam.
2. The thermal fluid generator assembly of claim 1, wherein electrical current flows through said at least one copper coil to generate an electromagnetic field.
3. The thermal fluid generator assembly of claim 2, wherein said electromagnetic field compresses said plasma jet stream.
4. The thermal fluid generator assembly of claim 1, wherein said thermal fluid generator is positioned downhole within a wellbore.
5. The thermal fluid generator assembly of claim 1, wherein said second gas comprises nitrogen.
6. The thermal fluid generator assembly of claim 5, further comprising a nitrogen generation assembly for extracting said nitrogen from ambient air and delivering said extracted nitrogen to said plasma torch or said shroud member.
7. The thermal fluid generator assembly of claim 1, wherein said water is sprayed in a frustoconical spray pattern.
8. A method for stimulating the recovery of hydrocarbons from a subterranean reservoir comprising: a) providing a thermal fluid generator assembly, wherein said thermal fluid generator assembly comprises: i) a shroud member; ii) a housing defining an inner chamber and having an outlet; iii) a plasma torch operationally attached to said shroud member for generating a plasma jet stream extending into said inner chamber of said housing; iv) at least one nozzle disposed on said shroud member in spaced relationship around said plasma torch; v) generating a magnetic field to compress said plasma jet stream; b) spraying water through said at least one nozzle at said plasma jet stream; c) generating steam in said inner chamber of said housing; d) delivering a second gas to said inner chamber of said housing to mix with said steam; e) delivering said mixture of steam and said second gas through said outlet of said housing; f) injecting said mixture of steam and said second gas into said subterranean reservoir.
9. The method of claim 8, wherein further comprising the step of circulating water to cool said plasma torch.
10. The method of claim 8, wherein said water is sprayed in a frustoconical spray pattern.
11. The method of claim 8, wherein said second gas comprises carbon dioxide.
12. The method of claim 8, wherein said second gas comprises nitrogen
13. The method of claim 12, wherein said nitrogen is extracted from air.
14. The method of claim 13, wherein at least a portion of said water sprayed through said at least one nozzle is generated during extraction of nitrogen from air.
15. The method of claim 8, wherein said thermal fluid generator assembly is positioned downhole within a wellbore.
16. The method of claim 15, wherein at least one gas is heated by said plasma torch prior to being injected into a subterranean reservoir.
17. The method of claim 16, wherein said at least one gas comprises carbon dioxide.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The foregoing summary, as well as any detailed description of the preferred embodiments, is better understood when read in conjunction with the drawings and figures contained herein. For the purpose of illustrating the invention, the drawings and figures show certain preferred embodiments. It is understood, however, that the invention is not limited to the specific methods and devices disclosed in such drawings or figures.
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DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
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[0037] Plasma steam generator assembly 100 comprises plasma torch 110 which is typically configured for non-transfer mode of operation. Said plasma torch 110 utilizes electrical (energy supplied by electrical input line 120) to excite a stream of gas into an ionized plasma state, forming plasma jet 130, also sometimes referred to as a corona. The ionized portion of the gas often reaches temperatures in the range of 10,000 degrees Kelvin (17,540 degrees Fahrenheit). However, only a relatively small portion of the plasma jet stream 130 is in the ionized state, typically only 1% of the stream. In a preferred embodiment, the temperature of the gas in the stream outside of the ionized central core is considerably less than in said core; the temperature of the central core of ionized gas decreases as the gas moves away from the plasma torch and mixes with lower temperature arc gas.
[0038] Nitrogen generator assembly 200 is used to provide nitrogen gas feed stock to plasma torch 110. Said nitrogen generator assembly 200 can comprise virtually any acceptable means for generating nitrogen and supplying said to plasma torch 110. In a preferred embodiment, said nitrogen generator assembly 200 comprises a conventional membrane-type nitrogen generator that can be used to extract desired volumes of nitrogen at a high flow rate from the surrounding atmosphere (typically ambient air). Said nitrogen generator assembly 200 comprises separate means to collect, compress and store the compressed air in storage tank(s).
[0039] In the embodiment depicted in
[0040] Still referring to
[0041] Electrical input requirements for plasma torch 110 are supplied via electrical transmission 120. A power supply (not shown) is provided for the conversion of AC power to high voltage DC power. In a preferred embodiment, said power supply can comprise a portable diesel generator or other suitable electricity supply. Additionally, an arc starter (not shown) can be provided to supply sufficient voltage to stimulate ionization with sufficient DC current to selectively start plasma torch 110.
[0042] De-ionized water exiting cooling loop 140 can be heated by the heat energy generated by plasma torch 110. Some or all of said de-ionized water flow stream existing said cooling loop 140 is redirected via line 141 toward the output plasma jet 130 of plasma torch 110; heat energy from said plasma torch 110 causes said de-ionized water to form high temperature steam 400. The resulting stream of high temperature steam 400 can be comingled and/or mixed with nitrogen discharged from the thermal fluid generator assembly.
[0043] In operation, at least one sensor is provided for real-time measurement and monitoring of system conditions at desired location(s) within said system. At least one programmable controller continuously monitors information sensed by said at least one sensor (including, for example, output parameters such as steam heat, fluid mixture quality, steam volume and/or other variables). Said at least one programmable controller receives, interprets and/or responds to information sensed by said at least one sensor, thereby permitting changes to output conditions by dynamically adjusting input(s) to plasma torch 110 and/or operational controls of said plasma torch 110 to achieve desired output parameters; said input(s) to plasma torch 110 can include, without limitation, electrical power in, cooling water flow rate and input gas flow rate. Additionally, said at least one controller can be manually operated.
[0044]
[0045] Generally, torch shroud member 150 comprises a mounting support structure for plasma torch 110, as well as a manifold-like conduit assembly to selectively direct water and nitrogen flow streams to desired locations and orientations relative to said plasma torch 110, and the output there from. In a preferred embodiment, water is directed through directionally oriented nozzles 160, disposed in spaced arrangement, to form a converging frustoconical stream or spray pattern of water at or into plasma jet 130 output from said plasma torch 110. Heat from said plasma jet 130 contacting said water stream flowing through said nozzles 160 results in the generation of high temperature steam. Additionally, shroud member 150 further comprises an annular space generally surrounding plasma torch 110 and water discharge nozzles 160. Outlet ports in the face of said shroud member 150 direct a high velocity stream of nitrogen gas into inner chamber 190a of housing 190, generally in the vicinity of steam generated at or near the outlet of plasma torch 110.
[0046] Referring to
[0047] Water exiting outlet 142 of cooling loop 140 is directed through water outlet conduit 143, wherein some or all of said flow stream of water stream is directed into nozzle supply conduit 145. Depending on water volume and/or flow rate requirements, a portion of the water flow stream may be selectively diverted to return conduit 144, which can direct said water back to a water supply assembly, disposal facility or other location for further handling. Water flowing into nozzle supply conduit 145 enters nozzle inlet port(s) 161 and flows through conduit(s) in shroud member 150 until said water flows to a plurality of directionally-oriented nozzles 160.
[0048] By way of illustration, it is to be observed that the present invention may comprise a single water inlet port 161 wherein said water is piped within said shroud 150 to a plurality of nozzles 160. Alternatively, shroud 150 may include a plurality of water inlet ports 161, wherein water is routed directly from each inlet port 161 to an associated nozzle 160 or group of nozzles 160. In a preferred embodiment, chemicals or other additives can be optionally added to said water stream through chemical injection conduit 146 prior to said water stream being directed to nozzle inlet port(s) 161.
[0049] Electrical positive terminal 121 and negative terminal 122 are electrically connected to plasma torch 110 and provide electrical power to ignite and operate said plasma torch 110. Power can be supplied via a portable electrical generator, electrical supply grid or other conventional means. Positive cathode 123 and the negative anode 124 are disposed within plasma torch 110, which is configured to operate in a “non-transfer mode” as opposed to a “transfer mode”.
[0050] Still referring to
[0051] Plasma jet (corona) 130 is depicted exiting the output of plasma torch 110, as would be the case when plasma steam generator assembly 100 is operating. Extending beyond said plasma jet 130 is high temperature stream of steam 400 that is created when de-ionized water is injected through nozzles 160 at or into said plasma corona 160. A blanket of nitrogen 410 surrounds said stream of steam 400 within inner chamber 190a of housing 190; said nitrogen blanket 410 is generally injected via conduits 171 into the annular space formed between steam 400 and the inner surface of housing 190. Further, said nitrogen blanket 410 mixes with steam 400 to form a mixture of nitrogen and steam 420 (and any injected chemicals or additives) within said inner chamber 190a of housing 190.
[0052] Heated mixture 420 is substantially contained and collected within inner chamber 190a of housing 190. Said heated fluids flow from the inner chamber 190a of housing 190, through bell/swage connection 191, and into piping/conduit 192 that can be beneficially in fluid communication with at least one wellbore, such as via a conventional piping or manifold system not depicted in
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[0057] In a preferred embodiment, at least one isolation packer assembly 270 is installed above tubing section 251 and subterranean reservoir 350; in some installations, at least one isolation packer assembly 270 is also installed below said reservoir 350. Said packer assembly 270 provides a seal between the exterior of tubing string 250 and the inner surface of wellbore 260 (typically casing installed in said wellbore) at or just above the depth of subterranean reservoir 350. The seal created by said isolation packer assembly 270 prevents flow of heated fluids (steam and/or associated fluids) that are directed downhole through tubing string 250 from traveling up the annular space between the exterior of tubing string 250 and the inner surface of wellbore 260. Rather, with said seal established, said fluids are directed into the subterranean reservoir 350 through perforations 261.
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[0059] Positioning said thermal fluid generator assembly 10 downhole requires that utility lines be run downhole. The utility lines consist of an electric power cable, de-ionized cooling water in and cooling water out lines as well as a gas supply line. As with the above ground configuration depicted in
[0060] In certain circumstances (typically based on reservoir conditions), gaseous carbon dioxide (CO2) can be used in place of, or in combination with, nitrogen in connection with the plasma steam generator assembly 10 of the present invention. Typically, the cost to generate CO2 can be a prohibiting factor. However, in the present invention, exhaust gas from internal combustion engines can be used to supply CO2; CO2 generated by diesel engines driving the motors for electric generator and the nitrogen generator can be commingled into the nitrogen stream via an inductor. In some circumstances, plasma generated using CO2 can be very desirable in certain oil reservoirs.
[0061] Additionally, in certain circumstances it can be beneficial to inject certain gas(es)—typically carbon dioxide—into subterranean formations in order to increase hydrocarbon production by displacing said hydrocarbons within a reservoir and directing said hydrocarbons toward one or more producing wellbore(s). Such gas injection is typically performed in reservoirs where hydrocarbon production rates have declined over time. Frequently, such carbon dioxide or other gas is stored at a significantly lower temperature than the reservoir(s) into which it is to be injected; this temperature differential can negatively impact gas injection performance and resultant hydrocarbon production from the reservoir(s) into which the gas is injected.
[0062] The thermal fluid generator assembly 10 of the present invention can be used to heat such carbon dioxide or other gas(es) prior to injection into subterranean reservoir(s). The temperature of the carbon dioxide or other gas(es) to be injected can be selectively raised to desired level(s); this temperature can often be as high or higher than the temperature of the subterranean reservoir(s) into which the carbon dioxide or other gas(es) are to be injected. Although other configurations can be envisioned without departing from the scope of the present invention, said carbon dioxide or other gas(es) can be pumped to a downhole location in proximity to the plasma torch of thermal fluid generator 10 situated at a downhole location within a wellbore. In certain cases, heating time can be selectively increased or decreased in order to control the amount of temperature change of the carbon dioxide or other gas(es) prior to injection into a reservoir.
[0063] The above-described invention has a number of particular features that should preferably be employed in combination, although each is useful separately without departure from the scope of the invention. While the preferred embodiment of the present invention is shown and described herein, it will be understood that the invention may be embodied otherwise than herein specifically illustrated or described, and that certain changes in form and arrangement of parts and the specific manner of practicing the invention may be made within the underlying idea or principles of the invention.