BACKGROUND
Artificial lift techniques are used to increase the flow rate of oil out of a production well. One commercially available type of an artificial lift is a gas lift. With a gas lift, compressed gas is injected into a well to increase the flow rate of produced fluid by decreasing head losses associated with weight of the column of fluids being produced. In particular, the injected gas reduces pressure on a bottom of the well by decreasing bulk density of the fluid in the well. The decreased density allows the fluid to flow more easily out of the well. Gas lifts, however, do not work in all situations. For example, gas lifts do not work well with a reserve of high viscosity oil (heavy oil). Typically, thermal methods are used to recover heavy oil from a reservoir. In a typical thermal method, steam generated at the surface is pumped down a drive side well into a reservoir. As a result of the heat exchange between the steam pumped into the well and the downhole fluids, the viscosity of the oil is reduced by an order of magnitude that allows it to be pumped out of a separate producing bore. A gas lift would not be used with a thermal system because the relatively cool temperature of the gas would counter the benefits of the heat exchange between the steam and the heavy oil therein increasing the viscosity of the oil and negating the desired effect of the thermal system.
Other examples where gas lifts are not suitable for use are production wells where there are high levels of paraffins or asphaltenes. The pressure drop associated with delivering the gas lift, changes the thermodynamic state and makes injection gases colder than the production fluid. The mixing of the cold gases with the production fluids acts to deposit these constituents on the walls of production piping. These deposits can reduce or stop the production of oil.
For the reasons stated above and for other reasons stated below, which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for an effective and efficient apparatus and method of extracting oil from a reservoir.
BRIEF SUMMARY
The above-mentioned problems of current systems are addressed by embodiments of the present invention and will be understood by reading and studying the following specification.
The following summary is made by way of example and not by way of limitation. It is merely provided to aid the reader in understanding some of the aspects of the invention.
In one embodiment, a downhole combustor system is provided. The downhole combustor system includes a housing, a combustor and an exhaust port. The housing is configured and arranged to be positioned down a production well. The housing further forms a combustion chamber. A combustor is received within the housing. The combustor is configured and arranged to combust fuel in the combustion chamber. The exhaust port is positioned to deliver exhaust fumes from the combustion chamber into a flow of oil out of the production well.
In another embodiment, another downhole combustor system for a production well is provided. The downhole combustor system includes a housing, at least one delivery connector, a combustor and a combustion chamber exhaust port. The housing has an oil and exhaust gas mixture chamber and a combustor chamber. The housing has at least one oil input port that passes through an outer shell of the housing allowing passage into the oil and exhaust gas mixture chamber for oil from a production well. The housing further has at least one oil and exhaust gas output port that passes through the outer shell of the housing and is spaced a select distance from the at least one oil input port. The at least one oil and exhaust gas output port is configured and arranged to pass oil and exhaust gas out of the housing. The housing further has at least one delivery passage that passes within the outer shell of the housing. The at least one delivery connector is coupled to the housing. Each delivery connector is in fluid communication with at least one associated delivery passage. The combustor is configured and arranged to combust fuel in the combustion chamber. The combustor is further configured and arranged to receive fuel and air passed in the at least one delivery passage. The combustion chamber exhaust port is positioned to pass exhaust gases from the combustion chamber to the oil and exhaust gas mixture chamber.
In still another embodiment, a method of extracting oil from an oil reservoir is provided. The method includes: positioning a downhole combustor in a production wellbore to the oil reservoir; delivering fuel to the combustor through passages in a housing containing the combustor; initiating an ignition system of the combustor; combusting the fuel in a combustion chamber in the housing; and venting exhaust gases into the wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention can be more easily understood and further advantages and uses thereof will be more readily apparent, when considered in view of the detailed description and the following figures in which:
FIG. 1 is a side view of a thermal gas lift including a downhole combustor of one embodiment of the present invention;
FIG. 2 is a side view of the thermal gas lift of FIG. 1;
FIG. 3 is a top view of the thermal gas lift of FIG. 1;
FIG. 4A is a cross-sectional side view of the thermal gas lift along section line 4A-4A of FIG. 2;
FIG. 4B is a cross-sectional side view of the thermal gas lift along section line 4B-4B of FIG. 3;
FIG. 4C is a cross-sectional side view of the thermal gas lift along section line 4C-4C of FIG. 3;
FIG. 5A is a cross-sectional top view of the thermal gas lift along section line 5A-5A of FIG. 2;
FIG. 5B is a cross-sectional top view of the thermal gas lift along section line 5B-5B of FIG. 2;
FIG. 5C is a cross-sectional top view of the thermal gas lift along section line 5C-5C of FIG. 2;
FIG. 5D is a cross-sectional top view of the thermal gas lift along section line 5D-5D of FIG. 2;
FIG. 5E is a cross-sectional top view of the thermal gas lift along section line 5E-5E of FIG. 2;
FIG. 6A is a partial close-up cross-sectional view of the thermal gas lift of FIG. 4B;
FIG. 6B is another partial close-up cross-sectional view of the thermal gas lift of FIG. 4B;
FIG. 6C is a partial close-up cross-sectional view of the thermal gas lift of FIG. 4C;
FIG. 6D is another partial close-up cross-sectional view of the thermal gas lift of FIG. 4C;
FIG. 7 is a cross-sectional side view of a power generator including a downhole combustor of one embodiment of the present application; and
FIG. 8 is a cross-sectional side view of a reforming system including a downhole combustor of one embodiment of the present application.
In accordance with common practice, the various described features are not drawn to scale but are drawn to emphasize specific features relevant to the present invention. Reference characters denote like elements throughout the figures and the specification.
DETAILED DESCRIPTION
In the following detailed description, reference is made to the accompanying drawings, which form a part hereof and in which is shown by way of illustration, specific embodiments in which the inventions may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the claims and equivalents thereof.
Embodiments of the present invention provide a downhole combustor system for use in a production well. In some embodiments, the downhole combustor system is part of a thermal gas lift 100. Embodiments of a combustion thermal gas lift provide advantages over traditional thermal methods that direct steam down a drive side well (dry well). For example, since very little water is generated in the downhole combustor system (i.e., merely in the form of water vapor in the combustion process), limited clean up of water is required. Moreover, embodiments are relatively portable, which allows for ease of use in remote locations such as offshore reservoirs. The downhole combustor system has many other applications that go beyond just heating oil, such as, but not limited to, gasification, electricity generation and reforming as discussed briefly below.
Referring to FIG. 1, a thermal gas lift 100 of an embodiment with a downhole combustor system is illustrated. FIG. 1 illustrates, a casing 122 positioned in a wellbore 204 drilled through the ground 202 to an oil reserve 205 containing oil 206. Down the wellbore in the casing 122 is positioned a thermal gas lift 100. A packing seal 124 is positioned between a housing 102 of the thermal gas lift 100 and the casing 122 to form a seal. The packing seal 124 prevents oil 206 from passing up around the outside of the housing 102 of the thermal gas lift 100. The housing 102 of the thermal gas lift 100 of FIG. 1 is shown having a plurality of oil intake ports 104. Oil 206 from the oil reservoir 205 enters the oil intake ports 104 in the housing 102. The oil 206 is then heated up in the housing 102, as discussed below, and is then passed out of oil and exhaust gas outlet ports 106 in the housing 102. As illustrated, the oil and exhaust gas outlet ports 106 (or oil and gas outlet ports 106) of the housing 102 are positioned above packing seal 124. The oil 206 above the packing seal 124 can then be pumped out using traditional pumping methods known in the art. Since the viscosity of the oil 206 will have been reduced by the thermal gas lift 100, the traditional pumping methods will be effective even for high viscosity oil (heavy oil) production. Also illustrated in FIG. 1, is a first delivery intake connector 108 and a second delivery intake connector 110. The first delivery intake connector 108 is designed to couple a first delivery conduit 308 to the thermal gas lift 100 and the second delivery intake connector 110 is designed to couple a second delivery conduit 310 to the thermal gas lift 100. In an embodiment, first and second delivery conduits 308, 310 deliver select gases, fluids, and the like, to the thermal gas lift 100 for combustion such as, but not limited to, air and methane. Although, only two delivery intake connectors 108 and 110 are shown, it will be understood that more or even less connectors can be used depending on what is needed for the function of the thermal gas lift 100. Moreover, in one embodiment, a delivery intake connector 108 or 110 provides a connection for electricity to power an igniter system for the combustor 500, as discussed below.
FIG. 2 illustrates a side view of the thermal gas lift 100 and the packing seal 124. The housing 102 includes a first housing portion 102a that includes the oil inlet ports 104 and the oil and gas outlet ports 106, a second housing portion 102b and a third housing portion 102c. FIG. 3 illustrates a top view of the thermal gas lift 100 within the casing 122. The top view of FIG. 3 illustrates the first delivery intake connector 108 and the second delivery intake connector 110. Referring to cross-sectional side views in FIGS. 4A-4C, the components of an embodiment of the thermal gas lift 100 are provided. In particular, FIG. 4A is a cross-sectional view of the thermal gas lift 100 along section line 4A-4A of FIG. 2, FIG. 4B is a cross-sectional view of the thermal gas lift 100 along section line 4B-4B of FIG. 3 and FIG. 4C is a cross-sectional view of the thermal gas lift 100 along section line 4C-4C of FIG. 3. The thermal gas lift 100 of this embodiment, includes a combustor system 101 that includes a combustor 500 that is received in the third housing portion 102c and a combustion chamber 200 that is formed within the second housing portion 102b. The thermal gas lift 100 further includes a thermal exchange system 300 and a mix chamber 207 (oil and exhaust gas mixing chamber). The combustor 500 of the combustor system 101 ignites gases pumped into the thermal gas lift 100 via the first and second delivery intake connectors 108 and 110. In particular, passages in the housing 102 deliver the gases to the combustor 500. For example, referring to close-up section view 402 of the thermal gas lift 100 illustrated in FIG. 6A, an illustration of the first delivery intake connector 108 is shown. As illustrated, the first housing portion 102a includes passages 302a that are aligned with a passage in the first delivery intake connector 108 in which a gas flows through. Passages 302a are within an outer shell 103 of the housing 102 and extend through the length of the first housing portion 102a, as illustrated in FIG. 4B. Referring to the close-up section view 404 illustrated in FIG. 6B, passages 302a extend to passages 302b that extends radially around a second end of the first housing portion 102a. The close-up section view 406 of FIG. 6C further illustrates the connection of passages 302b to passages 302c in the second housing portion 102b. Passages 302b extend in the second housing portion 102b to the combustor 500 as illustrated in the close-up section view 408 illustrated in FIG. 6D. Hence, one method of providing passages for fluids, such as fuel and air to the combustor 500 has been provided. Passages 302a, 302b, and 302c not only provide a delivery means, the passages 302a, 302b, and 302c also provide a way of cooling the jacket (housing 102). That is, the flow of relatively cool air and fuel passing through the passages 302a, 302b, and 302c, helps cool the housing portions 102a and 102b when the combustor 500 is operating.
Close-up section views 404 and 406 of FIGS. 6B and 6C show a connection sleeve 420 used to couple the first housing portion 102a to the second housing portion 102b. As illustrated in FIG. 6C, the connection sleeve 420 includes internal threads 422 that threadably engage external threads 130 on the second housing portion 102b. The external threads 130 of the second housing portion 102b are proximate a first end 132 of the second housing portion 102b. The connection sleeve 420 further includes an internal retaining shelf portion 424 proximate a first end 420a of the sleeve 420 that is configured to abut a lip 140 that extends from a surface of the first housing portion 102a to couple first housing portion 102a to the second housing portion 102b. The lip 140 extends from the first housing portion 102a proximate a second end 142 of the first housing portion 102a. External threads 130 that extend from the first end 132 of the second housing portion 102b terminate at a first connection ring 450 that extends around an outer surface of the second housing portion 102b. The first connection ring 450 of the second housing portion 102b abuts a second end 420b of the connection sleeve 420 when the connection sleeve 420 is coupling the first housing portion 102a to the second housing portion 102b. In one embodiment, a seal (not shown) is positioned between connections between the connection sleeve 420 and the first and second housing portions 102a and 102b to seal the combustion chamber 200.
Close-up section view 408 of FIG. 6D, illustrates a connection between the second housing portion 102b and the third housing portion 102c. The third housing portion 102c can also be referred to as the “combustor cover” 102c. The combustor cover 102c includes internal threads 460 that extend from an open end 462 of the combustor cover 102c a select distance. The combustor cover 102c further includes a closed end 464. The internal threads 460 of the combustor cover 102c are engaged with external threads 150 on the second housing portion 102b. The external threads 150 extend from a second end 152 of the second housing portion 102b to a second ring 154 that extends around an outer surface of the second housing portion 102b. As illustrated, an edge about the open end 462 of the combustor cover 102c engages the second ring 154 when the combustor cover 102c is threadably engaged with the second housing portion 102b. In one embodiment, a seal (not shown) is positioned between the combustor cover 102c and the second housing portion 102b to seal the combustor 500 from external elements.
Close-up section view 408 of FIG. 6D further illustrates the combustor 500 of an embodiment. A similar combustor is described in U.S. Provisional Patent Application No. 61/664,015, titled “Apparatuses and Methods Implementing a Downhole Combustor,” filed on Jun. 25, 2012, which is herein incorporated in its entirety by reference. The combustor 500 includes a fuel delivery conduit 508 that is coupled to a delivery passage, such as a delivery passage 302c, in the second housing portion 102b of the housing 102. The fuel delivery conduit 508 is coupled to deliver fuel to a pre-mix fuel injector 506. Also coupled to the pre-mix fuel injector 506 is an air delivery conduit 512. The air delivery conduit 512 receives air through one of the delivery passages, such as delivery passage 302c, illustrated in the second housing portion 102b of the housing 102. In one embodiment, the air is delivered from the delivery passages 302c into an inner chamber 511 formed in the third housing portion 102c of the housing 102. The air and the fuel are mixed in the pre-mix fuel injector 506 and are delivered into an ignition cavity 502. The ignition cavity 502 is designed to ensure consistent and reliable ignition of the air/fuel mixture, as described further in U.S. Provisional Patent Application No. 61/664,015, even in a relatively high pressure environment. That is, combustion can be achieved with the present design of the thermal gas lift 100 even though the pressure in the combustion area of the thermal gas lift 100 can reach 2,000 psi or more, while the thermal gas lift 100 itself is subject to pressures of 30,000 psi or more in deep oil reserves. One or more glow plugs 514 are used to initiate combustion in the ignition cavity 502. The combustor 500 further includes a fuel injector plate 504 that includes a plurality of fuel injector ports, which are in fluid communication with a fuel delivery passage in the second housing portion 102b of the housing 102. Also illustrated in FIG. 6D is an air injection plate 516. The air injection plate 516 includes a plurality of passages that pass air into the combustion chamber 200 of the housing 102. In particular, the plurality of passages in the air injection plate 516 is in fluid communication with the air delivery passages in the second housing portion 102b of the housing 102. Air from the air injection plate 516, (which in one embodiment is an air swirl plate 516) and fuel from the fuel injector plate 504 are mixed and burned in the combustion chamber 200 of housing 102. The fuel and the air in combustion chamber 200 are initially ignited by the ignited air-fuel mixture from the ignition cavity 502. Once the fuel and the air in the combustion chamber 200 are ignited, the power to the glow plugs 514 is shut off. As described above, in one embodiment one of the delivery intake connectors 108 or 110 provides a connection to a conductive path through the housing 102 to supply the power to the one or more glow plugs 514.
The chemical energy of the gas in the combustion chamber 200 is converted into thermal energy due to the combustion of the air-fuel mixture, and temperature rises in the combustion chamber 200. The heat from the hot gases is used by the thermal exchange system 300 (FIG. 4A) in the first housing portion 102a to heat up oil 206 from the oil reservoir 205 entering in the oil intake ports 104 of the housing 102 (FIG. 1). The thermal exchange system 300 includes heat exchange tubes 320. The incoming oil 206 from the oil input ports 104 flows around the heat exchange tubes 320 therein receiving heat from the heat exchange tubes 320. Some of the tubes 320 have exhaust passages 321 (or combustion chamber exhaust ports 321) that allow the hot gases to escape from the combustion chamber 200 into the oil 206 passing through the first housing portion 102a and out the oil and gas outlet ports 106. The heat exchange tubes 320 can be further seen in the cross-sectional top view of FIG. 5A. In particular, FIG. 5A illustrates a top cross-sectional view of the thermal gas lift 100 along section line 5A-5A of FIG. 2. As illustrated in this view, top views of the heat exchange tubes 320 in the oil and exhaust gas mixing chamber 207 of the first section 102a of the housing 102 are shown. Some of the heat exchange tubes 320 include exhaust passages 321 (or exhaust ports) that allow the exhaust gas from the combustion chamber 200 to travel into the oil and exhaust gas mixing chamber 207. Also illustrated in FIG. 5A, is the oil and gas outlet ports 106 through the first housing portion 102a and passages 302a that deliver the fuel and air to the combustor 500. As discussed above, one of the passages 302a can be used as a path for a conductor to provide power to the one or more glow plugs 514 for initial ignition of the combustor 500. FIG. 5B illustrates a cross-sectional top view along section line 5B-5B of FIG. 2. This view is below the oil and gas outlet ports 106 in the first housing section 102a, but still above the heat exchange tubes 320.
FIG. 5C illustrates a cross-sectional top view along section line 5C-5C of FIG. 2. FIG. 5C illustrates mid-portions of some of the heat exchange tubes 320. FIG. 5D illustrates a cross-sectional top view along section line 5D-5D of FIG. 2. FIG. 5D illustrates the oil intake ports 104 through the first housing section 102a. Finally, FIG. 5E illustrates a cross-sectional top view along section line 5E-5E of FIG. 2. FIG. 5E illustrates a top of the fuel injector plate 504, the air swirl plate 516 and a plurality of passages 302c through the second housing portion 102b. As discussed above, the passages 302c provide paths for the fuel and the air to the combustor 500, as well as a conductor path to provide power to the glow plugs 514 of the combustor 500.
As discussed above, the downhole combustor 500 may have many different applications. For example, referring to FIG. 7, a power generator 600 is illustrated. In this embodiment, the combustor 500 transitions into an axial flow turbo-expander 602. The combustor 500 heats the oil and the combination of the heated oil and exhaust gases turns a progressive cavity pump 604 of power generator 600 having a rotationally mounted rod 606 with offset helically swept fins 608 and 610. The rotation of the progressive cavity pump 604 is used to generate direct mechanical work. The mechanical work, in one embodiment, can be used to generate electricity. This embodiment is useful when the wellbore is really deep and losses from power supplied externally at those distances are great. Hence, a power generating source down the wellbore is beneficial in this situation. Another embodiment that uses a downhole combustor 500 is illustrated in FIG. 8. FIG. 8 illustrates a reforming system 700. A reforming system 700, similar to the thermal lift system described above, is used to improve oil mobility with a mixture of heat plus the hydrogenation of the oil with a catalyst to generate byproducts such as H2, H2O, CO and CO2. In an embodiment of the reforming system 700, the downhole combustor 500 will support reaction temperatures of approximately 200° C. to 800° C., depending on different reaction temperatures and reaction times. An exhaust gas of CO2 will act as a solvent, lowering the heavy oil viscosity and density. For higher hydrogen to carbon ratio fuels, (such as methane) a steam reformer section is added to alter the chemical composition to a lighter mobile oil for ease of transportation. Lower hydrogen to carbon ratio fuels (such as propane) can react with water in the heavy oil to add additional H2 for the reaction process. The reforming system 700 of FIG. 8 includes a high pressure combustor 500 that combusts gases delivered through the housing 102, as discussed above. Exhaust gases are passed through the reformer heat exchange system 710 which heats the oil that enters the oil inlet ports 104 in the housing 102. The exhaust gases are then injected into the oil in the oil and exhaust gas mixture chamber 207 and the reformed hydrocarbon is passed out the oil and gas outlet ports 106 of the housing 102. Hence, the downhole combustor system described above has many different applications.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiments shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
Patent Grant
9228738
