The invention relates to a method for excavating deposits from an underground formation layer.
Such a method is known from U.S. Pat. Nos. 2,796,129; 4,232,904; 4,442,896; 5,033,795 and 7,647,967.
In the methods known from these prior art references a chain cutter string is pulled through a channel in an underground formation layer, such as a coal seam, and the chain cutter is simultaneously moved such that the cutters scrape material from the wall of the channel.
In the method known from U.S. Pat. No. 4,232,904 a U-shaped tunnel is bored into a substantially horizontal coal seam in a hill such that an both an entrance and an exit hole are laterally displaced along the front surface of the hill. A chain drive having rotating cutters spaced therealong is then drawn through the tunnel by a motor located outside the tunnel. The motor provides continuous outward pressure on the chain, causing the blades to rotate, thereby cutting the coal, thereby cutting the coal from the inside back wall of the tunnel. Buckets mounted along the chain remove the coal from the tunnel.
In the method known from U.S. Pat. No. 4,442,896 a U-shaped channel is drilled in a substantially vertical plane, whereupon the chain cutter string is inserted into the U-shaped channel and induced to make an oscillating movement while a tension force is applied thereto, so that the chain cutter string scrapes material from the upper wall of the U-shaped channel and thereby cuts a substantially vertical cavity in the formation.
In the method known from U.S. Pat. No. 5,033,795 a substantially horizontal U-shaped trench is digged in a formation adjacent to a horizontal mineral deposit seam and a continuous chain saw string is rotated between guide wheels mounted on a pair caterpillar trucks that slowly move along the parallel legs of the U-shaped trench, such that the chain cutter string cuts a substantially horizontal cavity in the mineral deposit seam.
In the method known from U.S. Pat. No. 7,647,967 hydrocarbon production from a subsurface oil reservoir is enhanced by inserting a flexible linear cutting device, such as a segmented diamond wire saw, into a pair of intersecting wellbores, to form a fissure beginning a the intersection of the wellbores and extending along the lower part of the length of the wellbores, which fissure intersects with natural or previously formed fractures to enhance the permeability and productivity of the subsurface oil reservoir.
In the method known from U.S. Pat. No. 2,796,129 a chaincutter assembly is inserted into a V-shaped horizontal tunnel assembly arranged between three tri-angularly spaced vertical wells and oil sand from a formation between these wells is mined by pulling the chaincutter assembly up and down through the V-shaped tunnel assembly until the chaincutter assembly forms a straight line between two of the three wells. In case the chaincutter assembly gets stuck in rocks or other blockages in the formation then the only option to retrieve the chaincutter assembly is to break it up and pull the broken pieces out of the wells.
A disadvantage of the known cutting methods is that there is no provision to control the lateral pressure of the chain cutter string against the formation or prevent it from sticking so there is a risk of damage and breaking of the cutter chain due to an overload.
Therefore there is a need to provide an improved method for mining deposits from an underground layer wherein the lateral pressure between the chain cutter string and the formation can be controlled and there is a provision to release the chain when it gets stuck.
In accordance with the invention there is provided a method of excavating deposits from an underground formation layer, comprising:
Optionally, during an initial or subsequent moment of execution of the method:
Alternatively or subsequently, during an initial or subsequent moment of execution of the method:
In the latter case the chain cutter control cable is gradually slackened while the chain cutter string is pulled through the first section of the channel assembly, thereby controlling the pressure between the chain cutter string and the sidewall of the first section.
The chain cutter string may be pulled sequentially from the first to the second well and from the second to the first well to mine deposits from the underground formation layer.
The chain cutter string is an endless chain, which carries a series of cutting elements and is moved in a continuous motion through the first section of the channel assembly and the first and second wells to mine deposits from the underground formation layer and the cutting elements may be selected from the group of mechanical cutters and/or hydraulic jets.
The method according to the invention may be used to create at least plane with a high permeability in a viscous crude oil containing formation in order to Enhance Oil Recovery (EOR) therefrom and/or to mine hydrocarbon deposits selected from the group of coal, oil shale, tar sand and heavy crude from the subsurface formation layer and/or for other purposes.
These and other features, embodiments and advantages of the method and according to the invention are described in the accompanying claims, abstract and the following detailed description of non-limiting embodiments depicted in the accompanying drawings, in which description reference numerals are used which refer to corresponding reference numerals that are depicted in the drawings.
A channel assembly 8,9 and 10 traverses the formation layer 4 and interconnects each of the wells 1,2 and 3 at these locations 5,6 and 7.
A chain cutter string 11 is inserted via the first and second wells 1 and 2 into a first section 8, 9 of the channel assembly that extends between the first and second wells 1 and 2.
A chain cutter control cable 12 extends from the third well 3 into a second section 10 of the channel assembly and is connected to the chain cutter string 11 at a branchpoint 13 of the first and second sections 8,9 and 10 of the channel assembly.
During normal use the chain cutter string 1 may be moved in a continuous or oscillating mode through the first section 8,9 of the channel assembly while exerting a lateral force to the chain cutter string 11 by the chain cutter control cable 12 such that the chain cutter string 11 is pressed against the wall of the first section 8,9 of the channel assembly and is thereby induced to carve deposits from of the underground formation layer 4.
Carved out deposits may be flushed from the channel assembly 8,9, 10 by injecting water, steam and/or another fluid into the third well 3 and discharging a slurry comprising the stream of the injected fluid and cuttings of carved out deposits via one or both of the other wells 1,2. It may be advantageous to reverse or alternate the direction in which the fluid flows through the channel and well assembly 1,2,3,8,9,10.
Alternatively, during an initial or subsequent moment of execution of the method the first section of the channel assembly has a V-shape as illustrated by dotted lines 18, 19 and has a first leg 18, which extends from the first well 1 towards the third well 3 and a second leg 19, which extends from the third well 3 towards the second well 2 and the chain cutter string 11 extends through the first and second legs 18, 19 of the V-shaped first section of the channel assembly. After drilling of the V-shaped channel assembly the chain cutter control cable 12 is connected to the chain cutter string 11 at or near the location 7 where the third well 3 penetrates the formation layer 4, which location 7 then forms the branchpoint 13 of the first and second sections 12, 18, 19 of the channel assembly, whereupon the chain cutter string is pulled in a continuous or oscillating mode through the first section 18,19 to carve out deposits from the underground formation layer 4.
In that situation chain cutter control cable 12 is gradually slackened while the chain cutter string 11 is pulled through the first section of the channel assembly, thereby controlling the pressure between the chain cutter string and the sidewall of the first section 8,9.
It will be understood that the chain cutter assembly may be pulled up and down by the chain cutter control cable 12 such that subsequently triangularly shaped slices are carved from the formation layer 4, which slices are within the triangle formed by the first and second sections 8,9, 18 and 19 of the channel assembly shown in
After a substantial part of the deposits contained in the part of the formation layer 4 within the triangle within the sections 8,9, 18 and 19 are removed a fourth well 15 may be drilled and be connected by a third channel section 16 to the existing channel section 19, whereupon the chain cutter string may be inserted into the section 19 and the chain cutter control cable may be inserted via the fourth well 15 into the third channel section 16, whereupon the chain cutter string 11 may be moved in a continuous or oscillating manner through the existing channel section 19 and moved towards the fourth well 15 by the chain cutter control cable 12 until a triangular section of the formation layer 4 between the channel section 19 and lines 20 and 21 is carved from the formation layer.
The process of drilling further wells and carving further triangular sections of the formation layer 4 adjacent to existing channel sections 8,9,19,19,20,21 may be repeated in a similar manner as described with reference to the fourth well 15 in
It will be understood that the use of a chain cutter control cable 12 that controls the lateral pressure between the chain cutter string 11 and the wall of the channel assembly will optimize the cutting performance of the cutters mounted on the chain cutter string 11 and will reduce the risk of breaking of the chain cutter string 11 and provide a possibility to relieve it when stuck. It will further be understood that water, steam and or other fluid injection hoses may be connected to the chain cutter string 11 and/or chain cutter control cable 12 to flush carved out cuttings from the channel and well assembly, thereby reducing the risk of plugging of the channel and well assembly.
Furthermore fluid injection hoses may be used to inject a filler and/or tailings into the created cavity in order to inhibit subsidence of the overburden.
The continuous chain cutter assembly 50,51 traverses a first section 53 of a channel assembly that is located between a region of disturbed rock 61 and an undisturbed rock formation 60. The chain cutter assembly 50,51 comprises cutting blades 51 that are mounted on chain sections 50, which chain sections 50 are pivotably interconnected by connector pins 52.
At a branchpoint 53a the first section 53 is connected to a second section 62 of the channel assembly 53,62, at which branchpoint 53a the chain cutter string 50,51 is connected to a control device 54.
The control device 54 comprises a connection assembly 40 to apply a controlled pulling force to the chain cutter string 50,51. The control device 54 controls the pressure of clamp blades 41a,41b to fixate the position of the control device 54 in the horizontal borehole 62 while cutting, like fixation devices known as friends' or ‘camalots’ in mountain climbing. The teeth on the clamp blades 41a,41b penetrate into the undisturbed rock formation 60 when pulling on the chain 50,51. The clamp blades 41a,41b have a wide operating range with respect to width of the second section 62 of the channel assembly they are in.
The clamp blades 41a, 41b are mounted on a common shaft 41 and connected by strings 43 to a motor assembly 44 that can pull the strings 43 to relieve the clamp blades 41a, 41b from the wall of the horizontal borehole 62.
The connection assembly further comprises a spring 45 which is connected by a connecting rod 46 to a shaft 48 which rotatably carries a guide wheel 47 provided with cutter blades 49, which intermesh with the cutting blades 51 of the chain cutter string 50,51 to control the lateral pulling force exerted by the control device 54 on the chain cutter string 50,51.
The guide wheel 46 thereby accurately guides and presses the cutter blades 51 of the chain cutter string 50, 51 against the undisturbed rock formation 60. It will be understood that the wheel 47 may have more teeth than four and may have a corresponding larger diameter.
Optionally hydraulic jets can be mounted on the control device 54 to facilitate movement in forward and/or backward direction.
The control device 70,74 is arranged in a second section 76 of the subsurface channel assembly 75,76 and comprises a connection bar 70, which is connected by a pin 71 to a connection rod 74, which is slideably arranged within a cylindrical housing 83 in which a spring 84 is arranged and which housing 83 is connected to a chain cutting string control cable 94.
The control device 70,74 furthermore comprises a pin 71 to connect the connection bar 70 to the connection rod 74 in a pivotable manner and optionally a cutting blade 72 which is arranged at the end of the connection bar 70. A pin 73 pivotably connects the cutting chain 80 to the connection rod 70. In this case the cutting chain 80 is a cable 80 of two parts with eyes at the end 82a and 82b and connected to pin 73. Here four cutting blades 81 are mounted over the complete circumference of the cable.
The control device 70, 74 shown in
Optionally, the width of the cutters 81 of the oscillating cutter assembly shown in
It will further be understood that the wells 1,2 and 3 shown in
It will also be understood that the channel assemblies 8-10,53,62,75 and 76 shown in FIGS. 1,2 and 3 may define a dipped, non-horizontal, plane to facilitate flushing of the cutting deposits to the bottom of one of the wells 1,2 or 3 in which a slurry pump may be arrange to remove the cutting deposits to the earth surface.
It will further be understood that the three wells 1,2,3 and channel assembly 8,9,10 may be drilled by known deviated and or river-crossing drilling technologies, wherein the first and second wells 1,2 and the first and second sections 8,9 of the channel assembly are drilled as a single U-shaped well having two entrances at the earth surface and the third well 3 and third section of the channel assembly 10 are drilled as a single J-shaped well, which is drilled towards the branchpoint 13 by known navigation and homing-in techniques.
Finally, it will be understood that the first or second well 1 or 2 may be located above the branchpoint 13 so that the first and second sections of the channel assembly 8-10 have a L-shaped configuration instead of the T-shaped configuration shown in
Fraccing is widely used in the oil and gas industry to generate vertical fluid conduit planes to improve hydrocarbon production. But, there are circumstances that it cannot be done or is less effective. Examples are high permeable, vuggy reservoirs and subsurface formations where the risk is high that the fracture penetrates into a sedimentary layer causing problems.
Also, it can be advantageous to make a fracture with a relative large fracture aperture to fill the fracture with a gel, cement or other material to create a baffle for fluid flow of substantial areal dimensions. One application is the control of water ingress from an active aquifer, with or without pollutants, another is a sufficient wide fracture for viscous oil production or tight or shale gas production.
The chain cutter as described with reference to
In the case that the planes to be cut out are predominantly vertical, simpler well configurations can be applied as illustrated in the following figures.
The oscillating chain cutter 401 is anchored in the bottom by anchor 403 of well 400 via spring 404. The spring can freely rotate in the plane of cutting. The chain cutter control device 407 which controls the lateral force of the chain cutter on the rock is connected to the chain cutter via a guide wheel 408. This wheel can be provided with cutter blades. The chain cutter control device can be similar as the one shown in
After drilling wells 400 and 405 with well intervention at location 413, the chain cutter is along line 410 and connected to the control device at this location. While pulling on the control cable, the oscillating chain cutter progresses from dashed dotted line 410 to dashed dotted line 411 to dashed dotted line 412.
It is obvious from
Alternatively, spring 404 is a pneumatic or electrically driven actuator, or is replaced by a guiding wheel. In the latter case the chain cutter string returns through well 400 to the surface allowing for a continuous (non-oscillating) movement of the chain cutter.
Optionally, control cable 606 is left out and the lowering of the control device is activated and controlled by changing the operating mode of the cutting chains 601A and 601B since they can be operated in phase and out of phase. A mechanical device in the control unit act on frictional differences between the control device and the chain cutters in this case. Optionally, the springs 604 and 610 can be replaced by an oscillating electric or pneumatic actuator as in the examples given before.
It will be understood that when the cutting operations start the side track 711 form a first section of the channel assembly and the lower parts of the vertical wells 700 and 705 form a second and third part of the channel assembly and that each of the control cables 706 and 707 forms a chain cutter control cable which controls the lateral force between the chain cutter assembly 712 and the bottom of the side track 711 from which formation particles are carved out by the oscillating or continuously rotating chain cutter assembly 712.
There is no limitation to tilt the cutting plane in
Number | Date | Country | Kind |
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10188575.4 | Oct 2010 | EP | regional |
11183234.1 | Sep 2011 | EP | regional |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2011/068297 | 10/20/2011 | WO | 00 | 3/26/2015 |