CN102835185B - Insulated conductor heater and at least part of method for the formation of insulated electric conductor - Google Patents

Insulated conductor heater and at least part of method for the formation of insulated electric conductor Download PDF

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Publication number
CN102835185B
CN102835185B CN201180018299.8A CN201180018299A CN102835185B CN 102835185 B CN102835185 B CN 102835185B CN 201180018299 A CN201180018299 A CN 201180018299A CN 102835185 B CN102835185 B CN 102835185B
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China
Prior art keywords
electric conductor
conductor
insulated electric
stratum
temperature
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CN201180018299.8A
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CN102835185A (en
Inventor
R·M·巴斯
R·G·哈利
J·M·诺埃尔
R·A·谢弗
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Shell Internationale Research Maatschappij BV
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Shell Internationale Research Maatschappij BV
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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/40—Heating elements having the shape of rods or tubes
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B36/00—Heating, cooling, insulating arrangements for boreholes or wells, e.g. for use in permafrost zones
    • E21B36/04—Heating, cooling, insulating arrangements for boreholes or wells, e.g. for use in permafrost zones using electrical heaters

Abstract

A kind of insulated conductor heater can comprise electric conductor, and described electric conductor produces heat when electric current is provided to described electric conductor.Electrical insulator surrounds described electric conductor at least in part.Described electrical insulator has when electric conductor produces heat along with the past of time keeps the resistivity of substantial constant or increase.External electrical conductor surrounds described electrical insulator at least in part.

Description

Insulated conductor heater and at least part of method for the formation of insulated electric conductor
Technical field
The present invention relates to the system and method for sub-surface heatedly.More particularly, the present invention relates to the system and method for heating underground hydrocarbon formations.Particularly, the present invention relates to insulated conductor heater and at least part of method for the formation of insulated electric conductor.
Background technology
The hydrocarbon obtained from subsurface formations is generally used for the energy, raw material and the consumer goods.Due to the concern of using up available hydrocarbon source and the concern declined to the total quality of the hydrocarbon produced, cause more efficiently exploiting, processing and/or utilize the technique in available hydrocarbon source to develop.Technique can be used for isolating hydrocarbon material from entering and/or use methods availalbe to extract too expensive subsurface formations before on the spot.The chemistry of hydrocarbon material in change subsurface formations and/or physical property may be needed to be easier to isolate from subsurface formations to make hydrocarbon material, and/or to improve the value of hydrocarbon material.Chemistry and physical change can comprise the generation of hydrocarbon material in stratum separable go out the situ reaction of fluid, change of component, changes in solubility, variable density, phase transformation and/or viscosity B coefficent.
Heater can be placed in the wellbore, for formation in technique on the spot.There is the much dissimilar heater that can be used for formation.Utilize the example of the technique on the spot of donwhole heater to illustrate and authorize the U.S. Patent No. 2,634,961 of Ljungstorm; Authorize the U.S. Patent No. 2,732,195 of Ljungstorm; Authorize the United States Patent (USP) 2,780,450 of Ljungstorm; Authorize the United States Patent (USP) 2,789,805 of Ljungstorm; Authorize the United States Patent (USP) 2,923,535 of Ljungstorm; Authorize the people's such as VanMerus 4,886,118; With the United States Patent (USP) 6,688 authorizing the people such as Wellington, in 387.
Mineral insulation (MI) cable (insulated electric conductor) for such as heating hydrocarbon containing formation in the application of underground is in some applications longer, larger external diameter can be had, and can operate at common voltage and the higher voltage of temperature and temperature in than MI cable industry.Much potential problem is there is in the manufacture and/or assembling process of the insulated electric conductor of length length.
Such as, there is the potential electricity caused owing to passing by time for the electrical insulator in insulated electric conductor deterioration occurs and/or mechanical problem.Also there are the potential problems relevant to electrical insulator needing to overcome in the assembling process of insulated conductor heater.Such as core is heaved or the problem such as other mechanical defects may occur in insulated conductor heater assembling process.There is such situation and may cause electric problem in heater use procedure, and heater may be made can not to be used for its expection object.
In addition, assemble at insulated electric conductor and/or be installed in the process of underground, the problem of the increase stress on insulated electric conductor may be there is.Such as, the miscellaneous part on insulated electric conductor or in insulated electric conductor can produce mechanical stress for transporting with winding on the spool of installing insulating conductor and expansion insulated electric conductor.Thus, the reduction or eliminate potential problem in the manufacture of insulated electric conductor, assembling and/or installation process of more reliable system and method is needed.
Summary of the invention
Embodiment as herein described relates in general to for the treatment of the system of subsurface formations, method and heater.Embodiment as herein described also relates in general to the heater wherein with novel components.Such heater obtains by using system and method as herein described.
In certain embodiments, the invention provides one or more systems, method and/or heater.In certain embodiments, described system, method and/or heater are for the treatment of subsurface formations.
In certain embodiments, insulated conductor heater comprises: electric conductor, and described electric conductor is configured to produce heat when electric current is provided to described electric conductor; Surround the electrical insulator of described electric conductor at least in part, wherein said electrical insulator has when electric conductor produces heat along with the time keeps the resistivity of substantial constant or increase in the past; And external electrical conductor, described external electrical conductor surrounds described electrical insulator at least in part.
In certain embodiments, insulated conductor heater comprises: electric conductor, and described electric conductor is configured to produce heat when electric current is provided to described electric conductor; Surround the electrical insulator of described electric conductor at least in part, wherein said electrical insulator comprises one or more collets, and described collets have when electric conductor produces heat along with the time keeps the resistivity of substantial constant or increase in the past; And external electrical conductor, described external electrical conductor surrounds described electrical insulator at least in part.
In certain embodiments, at least part of method for the formation of insulated electric conductor comprises: by insulated electric conductor partly for columniform Part I be placed in elongated cylindrical internal electrical conductor at least partly and partly for columniform elongated external electrical conductor at least part of between; By insulated electric conductor partly at least one extention columniform be placed in the external electrical conductor formed at least partly and partly of described internal electrical conductor at least part of between, the extention of wherein said insulated electric conductor along the length of this part of described elongated external electrical conductor from the Part I of insulated electric conductor flatly dislocation open; And make the extention of described insulated electric conductor shift to the Part I of described insulated electric conductor with the power of set point value, with the Part I making the extention of described insulated electric conductor and described insulated electric conductor substantially against each other.
According to the present invention, provide a kind of insulated conductor heater, comprising:
Electric conductor, described electric conductor is configured to produce heat when electric current is provided to described electric conductor;
Electrical insulator, described electrical insulator surrounds described electric conductor at least in part, and wherein said electrical insulator has when electric conductor produces heat along with the past of time keeps the resistivity of substantial constant or increase; And
External electrical conductor, described external electrical conductor surrounds described electrical insulator at least in part.
Alternatively, described electrical insulator comprises purified magnesium oxide.
Alternatively, described electrical insulator comprises Powder Oxidation magnesium.
Alternatively, described heater configuration becomes to be arranged in the opening of subsurface formations.
Alternatively, described heater configuration becomes to be arranged in the opening of subsurface formations, and described heater configuration becomes hot to providing at least partially of subsurface formations.
According to the present invention, additionally provide a kind of insulated conductor heater, comprising:
Electric conductor, described electric conductor is configured to produce heat when electric current is provided to described electric conductor;
Electrical insulator, described electrical insulator surrounds described electric conductor at least in part, wherein said electrical insulator comprises one or more collets, and described collets have when electric conductor produces heat along with the time keeps the resistivity of substantial constant or increase in the past; And
External electrical conductor, described external electrical conductor surrounds described electrical insulator at least in part.
Alternatively, described collets comprise purified magnesia block.
Alternatively, described collets are formed by Powder Oxidation magnesium.
Alternatively, described heater configuration becomes to be arranged in the opening of subsurface formations.
Alternatively, described heater configuration becomes to be arranged in the opening of subsurface formations, and described heater configuration becomes hot to providing at least partially of subsurface formations.
According to the present invention, additionally provide a kind of at least part of method for the formation of insulated electric conductor, comprising:
By insulated electric conductor partly for columniform Part I be placed in elongated cylindrical internal electrical conductor at least partly and partly for columniform elongated external electrical conductor at least part of between;
By insulated electric conductor partly at least one extention columniform be placed in the external electrical conductor formed at least partly and partly of described internal electrical conductor at least part of between, the extention of wherein said insulated electric conductor along the length of this part of described elongated external electrical conductor from the Part I of insulated electric conductor flatly dislocation open; And
The extention of described insulated electric conductor is made to shift to the Part I of described insulated electric conductor with the power of set point value, with the Part I making the extention of described insulated electric conductor and described insulated electric conductor substantially against each other,
Wherein, the electrical insulator formed by Part I and the extention of described insulated electric conductor has when internal electrical conductor produces heat along with the past of time keeps the resistivity of substantial constant or increase.
Alternatively, described method also comprises mechanically or pneumatically utilizes the power of set point value to make the extention of described insulated electric conductor shift to the Part I of described insulated electric conductor.
Alternatively, described method is also included in and makes after the extention of described insulated electric conductor shifts to the Part I of described insulated electric conductor, to form columniform elongated external electrical conductor substantially by the part of the described external electrical conductor comprising described insulated electric conductor part.
Alternatively, described method is also included in formation and substantially forms at least part of of described insulated electric conductor after columniform elongated external electrical conductor.
Alternatively, described method also comprises that to be formed partly for columniform elongated external electrical conductor by the elongate strip of electric conducting material at least part of.
Alternatively, described method also comprises that the part of elongated cylindrical internal electrical conductor is arranged in is partly the part of columniform elongated external electrical conductor.
According to the present invention, additionally provide a kind of insulated conductor heater, comprising:
Electric conductor;
Electrical insulator, wherein said electrical insulator has when electric conductor produces heat along with the past of time keeps the resistivity of substantial constant or increase; And
External electrical conductor.
In a further embodiment, the feature from specific embodiment can with the Feature Combination from other embodiments.Such as, from an embodiment feature can with the Feature Combination of any one embodiment from other embodiments.
In a further embodiment, any one processing that subsurface formations uses in method as herein described, system, power supply or heater is carried out.
In a further embodiment, other features can add specific embodiment as herein described to.
Accompanying drawing explanation
By referring to carry out below in conjunction with accompanying drawing to but the detailed description of exemplary embodiment at present preferred according to the present invention, by the feature and advantage of method and apparatus of the present invention for comprehend.
Fig. 1 shows the explanatory view of the embodiment of the part with regard to heat treatment system for the treatment of hydrocarbon containing formation.
Fig. 2 illustrates an embodiment of insulated electric conductor thermal source.
Fig. 3 illustrates an embodiment of insulated electric conductor thermal source.
Fig. 4 illustrates an embodiment of insulated electric conductor thermal source.
Fig. 5 A and 5B illustrates the cutaway view of an embodiment for the temperature-limiting heater parts in insulated conductor heater.
Fig. 6-8 illustrates the embodiment that can be used to provide the block pressing device of axial force to the block in heater assembly.
Fig. 9 illustrates an embodiment of plunger, and shape of cross section that this plunger has allows plunger to provide to act on block but power on the core do not acted in sheath.
Figure 10 illustrates an embodiment of the plunger that can be used to the block pushing skew (interlocking).
Figure 11 illustrates the embodiment that can be used to the plunger pushing the block that the top/end is arranged.
Although the present invention admits of various modification and alternative form, show its specific embodiment by way of example in the accompanying drawings, and will be described in detail them here.Accompanying drawing can not to scale (NTS) be drawn.Should understand, accompanying drawing and the detailed description about it are not intended to limit the invention to particular forms disclosed, but contrary, modification, equivalents and alternative form that the present invention will cover in the spirit and scope of the present invention that all fall into and be defined by the following claims.
Embodiment
Description below relates in general to the system and method for the treatment of the hydrocarbon in stratum.Process can be carried out to produce hydrocarbon products, hydrogen and other products in such stratum.
" alternating current (AC) " refers to time dependent electric current, and it sinusoidally changes direction substantially.AC produces kelvin effect electric current in ferromagnetic conductor.
In the scope reducing thermal output heating system, equipment and method, term " automatically " or " automatically " refer to that this type systematic, equipment and method play a role according to specific mode and do not use external control (such as peripheral control unit, as having the controller of temperature sensor and feedback loop, PID controller or predictive controller).
" connection " is meant to (such as, one or more intermediary connects) connected directly or indirectly between one or more object or parts.Term " directly connects " the direct connection be meant between object and parts, to make object or parts be connected to each other directly, thus object or parts is operated in single-point (" pointofuse ") mode.
" Curie temperature " refers to the temperature losing its whole ferromagnetic property at the above ferrimagnet of this temperature.Except lose its ferromagnetic property whole more than Curie temperature except, ferrimagnet also starts to lose its ferromagnetic property through ferrimagnet at the electric current increased.
" stratum " comprises one or more hydrocarbon bearing formation, one or more non-hydrocarbon layers, overlying rock and/or underlying stratum." hydrocarbon layers " refers to the layer of the hydrocarbonaceous in stratum.Hydrocarbon layers can comprise non-hydrocarbon material and hydrocarbon material." overlying rock " and/or " underlying stratum " comprises one or more dissimilar impermeable materials.Such as, overlying rock and/or underlying stratum can comprise rock, shale, mud stone or wet/tight carbonate.With regard in some embodiments of heat treating processes, overlying rock and/or underlying stratum can be included in relatively impermeable in heat treatment process on the spot and a hydrocarbon bearing formation that is not temperature influence or multiple hydrocarbon bearing formation, the described significant characteristic variations causing multiple hydrocarbon bearing formations of overlying rock and/or underlying stratum with regard to heat treating processes.Such as, underlying stratum can comprise shale or mud stone, but underlying stratum does not allow to be heated to pyrolysis temperature in heat treatment process on the spot.In some cases, overlying rock and/or underlying stratum can have certain permeability.
" formation fluid " refers to the fluid be present in stratum, and can comprise pyrolyzation fluid, synthesis gas, mobilization hydrocarbon and water (steam).Formation fluid can comprise hydrocarbon fluid and non-hydrocarbon fluids.Term " mobilization fluid " refers to the fluid that can flow due to the heat treatment of formation in hydrocarbon containing formation." fluid of production " refers to the isolated fluid from stratum.
Energy fluence that " heat flux " is time per unit per unit area (such as watt/square metre).
" thermal source " for for basically by conduction and/or radiant heat transmission to stratum provide at least partially heat any system.Such as, thermal source can comprise electric conducting material and/or electric heater, such as, arrange conductor in circuit and/or slender member, insulated electric conductor etc.Thermal source also can comprise the system by combustion fuel generation heat in or stratum outside on stratum.Described system can be surface combustion burner, downhole gas burner, nonflame profile combustion chamber and natural distributed combustion chamber.In certain embodiments, the heat being provided to one or more thermal source or the heat produced in one or more thermal source can be provided by other energy sources.Other energy sources can direct formation, or described energy can be applied to the Transfer Medium of direct or indirect formation.Should understand, one or more thermals source heat being applied to stratum can use the different energy.Thus, such as, for the stratum of specifying, some thermals source can from electric conducting material, resistance heater heat supply, some thermals source provide heat by burning, some thermals source can provide heat from one or more other energy (such as, chemical reaction, solar energy, wind energy, biomass or other regenerative resources).Chemical reaction can comprise exothermic reaction (such as oxidation reaction).Thermal source also can comprise electric conducting material and/or heater, and it provides heat to close and/or around heating location such as heater well region.
" heater " is any system for producing heat in well or near shaft area or thermal source.Heater may be, but not limited to, electric heater, burner, the combustion chamber of reacting with the material in stratum or the material produced from stratum, and/or it combines.
" hydrocarbon " is defined as the molecule formed primarily of carbon and hydrogen atom usually.Hydrocarbon also can comprise other elements, such as but not limited to halogen, metallic element, nitrogen, oxygen and/or sulphur.Hydrocarbon may be, but not limited to, oil bearing rock, pitch, pyrobitumen, oil, natural mineral wax and asphaltite.Hydrocarbon can be arranged in the Minerals And Rocks or adjacent with mineral substrate of the earth.Matrix can include but not limited to sedimentary rock, sand, silicilyte, carbonate, diatomite and other porous medias." hydrocarbon fluid " is the fluid comprising hydrocarbon.Hydrocarbon fluid can comprise, carry non-hydrocarbon fluids secretly, or is entrained in non-hydrocarbon fluids, and described non-hydrocarbon fluids is such as hydrogen, nitrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, water and ammonia.
" on the spot conversion process " refers to, from heat source hydrocarbon containing formation, be increased to higher than pyrolysis temperature by the temperature at least partially on stratum, to generate the technique of pyrolyzation fluid in the earth formation.
" with regard to heat treating processes " refers to use heat source hydrocarbon containing formation, the temperature at least partially on stratum is increased to higher than formation mobilization fluid, causes hydrocarbon material visbreaking and/or pyrolysis, thus produce the temperature of mobilization fluid, visbroken fluids and/or pyrolyzation fluid in the earth formation.
" insulated electric conductor " refers to conduct electricity and any elongated material covered by electrical insulating material in whole or in part.
" modulating dc current (DC) " refers to any changing currents with time of non-sine substantially that can produce kelvin effect electric current in ferromagnetic conductor.
" nitride " refers to the compound of one or more other elements in nitrogen and periodic table.Nitride includes but not limited to silicon nitride, boron nitride or aluminium nitride.
" perforation " comprises the opening of permission inflow in the wall of pipeline, pipe, conduit or other flow channels or outflow conduit, pipe, conduit or other flow channels, groove, hole or hole.
" phase transition temperature " of ferrimagnet refers to the temperature or the temperature range that undergo phase transition (such as from ferrite to austenite) period at material, and this phase transformation makes the magnetic permeability of ferrimagnet reduce.The reduction of this magnetic permeability be similar to due under Curie temperature ferrimagnet magnetic transition and the magnetic permeability that causes reduces.
" pyrolysis " is that chemical bond disconnects due to the applying of heat.Such as, pyrolysis can comprise only by heating change compound into one or more other materials.Heat can be delivered to the part on stratum to cause pyrolysis.
" pyrolyzation fluid " or " thermal decomposition product " refers to the fluid substantially generated in hydrocarbon pyrolytic process.The fluid generated by pyrolytic reaction can with other fluid chemical field in stratum.Mixture will be considered to pyrolyzation fluid or thermal decomposition product.As used herein, " pyrolysis zone " refers to the volume (such as, relatively permeable stratum, as tar sand formation) reacting to be formed pyrolyzation fluid on stratum.
" superposition of heat " refers to that the selected part from two or more thermals source to stratum provides heat, affects by these thermals source to make the formation temperature of at least between heat sources position.
" temperature-limiting heater " typically refers to and more than set point of temperature, to control thermal output (such as, reducing thermal output) and without the need to using the heater of external control, described external control is such as temperature controller, power governor, rectifier or other device.Temperature-limiting heater can be the resistance heater that AC (alternating current) or modulation (such as " copped wave ") DC (direct current) are powered.
" thickness " of layer refers to the thickness in the cross section of layer, and wherein, described cross section orthogonal is in the surface of described layer.
" changing currents with time " refers in ferromagnetic conductor, produce kelvin effect electric current and the time dependent electric current of size.Changing currents with time not only comprises alternating current (AC) but also comprise modulating dc current (DC).
Wherein electric current is directly applied to " regulate than " of the temperature-limiting heater of heater is for given electric current, the ratio of the minimum resistance more than maximum AC below Curie temperature or modulation DC resistance and Curie temperature.The adjustment of induction heater than being given electric current for being applied to heater, the maximum heat below Curie temperature export with Curie temperature more than the ratio that exports of minimum thermal.
" u shape pit shaft " refers to the pit shaft passed at least partially and by the second opening in stratum extending through stratum from the first opening stratum.In this article, pit shaft can only substantially in " v " shape or " u " shape, for the pit shaft being considered as " u " shape, " leg " of " u " shape should be understood to do not need parallel to each other or perpendicular to " end " of " u ".
Term " pit shaft " refers in stratum by drilling well or the hole that will be formed in pipeline insert into stratum.Pit shaft can have substantially circular cross section, or other shape of cross sections.As used herein, term " well " and " opening ", when relating to the opening in stratum, can exchange with term " pit shaft " and using.
Stratum can process to produce much different products in many ways.In heat treatment process on the spot, different steps or technique can be used for processing stratum.In certain embodiments, one or more parts on stratum isolate solvable mineral by solution mining from described part.Solution exploitation mineral can before with regard to heat treating processes, carry out in process and/or afterwards.In certain embodiments, the mean temperature of carrying out one or more parts of solution mining can keep below about 120 DEG C.
In certain embodiments, one or more parts on stratum are heated to be separated water outlet from described part, and/or isolates methane and other volatile hydrocarbons from described part.In certain embodiments, isolate in process at water and volatile hydrocarbon, mean temperature can be elevated to temperature lower than about 220 DEG C from ambient temperature.
In certain embodiments, one or more parts on stratum are heated to the temperature allowing hydrocarbon motion in stratum and/or visbreaking.In certain embodiments, the mean temperature of one or more parts on stratum is elevated to the mobilization temperature (such as, being elevated to from 100 DEG C to 250 DEG C, from 120 DEG C to 240 DEG C, or from the temperature range of 150 DEG C to 230 DEG C) of the hydrocarbon in described part.
In certain embodiments, one or more part is heated to the temperature allowing to carry out pyrolytic reaction in stratum.In certain embodiments, the mean temperature of one or more parts on stratum can be elevated to the temperature (such as from 230 DEG C to 900 DEG C, from 240 DEG C to 400 DEG C or from the temperature range of 250 DEG C to 350 DEG C) of the hydrocarbon pyrolysis in described part.
Use multiple heat source hydrocarbon containing formation may form thermal gradient around thermal source, the hydrocarbon in stratum is elevated to preferred temperature by described thermal source under the expectation rate of heat addition.By expecting that the mobilization temperature range of product and/or the temperature increase rate of pyrolysis temperature range can affect quality and the quantity of the formation fluid produced from hydrocarbon containing formation for obtaining.Formation temperature is slowly raised through mobilization temperature range and/or pyrolysis temperature range, the hydrocarbon producing high-quality height api gravity from stratum can be allowed.Slow rising formation temperature can allow to isolate by mobilization temperature range and/or pyrolysis temperature range and be present in a large amount of hydrocarbon in stratum as hydrocarbon products.
In some heat treatment embodiments on the spot, the part on stratum is heated to preferred temperature, instead of temperature is slowly raised through a temperature range.In certain embodiments, preferred temperature is 300 DEG C, 325 DEG C or 350 DEG C.Other temperature can be selected as preferred temperature.
The superposition carrying out the heat of self-heat power allows preferred temperature in the earth formation relatively fast and set up efficiently.Adjustable energy input from thermal source to stratum, to remain essentially in preferred temperature by the temperature in stratum.
By producing well from stratum activity in production and/or thermal decomposition product.In certain embodiments, the mean temperature of one or more part is elevated to mobilization temperature, and hydrocarbon is produced from producing well.Because mobilization is reduced to lower than set point value, therefore the mean temperature of one or more part can be elevated to pyrolysis temperature after manufacturing.In certain embodiments, the mean temperature of one or more part can be elevated to pyrolysis temperature and not produce too much before reaching pyrolysis temperature.The formation fluid comprising thermal decomposition product is produced by producing well.
In certain embodiments, after mobilization and/or pyrolysis, the mean temperature of one or more part can be elevated to the temperature enough allowing to carry out synthesis gas production.In certain embodiments, hydrocarbon can be elevated to the temperature enough allowing to carry out synthesis gas production, but not produce too much before reaching the temperature enough allowing to carry out synthesis gas production.Such as, synthesis gas can at about 400 DEG C to about 1200 DEG C, about 500 DEG C to about 1100 DEG C, or generate in the temperature range of about 550 DEG C to about 1000 DEG C.The fluid (such as steam and/or water) producing synthesis gas can be incorporated in described part and produce synthesis gas.Synthesis gas can be produced from producing well.
Solution mining, isolate volatile hydrocarbon and water, make hydrocarbon mobilization, pyrolysed hydrocarbon, generation synthesis gas and/or other technique can carry out in heat treatment process on the spot.In certain embodiments, some techniques can be carried out after with regard to heat treating processes.Such step can include but not limited to, from the partially recycled heat processed, pre-treatment part storing fluid (such as water and/or hydrocarbon) and/or pre-treatment part in carbon dioxide sequestration.
Fig. 1 illustrates the schematic diagram of the embodiment of the part with regard to heat treatment system for the treatment of hydrocarbon containing formation.Should can comprise with regard to heat treatment system and intercept well 200.Intercept well to be used for forming transfer barrier around processing region.Transfer barrier suppression fluid flows into and/or flows out treatment region.Intercept well and include but not limited to dewatering well, vacuum well, trapping well, injector well, grout wells, freezing well or its combination.In certain embodiments, intercepting well 200 is dewatering well.Dewatering well can be removed liquid water and/or suppress liquid water enter ground layer segment to be heated or arrive the stratum of heating.In the embodiment shown in fig. 1, intercept well 200 and be shown as and only extend along the side of thermal source 202, but obstruct well usually around for or be ready to use in whole thermals source 202 of formation heat-treatment zone.
Thermal source 202 be placed on stratum at least partially in.Thermal source 202 can comprise heater, such as insulated electric conductor, pipe inner wire heater, surface combustion burner, nonflame profile combustion chamber and/or natural distributed combustion chamber.Thermal source 202 also can comprise the heater of other types.Thermal source 202 is warm to providing at least partially of stratum, with the hydrocarbon in formation.Energy is provided to thermal source 202 by supply lines 204.Supply lines 204 can construct by different way according to for a thermal source of formation or the type of multiple thermal source.Supply lines 204 for thermal source can transmit the electric power for electric heater, can carry the fuel for burner, or carries the heat exchanging fluid circulated in the earth formation.In certain embodiments, can be provided by a nuclear power station or multiple nuclear power station for the electric power with regard to heat treating processes.The use of nuclear power can make to reduce or eliminate discharges carbon dioxide from regard to heat treating processes.
When formation, stratum expansion and rock-soil mechanics can be caused to move to the heat input in stratum.Thermal source can before dehydration, with dehydration simultaneously or open in dehydration.Computer simulation can be the response modeling of stratum to heating.Computer simulation can be used to develop mode and the sequential for starting thermal source in stratum, with the function making the rock-soil mechanics on stratum move other equipment that can not adversely affect in thermal source, producing well and stratum.
Formation can cause the permeability on stratum and/or the raising of voidage.The raising of permeability and/or voidage may due to the material in stratum because of evaporation be separated water outlet, isolate hydrocarbon and/or form crackle and reduce and cause.Due to permeability and the voidage of the raising on stratum, fluid can more easily stratum by heating part in flow.Due to improve permeability and voidage, stratum can be passed the sizable distance of strata deformation by the fluid in heating part.Described sizable distance more than 1000m, can depend on many factors, the temperature on the permeability on such as stratum, the performance of fluid, stratum, makes the barometric gradient of fluid movement.The ability that fluid moves quite large distance in the earth formation makes producing well 206 can be relatively far spaced apart in the earth formation.
Producing well 206 is for isolating formation fluid from stratum.In certain embodiments, producing well 206 comprises thermal source.Thermal source in producing well can producing well place or near one or more parts of formation.At some with regard in heat treating processes embodiment, the heat being provided to stratum from producing well of every meter of producing well is less than the heat being applied to stratum from the thermal source of formation of every meter of thermal source.The heat being applied to stratum from producing well is by evaporation and isolate the liquid phase fluid adjacent with producing well, and/or by forming macroscopic view and/or microfissure improves the stratum permeability adjacent with producing well, improves the stratum permeability adjacent with producing well.
A more than thermal source can be arranged in producing well.When stratum is fully heated by the heat superposition from adjacent multiple thermal source, thus when offsetting the benefit by using producing well formation to provide, the thermal source in producing well bottom can be closed.In certain embodiments, after the thermal source in producing well bottom stops, the thermal source in the top of producing well can stay open.Thermal source in producing well top can suppress condensation and the backflow of formation fluid.
In certain embodiments, the thermal source in producing well 206 allows formation fluid to isolate from stratum with vapor phase.Producing well place or through producing well provide heating can: (1) when produce fluid move in producing well near overlying rock time, suppress condensation and/or the backflow of such production fluid, (2) the heat input in stratum is brought up to, (3) compared with the producing well not having thermal source, improve the productivity ratio of producing well, (4) suppress the condensation of producing well medium high carbon number compound (hydrocarbon of C6 hydrocarbon and Geng Gao carbon number), and/or (5) improve producing well place or neighbouring stratum permeability.
Subsurface pressure in stratum may correspond to the fluid pressure produced in stratum.When being raised by the temperature in heating part of stratum, can be produced and evaporation of water and increasing due to the thermal expansion of fluid on the spot, the fluid that increases by the pressure in heating part.Control fluid from the pressure isolated speed tolerable control stratum, stratum.Pressure in stratum can be determined at multiple diverse location place, such as, near producing well or producing well place, near heating sources or thermal source place or monitor well place.
In some hydrocarbon containing formations, produce hydrocarbon from stratum and be suppressed, until at least some of hydrocarbon in stratum is by mobilization and/or pyrolysis.When formation fluid has selected quality, formation fluid can be produced from stratum.In certain embodiments, selected quality comprises at least about 20 °, the api gravity of 30 ° or 40 °.Suppress to produce until at least some hydrocarbon is by mobilization and/or pyrolysis, the conversion of heavy hydrocarbon to lighter hydrocarbons can be improved.Suppress initial production to reduce as far as possible and produce heavy hydrocarbon from stratum.The production of a large amount of heavy hydrocarbon may need expensive equipment, and/or shortens the useful life of production equipment.
In some hydrocarbon containing formations, the hydrocarbon in stratum can stratum by heating part in produce large permeability before, be heated to mobilization and/or pyrolysis temperature.Initial shortage permeability can suppress the fluid produced to be transported to producing well 206.In initial warm, at close thermal source place, the fluid pressure in stratum can increase.The fluid pressure increased discharges by one or more thermal source 202, monitor, changes and/or controls.Such as, selected thermal source 202 or independent relief well can comprise pressure-reducing valve, and some fluids are isolated from stratum by its permission.
In certain embodiments, the pressure that the expansion of other fluids owing to producing in mobilization fluid, pyrolyzation fluid or stratum can be allowed to produce improves, but can not there is the path or any other Pressure Drop that lead to producing well 206 in stratum.Fluid pressure can allow to increase to lithostatic pressure.When fluid is close to lithostatic pressure, crackle can be formed in hydrocarbon containing formation.Such as, crackle can stratum by heating part in formed from thermal source 202 to producing well.Some pressure in described part can be discharged by the generation of crackle in heating part.Pressure in stratum may must remain on below selected pressure, to suppress the coking of hydrocarbon in less desirable product, the fracture of overlying rock or underlying stratum and/or stratum.
Arrival mobilization and/or pyrolysis temperature and can from stratum produce after, pressure in stratum can change, thus the component of the formation fluid of change and/or production control, control condensable fluid in stratum with can not percentage compared with condensed fluid, and/or control the api gravity of the formation fluid produced.Such as, the production that pressure can cause larger condensable fluid component is reduced.Condensable fluid component can comprise the alkene of larger percentage.
At some with regard in heat treating processes embodiment, the pressure in stratum can keep enough high, produces with the formation fluid promoting to have the api gravity being greater than 20 °.Keep the pressure increased can suppress with regard to stratum settlement in heat treatment process in the earth formation.Keep the pressure increased can to reduce or eliminate in surface layer fluid compressively in collecting pipe, transport fluid into the needs for the treatment of facility.
Stratum by heating part in keep the pressure increased can allow to produce the hydrocarbon of quality and the low relative molecular amount in a large number with raising astoundingly.Pressure can remain the compound higher than selected carbon number making the formation fluid produced have minimum.Selected carbon number can be 25 to the maximum, is 20 to the maximum, is 12 to the maximum, or is 8 to the maximum.Some high carbon number compounds can be carried secretly in steam in the earth formation, and can isolate from stratum with steam.Keep the pressure increased that high carbon number compounds and/or polycyclic hydrocarbon compounds can be suppressed to be entrained in steam in the earth formation.High carbon number compounds and/or polycyclic hydrocarbon compounds can liquid phase retain very long-time in the earth formation.This can be compound pyrolysis very for a long time and provides grace time, to form comparatively low carbon number compound.
The generation of the hydrocarbon of low relative molecular amount is considered to partly due to automatic generation and the reaction of the hydrogen in a part for hydrocarbon containing formation.Such as, keep the pressure increased that the hydrogen produced in pyrolytic process can be forced to enter liquid phase in stratum.The temperature described part be heated in pyrolysis temperature range can by the hydrocarbon pyrolysis in stratum to produce liquid phase pyrolysis fluid.The liquid phase pyrolysis fluid components produced can comprise double bond and/or base.Hydrogen (H in liquid phase 2) double bond in the pyrolyzation fluid of generation can be reduced, reduce the polymerization of long-chain compound from the pyrolyzation fluid produced or the possibility of formation thus.In addition, H 2also can neutralize the base in the pyrolyzation fluid of generation.H in liquid phase 2the pyrolyzation fluid produced can be suppressed to react each other and/or react with other compounds in stratum.
The formation fluid produced from producing well 206 is transferred to treatment facility 210 by collecting pipe 208.Formation fluid also can be produced from thermal source 202.Such as, fluid can produce from thermal source 202 pressure controlled the stratum adjacent with described thermal source.The fluid produced from thermal source 202 to collecting pipe 208 by conduit or Pipeline transport, or is produced fluid and is delivered directly to treatment facility 210 by conduit or pipeline.Treatment facility 210 can comprise separator, reaction unit, lifting device, fuel cell, turbine, storage container and/or for the treatment of the other system of producing formation fluid and device.Described treatment facility can form the transfer the fuel at least partially carrying out the hydrocarbon produced since stratum.In certain embodiments, transfer the fuel can be burner oil, such as JP-8.
Insulated electric conductor can be used as the electrical heater element of heater or thermal source.Insulated electric conductor can comprise by electrical insulator around internal electrical conductor (core), and external electrical conductor (sheath).Electrical insulator can comprise mineral insulating material (such as magnesium oxide) or other electrical insulating materials.
In certain embodiments, insulated electric conductor is placed in the opening in hydrocarbon containing formation.In some embodiments, insulated electric conductor is placed in the bore hole opening in hydrocarbon containing formation.Insulated electric conductor is placed in the bore hole opening in hydrocarbon containing formation and heat can be made to be delivered to stratum by radiation and conduction from insulated electric conductor.Use bore hole opening can be convenient to insulated electric conductor to fetch from well, if necessary.
In certain embodiments, insulated electric conductor is placed in sleeve pipe in the earth formation, can be fixed in stratum, sand, rubble or other fillers maybe can be used to be packed in opening.Insulated electric conductor can be supported on setting supporting member in the opening.Supporting member can be cable, bar or pipeline (such as conduit).Supporting member can be made up of metal, pottery, inorganic material or its combination.Because the part of in use supporting member can be exposed to formation fluid and heating, therefore supporting member can chemical species and/or heat-resisting.
The connector of tether, spot welding and/or other types can be used for insulated electric conductor to be connected to supporting member at the diverse location place along insulated electric conductor length.Supporting member can be attached to well head at upper surface place, stratum.In certain embodiments, insulated electric conductor has enough structural strengths, thus does not need supporting member.Insulated electric conductor can have at least some flexibility under many circumstances, to prevent thermal expansion from damaging when occurrence temperature changes.
In certain embodiments, insulated electric conductor is placed in the wellbore when not having supporting member and/or centralizer.There is no the insulated electric conductor of supporting member and/or centralizer to have to suppress the appropriately combined of the insulated electric conductor in use heat and corrosion resistance of fault, creep strength, length, thickness (diameter) and metallurgical performance.
Fig. 2 illustrates the three-dimensional view of the end of an embodiment of insulated electric conductor 252.Insulated electric conductor 252 can have the shape of cross section of any expectation, such as, be still not limited to circle (shown in Fig. 2), triangle, ellipse, rectangle, hexagon or irregularly shaped.In certain embodiments, insulated electric conductor 252 comprises core 218, electrical insulator 214 and sheath 216.Core 218 can at electric current by resistance heating during described core.Alternating current or changing currents with time and/or direct current can be used for providing power to core 218, to make core resistance heating.
In certain embodiments, electrical insulator 214 suppresses current leakage to sheath 216 and arc discharge.Electrical insulator 214 can by the heat heat transfer of generation in core 218 to sheath 216.Sheath 216 can to stratum radiation or heat by conduction.In certain embodiments, insulated electric conductor 252 length is 1000 meters or longer.Longer or shorter insulated electric conductor also can be used for the needs meeting application-specific.The size of the core 218 of insulated electric conductor 252, electrical insulator 214 and sheath 216 may be selected to insulated electric conductor is had enough intensity comes even still can self-supporting under upper limit working temperature.Such insulated electric conductor can from well head or the cradle hangs being arranged on the near interface between overlying rock and hydrocarbon containing formation, and without the need to extending to the supporting member in hydrocarbon containing formation together with insulated electric conductor.
Insulated electric conductor 252 can be designed for and operate under Gao Keda about 1650 watts/meter or higher power level.In certain embodiments, when formation, operate under the power level of insulated electric conductor 252 between about 300 watts/meter and about 1150 watts/meter.Insulated electric conductor 252 can be designed so that the maximum voltage level under usual operating temperature does not make electrical insulator 214 produce significant heat and/or electrical breakdown.Insulated electric conductor 252 can be designed so that sheath 216 is no more than and will cause the significantly reduced temperature of sheath material corrosion resisting property.In certain embodiments, insulated electric conductor 252 can be designed to reach the temperature in the scope between about 650 DEG C and about 900 DEG C.Can be formed there are other opereating specifications insulated electric conductor to meet specific operation requirement.
Fig. 2 illustrates the insulated electric conductor 252 with single core 218.In certain embodiments, insulated electric conductor 252 has two or more cores 218.Such as, single insulated electric conductor can have three cores.Core 218 can be made up of metal or other electric conducting materials.Metal for the formation of core 218 can include but not limited to nichrome, copper, nickel, carbon steel, stainless steel and combination thereof.In certain embodiments, core 218 is chosen to have certain diameter and resistivity at the operational makes it in electricity with the resistance making it and obtained by Ohm's law and configuration aspects is stablized, thus the maximum voltage that the every meter of power consumption, heater length and/or the core material that realize selecting allow.
In certain embodiments, core 218 is made from a variety of materials along the length of insulated electric conductor 252.Such as, the Part I of core 218 can be made up of the material that the Part II of core described in resistance ratio is much lower.Part I can with do not need to be heated to the stratum placed adjacent with the second the same high-temperature in stratum, described second stratum is adjacent with Part II.The resistivity of the various piece of core 218 is by having variable-diameter and/or assigning to regulate by having the multiple cores be made up of different materials.
Electrical insulator 214 can be made of a variety of materials.Normally used powder can include but not limited to, MgO, Al 2o 3, zirconia, BeO, the different chemical variant of spinelle, and combination.MgO can provide good heat conductivity and electrical insulation capability.The electrical insulation capability expected comprises low-leakage current and high dielectric strength.Low-leakage current reduces the possibility of thermal breakdown, and high dielectric strength reduces the possibility striding across insulator arc discharge.If leakage current causes the progressive rising of the temperature of insulator, then may there is thermal breakdown, also cause striding across insulator arc discharge.
Sheath 216 can be outer metal level or conductive layer.Sheath 216 can be in hot formation fluid and contact.Sheath 216 can be made up of the material under high-temperature with highly corrosion resistant.The alloy that can be used for the desired operation temperature range of sheath 216 include but not limited to 304 stainless steels, 310 stainless steels, with (IncoAlloysInternational, Huntington, WestVirginia, U.S.A.).The thickness of sheath 216 enough may use and continue 30 to ten years in heat and corrosive atmosphere.The thickness of sheath 216 can usually at about 1mm with about change between 3.5mm.Such as, the 310 stainless steel skins that 1.3mm is thick can be used as sheath 216, to provide the formation being continued above 3 years by the good chemical resistance of the sulfidation corrosion in the thermal treatment zone.Larger or less jacket thickness can be used for meeting specifically applies requirement.
One or more insulated electric conductor can be placed in opening in the earth formation, to form a thermal source or multiple thermal source.Each insulated electric conductor that electric current can transport through in opening carrys out formation.Alternatively, electric current can transport through the selected insulated electric conductor in opening.The conductor do not used can be used as back-up heater.Insulated electric conductor any convenient manner can be electrically coupled to power supply.Every one end of insulated electric conductor can be connected to the lead-in cable through well head.Such structure has 180 ° of bendings near being arranged on bottom thermal source (" zig zag " bending) or part of turning round usually.The insulated electric conductors comprising 180 ° of bendings or part of turning round can not need bottom terminals, but 180 ° to bend or turn round part may be electricity in heater and/or structural weak points.Insulated electric conductor can series, parallel or electrically connect together with connection in series-parallel hybrid mode.In some embodiments of thermal source, electric current can be sent in the conductor of insulated electric conductor, and by place bottom thermal source, core 218 is connected to sheath 216 (shown in Fig. 2) and is returned by the sheath of insulated electric conductor.
In certain embodiments, three insulated electric conductors 252 are electrically coupled to power supply with 3 phase Y-shaped structures.Fig. 3 illustrates in the opening in subsurface formations with the embodiment of three insulated electric conductors of Y-shaped structure connection.Fig. 4 illustrates the embodiment of three insulated electric conductors 252 that can take out from the opening 238 stratum.Three insulated electric conductors in Y-shaped structure do not need bottom to connect.Alternatively, whole three insulated electric conductors of Y-shaped structure can link together near the bottom of opening.Described connection can directly be formed in the end of the heating part of insulated electric conductor or in the end of cold pin (less resistive part), and wherein said cold pin is connected to heating part at the bottom place of insulated electric conductor.Bottom connects the tank that insulator can be used to fill or seal or the tank using epoxy resin filling obtains.This insulator can be the component identical with the insulator being used as electrical insulating material.
In Fig. 3 and 4, illustrated three insulated electric conductors 252 can use centralizer 222 to be connected to supporting member 220.Alternatively, insulated electric conductor 252 can use metal tape to be directly bundled into supporting member 220.Centralizer 222 can make insulated electric conductor 252 be held in place on supporting member 220 and/or suppress the movement of insulated electric conductor 252 on supporting member 220.Centralizer 222 can be made up of metal, pottery or its combination.Metal can be the metal that stainless steel maybe can tolerate any other type of corrosion and hot environment.In certain embodiments, centralizer 222 is the bending metals band being welded to supporting member with the distance being less than about 6m.Al is may be, but not limited to, for the pottery in centralizer 222 2o 3, MgO or other electrical insulators.Centralizer 222 can keep the position of insulated electric conductor 252 on supporting member 220, is suppressed under the operating temperature of insulated electric conductor to make the movement of insulated electric conductor.But insulated electric conductor 252 is some flexibility also, to bear the expansion of supporting member 220 in heating process.
Supporting member 220, insulated electric conductor 252 and centralizer 222 can be placed in the opening 238 in hydrocarbon layers 240.Insulated electric conductor 252 can use cold pin 226 to be connected to bottom conductor junction surface 224.Each insulated electric conductor 252 can electrically connect by bottom conductor junction surface 224 each other.Bottom conductor junction surface 224 can comprise conduction but in opening 238 occur temperature under infusible material.Cold pin 226 can be have insulated electric conductor more low-resistance than insulated electric conductor 252.
Introduce conductor 228 and can be connected to well head 242, to provide electric power to insulated electric conductor 252.Introduce conductor 228 to be made up of the conductor of rather low resistance, produce to make relatively little heat introduce conductor because electric current passes through.In certain embodiments, the twisted copper wires that conductor is rubber or polymer insulation is introduced.In certain embodiments, introducing conductor is the mineral insulated conductor with copper core.Introduce conductor 228 and be connected to well head 242 by the sealing flange be arranged between overlying rock 246 and surface 250 at surperficial 250 places.Sealing flange can escape to surface 250 from opening 238 by suppression fluid.
In certain embodiments, introducing conductor 228 uses transition conductor 230 to be connected to insulated electric conductor 252.Transition conductor 230 can be the less resistive part of insulated electric conductor 252.Transition conductor 230 can be described as " cold pin " of insulated electric conductor 252.Transition conductor 230 can be designed to the power that per unit length consumes about 1/10th to about 1/5th of consumed power in the main heating part per unit length of insulated electric conductor 252.Transition conductor 230 can usually at about 1.5m with about between 15m, but can use shorter or longer length to adapt to application-specific requirement.In one embodiment, the conductor of transition conductor 230 is copper.The electrical insulator of transition conductor 230 can be the electrical insulator with identical type used in main heating part.The sheath of transition conductor 230 can be made up of corrosion resistant material.
In certain embodiments, transition conductor 230 is connected to by junction joint or other connecting joints and introduces conductor 228.Junction joint also can be used for transition conductor 230 to be connected to insulated electric conductor 252.Junction joint can tolerate the temperature (such as equaling target area operating temperature or the temperature for the half of target area operating temperature) close to target area operating temperature, depends on whether the number of conductor in opening and junction joint interlock.The density of the electrical insulating material in junction joint should be enough high to tolerate temperature required and operating voltage under many circumstances.
In certain embodiments, as shown in Figure 3, filler 248 is arranged between overlying rock sleeve pipe 244 and opening 238.In certain embodiments, overlying rock sleeve pipe 244 can be fixed to overlying rock 246 by reinforcing material 232.Filler 248 can flow to surface 250 from opening 238 by suppression fluid.Reinforcing material 232 can comprise the G level or H class a portland cement, slag or silica flour and/or its mixture that such as mix with the silica flour for improving high-temperature behavior.In certain embodiments, reinforcing material 232 radial direction extends the width of about 5cm to about 25cm.
As shown in Figures 3 and 4, supporting member 220 and introducing conductor 228 can be connected to well head 242 at surface 250 place on stratum.Surface conductor 234 can be attached to well head 242 around reinforcing material 232.The embodiment of surface conductor may extend into the degree of depth of about 3m to about 515m in the opening in stratum.Alternatively, surface conductor may extend into the degree of depth of about 9m in stratum.Electric current can be provided to insulated electric conductor 252 from power supply, thus produces heat due to the resistance of insulated electric conductor.Can transmit opening 238 from the heat of three insulated electric conductors 252 generations and carry out heat hydrocarbon layer 240 at least partially.
The heat produced by insulated electric conductor 252 can heat hydrocarbon containing formation at least partially.In certain embodiments, stratum is transferred heat to basically by the heat produced to the radiation on stratum.Due to the gas existed in opening, therefore some heat are by the conduction of heat or convection current transmission.Opening can be bore hole opening, as shown in Figures 3 and 4.Bore hole opening eliminate to by the heater thermosetting jail cost relevant to stratum, the cost relevant to sleeve pipe, and/or heater is encapsulated in the cost in hole.In addition, the heat trnasfer undertaken by radiation is usually than more efficient by conduction, and therefore heater can operate at a lower temperature in uncased wellbore.Conductive heat transfer in thermal source initial operation process strengthens by adding gas in the opening.Under gas can remain on the pressure of Gao Keda about 27 bar absolute pressure.Gas can include but not limited to carbon dioxide and/or helium.Insulated conductor heater in uncased wellbore can advantageously free wxpansion or contraction, with accommodate thermal expansion and contraction.Insulated conductor heater can advantageously can take out or arrangement again from uncased wellbore.
In certain embodiments, insulated conductor heater assembly uses winding assembly to install or takes out.A more than winding assembly can be used for installing insulating conductor and supporting member simultaneously.Alternatively, supporting member can use coil device to install.Heater can be unfolded, and is connected to support time in support fill-in well.Electric heater and supporting member can launch from winding assembly.Liner can be connected to supporting member and heater along the length of supporting member.Other winding assemblies can be used for other electrical heater element.
Temperature-limiting heater can be at certain temperatures for heater provides the structure of automatic temp limit performance and/or can comprise at certain temperatures for heater provides the material of automatic temp limit performance.In certain embodiments, ferrimagnet is used in temperature-limiting heater.Ferrimagnet the Curie temperature of material and/or transition temperature range or near can self limit temperature, to provide the heat of minimizing when changing currents with time puts on material.In certain embodiments, the temperature of ferrimagnet self limit temperature-limiting heater under selected temperature, this selected temperature is approximately Curie temperature and/or in transition temperature range.In certain embodiments, selected temperature in about 35 DEG C of transition temperature range and/or Curie temperature, in about 25 DEG C, in about 20 DEG C, or in about 10 DEG C.In certain embodiments, ferrimagnet and other material (such as high conductance material, high-strength material, resistant material or its combine) connect to provide various electricity and/or mechanical performance.Some parts of temperature-limiting heater can have the resistance (by different geometries and/or by use different ferromagnetism and/or nonferromugnetic material caused by) lower than other parts of temperature-limiting heater.Make the parts of temperature-limiting heater have various material and/or size, just allow the expectation thermal output of each parts obtained from heater.
Temperature-limiting heater other heater comparable is more reliable.Temperature-limiting heater can comparatively be not easy to due to the focus in stratum and damage or lost efficacy.In certain embodiments, temperature-limiting heater allows homogeneous heating stratum substantially.In certain embodiments, temperature-limiting heater can by the whole length along heater operation and more effectively formation under higher evenly heat exports.Temperature-limiting heater is along whole length operation under higher evenly heat exports of heater, if this is because exceed along the temperature of any point of heater or be about to exceed the maximum allowable operating temperature (M.A.O.T.) of heater, the power being sent to heater need not be lowered to the degree of whole heater, and so typical constant wattage heater is exactly.The thermal output close to the Curie temperature of heater and/or the part of transition temperature range carrying out self-limiting heater temperature automatically reduces, and does not need the changing currents with time to being applied to heater to carry out in check adjustment.Due to the change of the electrical property (such as resistance) of the part of temperature-limiting heater, thermal output automatically reduces.Therefore, during the greater part of heating process, supply more power by temperature-limiting heater.
In certain embodiments, when temperature-limiting heater is by changing currents with time energy supply, first the system comprising temperature-limiting heater provides the first thermal output, then when transition temperature range and/or the Curie temperature of the active component close to heater, at transition temperature range and/or the Curie temperature of the active component of heater, or more than the transition temperature range and/or Curie temperature of the active component of heater, provide (the second thermal output) thermal output of reduction.First thermal output is thermal output at a certain temperature, and below this temperature, temperature-limiting heater starts self limit.In certain embodiments, first thermal output is the temperature of below the Curie temperature of ferrimagnet in temperature-limiting heater and/or transition temperature range about 50 DEG C, the temperature of about 75 DEG C below, the below thermal output of the temperature of about 100 DEG C or the temperature of following about 125 DEG C.
Changing currents with time (alternating current or the modulating dc current) energy supply of temperature-limiting heater by supplying at well head.Well head can comprise power supply and for other parts (such as modulating part, transformer and/or capacitor) to temperature-limiting heater supply power.Temperature-limiting heater can be one of many heaters of the part for formation.
In certain embodiments, thinner conductive layer is used for the major part providing the resistance heat of temperature-limiting heater to export under up to the Curie temperature of ferromagnetic conductor and/or the temperature of transition temperature range or the temperature near it.This type of temperature-limiting heater can be used as the heater in insulated conductor heater.The heater of insulated conductor heater can be positioned at epitheca inside, between this epitheca and heater, have insulating barrier.
Fig. 5 A and 5B shows the cutaway view of an embodiment of the insulated conductor heater of the temperature-limiting heater had as heater.Insulated electric conductor 252 comprises core 218, ferromagnetic conductor 236, inner conductor 212, electrical insulator 214 and sheath 216.Core 218 is copper core.Ferromagnetic conductor 236 is such as iron or ferroalloy.
The thinner conductive layer that inner conductor 212 is formed for nonferromugnetic material, has higher conductivity than ferromagnetic conductor 236.In certain embodiments, inner conductor 212 is copper.Inner conductor 212 can be copper alloy.Copper alloy has more flat resistance relative to temperature curve than blunt copper usually.More flat resistance can provide the less change of the thermal output according to the temperature change up to Curie temperature and/or transition temperature range relative to temperature curve.In certain embodiments, inner conductor 212 is for having copper (the such as CuNi of the nickel calculating by weight 6% 6or LOHM tM).In certain embodiments, inner conductor 212 is CuNi 10fe 1mn alloy.Below the Curie temperature and/or transition temperature range of ferromagnetic conductor 236, the major part of the current flowing of inner conductor 212 is led in the magnetic behavior constraint of ferromagnetic conductor.Therefore, below Curie temperature and/or transition temperature range, the major part that inner conductor 212 provides the resistance heat of insulated electric conductor 252 to export.
In certain embodiments, together with core 218 and ferromagnetic conductor 236, inner conductor 212 size makes inner conductor provide the heat output of expectation and the adjustment ratio of expectation.Such as, inner conductor 212 can have the cross-sectional area of about 2 or 3 times of the cross-sectional area lower than core 218.Usually, if inner conductor is copper or copper alloy, inner conductor 212 must have less cross-sectional area, to provide the thermal output of expectation.Have in the embodiment of copper inner conductor 212 at one, core 218 has the diameter of 0.66cm, and ferromagnetic conductor 236 has the external diameter of 0.91cm, and inner conductor 212 has the external diameter of 1.03cm, electrical insulator 214 has the external diameter of 1.53cm, and sheath 216 has the external diameter of 1.79cm.Have in the embodiment of CuNi6 inner conductor 212 at one, core 218 has the diameter of 0.66cm, and ferromagnetic conductor 236 has the external diameter of 0.91cm, and inner conductor 212 has the external diameter of 1.12cm, electrical insulator 214 has the external diameter of 1.63cm, and sheath 216 has the external diameter of 1.88cm.With below Curie temperature and/or transition temperature range, do not use thin inner conductor to compared with the insulated electric conductor providing most of thermal output, this type of insulated electric conductor is usually less and manufacturing cost is lower.
Electrical insulator 214 can be magnesium oxide, aluminium oxide, silicon dioxide, beryllium oxide, boron nitride, silicon nitride or its combination.In certain embodiments, electrical insulator 214 is magnesian compacted powder.In certain embodiments, electrical insulator 214 comprises the bead of silicon nitride.
In certain embodiments, little material layer is placed between electrical insulator 214 and inner conductor 212 to prevent copper from migrating to electrical insulator at relatively high temperatures.Such as, little nickel dam (such as the nickel of about 0.5mm) can be placed between electrical insulator 214 and inner conductor 212.
Sheath 216 is made up of resistant material, such as but be not limited to 347 stainless steels, 347H stainless steel, 446 stainless steels or 825 stainless steels.In certain embodiments, at the Curie temperature and/or transition temperature range or more of ferromagnetic conductor 236, sheath 216 provides some mechanical strengths for insulated electric conductor 252.In certain embodiments, sheath 216 is not used for conduction current.
There are many potential problems when manufacturing insulated electric conductor (such as length is 10m or longer) of length.Such as, gap may be present between the material block for the formation of the electrical insulator in insulated electric conductor.These gaps may cause heaving or mechanical defect in the core of insulated electric conductor or other parts.Insulated electric conductor comprises the insulated electric conductor (not almost being with or without the insulated electric conductor providing thermal output) in the insulated electric conductor as heater and/or the overburden portion for stratum.Such as, insulated electric conductor can be mineral insulated conductor, as mineral insulated cable.
In the typical process for the manufacture of (formation) insulated electric conductor, the sheath of insulated electric conductor starts as electric conducting material (such as stainless steel) bar.Sheath bar forms the shape of (being longitudinally rolled into) partial cylindrical shapes, and electrical insulator block (such as magnesia block) is inserted into partly in columniform sheath.The block inserted can be part cylindrical block, such as semicylinder block.After insertion block, the longitudinal core being generally solid cylinder is placed in part cylindrical and semicylinder block.Core is made up of electric conducting material such as copper, nickel and/or steel.
Once electrical insulator block and core in place after, then the part comprising the sheath of block and core can form complete cylinder around block and core.The longitudinal edge of the closing cylinder of sheath can carry out welding to form the insulated electric conductor assembly of core and the electrical insulator having and be positioned at sheath.Insertion block and the cylindrical technique of closed sheath can repeat along the length of sheath to form the insulated electric conductor assembly of desired length.
When forming insulated electric conductor assembly, further step can be taked to reduce the gap in assembly.Such as, insulated electric conductor assembly can be moved the gap reduced by progressive reduction system in assembly.An example of progressive reduction system is roll system.In this roll system, insulated electric conductor assembly can advance through multiple level and vertical roller, and wherein assembly replaces between level and vertical roller.Roller can reduce the size of insulated electric conductor assembly progressively to final expectation external diameter.
If allowing that electrical insulator block is freely sat during insulated electric conductor assembly reduces technique is placed in sheath, one or more gaps had between them then in block, these gaps cause such as core to be heaved or the problem of other mechanical defect and so on occurs in the insulated electric conductor assembly reduced.The appearance of problems may cause the electric problem between the insulated electric conductor assembly operating period and assembly may be made can not to be used for its desired use.Therefore, need a kind of reliable method, it ensures reduce during insulated electric conductor assembly reduces technique or eliminate the gap between electrical insulator block.
In certain embodiments, the block that axial force imposes in insulated electric conductor assembly make the gap between block reduce as far as possible.Such as, when inserting in insulated electric conductor assembly for one or more pieces, the block that has been arranged in assembly can be abutted against and axially along the block that assembly pushing (mechanically or pneumatically) is inserted.There is provided and keep the power of length between block along assembly during by moving when assembly and reducing technique by assembly, and the gap utilizing the enough power block abutted against in insulated electric conductor assembly to push the block inserted as far as possible to reduce between block.
Fig. 6-8 shows an embodiment of block pressing device 254, and described piece of pressing device can be used to provide axial force to the block in insulated electric conductor assembly.In certain embodiments, as shown in Figure 6, device 254 comprises insulated electric conductor holder 256, plunger guide device 258 and cylinder 260.Device 254 can be arranged in the assembly line for the manufacture of insulated electric conductor assembly.In certain embodiments, device 254 is arranged in the part place of the assembly line for block being inserted sheath.Such as, device 254 is between step sheath bar being longitudinally rolled into part cylindrical shape and the step being inserted by core in insulated electric conductor assembly.After insertion core, the sheath comprising block and core can form complete cylinder.In certain embodiments, core inserted and block inserts around core in sheath before block.
In certain embodiments, insulated electric conductor holder 256 shape is suitable for keeping the part of sheath 216 and allowing that jacket assembly moves by insulated electric conductor holder, simultaneously the other parts of the sheath side by side mobile other parts by assembly line.Insulated electric conductor holder 256 can be attached to plunger guide device 258 and cylinder 260.
In certain embodiments, block holder 262 is attached to insulated electric conductor holder 256.Block holder 262 can be for depositing block 264 and block 264 being inserted the device in sheath 216.In certain embodiments, block 264 is formed by two half-cylinders block 264A, 264B.Block 264 can be made up of the electrical insulator being applicable in insulated electric conductor assembly, such as but be not limited to magnesium oxide.In certain embodiments, block 264 length is approximately 6 ".But, the length of block 264 can according to expect or insulated electric conductor assembly need change.
Separator can be used to block 264A, 264B in separately block holder 262 to make block can correctly insert in sheath 216.As shown in Figure 8, block 264A, 264B can sheath through insulated electric conductor holder 256 time utilize gravity to be sent to sheath 216 from block holder 262.Block 264A, 264B can insert in sheath 216 by the mode that is directly arranged side by side and (after the insertion, be placed in sheath the direct side-by-side horizontal of block).
When block 264A, 264B insert in sheath 216, block can be made to move (pushing), to remove the gap between the block in sheath towards the block previously inserted.Can use the plunger 266 shown in Fig. 8 that block 264A, 264B are moved towards the block previously inserted.Plunger 266 can be positioned at sheath 216 to be provided pressure to make plunger to the block of sheath and does not provide pressure to sheath self.
In certain embodiments, the shape of cross section that plunger 266 has is allowed that plunger is freely mobile in sheath 216 and on block, is provided axial force and core not in sheath provides power.Fig. 9 shows an embodiment of plunger 266, and the shape of cross section that wherein plunger 266 has allows that plunger provides power but core not in sheath provides power on block.In certain embodiments, plunger 266 is made up of pottery or is scribbled ceramic material.An example of spendable ceramic material is the aluminium oxide (ZTA) of zirconium dioxide malleableize.Use the plunger of pottery or band ceramic coating that block can be prevented when power is put on block by plunger by plunger wear.
In certain embodiments, cylinder 260 utilizes one or more bar to be attached to plunger guide device 258 (as shown in figs 6 and 7).Cylinder 260 and plunger guide device 258 can be aligned with sheath 216 and plunger 266 to prevent from increasing angular momentum to block or sheath.Bidirectional valve can be used to operate cylinder 260 to make cylinder to provide positive air pressure according to which side of cylinder and extend or retract.When cylinder 260 extends (as shown in Figure 6), plunger guide device 258 moves away to make plunger 266 be moved to side and to allow that block 264A, 264B insert (such as falling) to sheath 216 from block holder 262 from insulated electric conductor holder 256.
When cylinder 260 is retracted (as shown in Figure 7), plunger guide device 258 to move and plunger 266 provides the power of set point value on block 264A, 264B towards plunger 266.Plunger 266 provides the power of set point value to be pressed against by block on the previous block inserted in sheath 216 on block 264A, 264B.The value of the power provided on block 264A, 264B by plunger 266 can be selected according to factors, these factors such as but be not limited to sheath move by speed during assembly line, prevent from being formed between block adjacent in sheath the power needed for gap value, can block be applied to and the peak of the power of block can not be damaged, or its combination.Such as, the set point value of power can between about 100 ft lbfs and about 500 ft lbfs (such as about 400 ft lbfs).In certain embodiments, the set point value of power is for preventing the minimum value that there is the power needed for gap between block adjacent in sheath.The set point value of power is determined by the value of the air pressure being provided to cylinder.
At block 264A, 264B by after the block pushing of previously having inserted, the air pressure in cylinder 260 is inverted and cylinder extends that plunger 266 is retracted and other block falls into sheath 216 from block holder 262.This technique can repeat until sheath 216 is filled with the block up to the desired length needed for insulated electric conductor assembly.
In certain embodiments, use cam that plunger 266 is moved back and forth (extend and retract), this cam makes the direction of the air pressure being provided to cylinder 260 alternately.This cam such as can be attached to the bidirectional valve for operating cylinder.This cam can have operating valve to extend the primary importance of cylinder and operating valve with the second place of retraction cylinder.By operation plunger, this cam is moved between the first and second positions, to make cam in the operation extending cylinder switching between retraction.
By the extension of plunger 266 be retracted in power block 264A, 264B providing interval, the string of the block just in insertion sheath 216 provides the power of set point value.String to the block in sheath provides this power, just eliminates and prevents gap from being formed between adjacent block.Gap between anti-stops, just reduces the possibility that machinery in insulated electric conductor assembly and/or electric fault occur.
In certain embodiments, block 264A, 264B is by be directly arranged side by side other method except mode to insert in sheath 216 except above-mentioned.Such as, the staggered mode that is arranged side by side can opened along the length offset of sheath by wherein block inserts block.According to this setup, plunger can have different shapes to adapt to the block offseted.Such as, Figure 10 shows an embodiment of plunger 266, and this plunger 266 can be used to push (interlocking) block offseted.As another example, block can insert by top/end set-up mode (a semicylinder block is positioned on second half cylinder block top).Top/end set-up mode can make block be located immediately at over each other or be in and offset (interlocking) relation.Figure 11 shows an embodiment of plunger 266, and this plunger 266 can be used to the block pushing the setting of the top/end.Block in sheath is offseted or interlocks to rotate relative to the block before or after the block inserted by anti-stops.
Another potential problems source had in the insulated electric conductor of length (such as length is 10m or longer) is that the electrical property of electrical insulator may the deterioration along with the past of time.Any little change of electrical property (such as resistivity) all may cause insulated electric conductor to lose efficacy.Owing to being usually made up of some electrical insulator blocks for the electrical insulator in length insulated electric conductor, as mentioned above, the improvement for the manufacture of the technique of electrical insulator block can increase the reliability of insulated electric conductor.In certain embodiments, electrical insulator is modified into there is between the insulated electric conductor operating period (such as during producing heat by insulated conductor heater) along with past of time and keep the resistivity of substantial constant.
In certain embodiments, electrical insulator block (such as magnesia block) is purified to remove the impurity that may cause block deterioration along with the past of time.Such as, the raw material for electrical insulator block can be heated to higher temperature metal oxide impurities to be transformed into metallic element (such as, iron oxides impurities can be transformed into ferro element).The comparable metal oxide of metallic element is easier to be removed from electrical insulator raw material.Therefore, the raw-material purity of electrical insulator improves by raw material being heated to higher temperature before removal of impurity.Raw material are heated to higher temperature by such as using plasma discharge.
In certain embodiments, use hot pressing to manufacture electrical insulator block, hot pressing is the method for the manufacture of pottery well known in the prior art.Pyroelectric Media insulator block can make the contact point place fusion of raw material in insulated conductor heater in block.The fusion of block at contact point place can improve the electrical property of electrical insulator.
In certain embodiments, air cooling electric insulator block in an oven that is dry or purification is used.Air that is that use drying or that purify can reduce impurity during cooling procedure or moisture adds in block.The reliability that moisture can increase the electrical property of block is removed from block.
In certain embodiments, electrical insulator block is not heat-treated during the technique manufacturing block.Not heat-treating block can resistivity in maintainance block and the deterioration along with the past of time of anti-stops.In certain embodiments, with heating rate's electrical insulator block slowly to help the resistivity in maintainance block.
In certain embodiments, the core of insulated electric conductor scribbles and prevents migration impurity to the material in the electrical insulator of insulated electric conductor.Such as, utilize nickel or coating alloy 180 (Alloy180) core can prevent material from migrating to electrical insulator from alloy 180.In certain embodiments, core is made up of the material not migrating in electrical insulator.Such as, carbon steel core may not cause electrical insulator deterioration along with the past of time.
In certain embodiments, electrical insulator is manufactured by powder raw material such as Powder Oxidation magnesium.Powder Oxidation magnesium other type magnesium oxide comparable resists deterioration better.
Should understand, the invention is not restricted to described particular system, described system can change certainly.Should also be understood that term used herein only for the object describing specific embodiment, be not intended to limit.When using in this manual, " one ", " one " and " being somebody's turn to do " of singulative comprises a plurality of involved thing, unless described content explicitly points out in addition.Thus, such as, mention the combination that " core " comprises two or more cores, mention the mixture that " a kind of material " comprises multiple material.
By means of this specification, other modification of various aspects of the present invention and alternate embodiment will be apparent for those skilled in the art.Therefore, this explanation is exemplary by being only considered as, and for instructing those skilled in the art to realize general fashion of the present invention.Should understand, form of the present invention shown and described herein should be considered as presently preferred embodiment.The element illustrated herein and describe and material replaceable, parts and technique can be put upside down, and features more of the present invention can independently use, and this is apparent for benefiting from the those skilled in the art after to explanation of the present invention.Can change described element and not depart from the spirit and scope of the present invention below described in claims.
Should be appreciated that and with the Feature Combination of other claim or can to separate in each feature of the following stated claims.Such as, the feature of two or more dependent claims may be combined to form multinomial dependent claims.

Claims (6)

1., for the formation of an at least part of method for insulated electric conductor, comprising:
By insulated electric conductor partly for columniform Part I be placed in elongated cylindrical internal electrical conductor at least partly and partly for columniform elongated external electrical conductor at least part of between;
By insulated electric conductor partly at least one extention columniform be placed in the external electrical conductor formed at least partly and partly of described internal electrical conductor at least part of between, the extention of wherein said insulated electric conductor along the length of this part of described elongated external electrical conductor from the Part I of insulated electric conductor flatly dislocation open; And
The extention of described insulated electric conductor is made to shift to the Part I of described insulated electric conductor with the power of set point value, with the Part I making the extention of described insulated electric conductor and described insulated electric conductor substantially against each other,
Wherein, the electrical insulator formed by Part I and the extention of described insulated electric conductor has when internal electrical conductor produces heat along with the past of time keeps the resistivity of substantial constant or increase.
2. method according to claim 1, also comprises mechanically or pneumatically utilizes the power of set point value to make the extention of described insulated electric conductor shift to the Part I of described insulated electric conductor.
3. method according to claim 1, also be included in and make after the extention of described insulated electric conductor shifts to the Part I of described insulated electric conductor, to form columniform elongated external electrical conductor substantially by the part of the described external electrical conductor comprising described insulated electric conductor part.
4. method according to claim 3, is also included in formation and substantially forms at least part of of described insulated electric conductor after columniform elongated external electrical conductor.
5. method according to claim 1, also comprises that to be formed partly for columniform elongated external electrical conductor by the elongate strip of electric conducting material at least part of.
6. method according to claim 1, also comprises that the part of elongated cylindrical internal electrical conductor is arranged in is partly the part of columniform elongated external electrical conductor.
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