CA1170174A - Downhole steam generator with improved preheating, combustion and protection features - Google Patents
Downhole steam generator with improved preheating, combustion and protection featuresInfo
- Publication number
- CA1170174A CA1170174A CA000393351A CA393351A CA1170174A CA 1170174 A CA1170174 A CA 1170174A CA 000393351 A CA000393351 A CA 000393351A CA 393351 A CA393351 A CA 393351A CA 1170174 A CA1170174 A CA 1170174A
- Authority
- CA
- Canada
- Prior art keywords
- steam
- water
- fuel
- combustion
- combustion chamber
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- 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
- E21B36/02—Heating, cooling, insulating arrangements for boreholes or wells, e.g. for use in permafrost zones using burners
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D11/00—Burners using a direct spraying action of liquid droplets or vaporised liquid into the combustion space
- F23D11/36—Details, e.g. burner cooling means, noise reduction means
- F23D11/44—Preheating devices; Vaporising devices
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23M—CASINGS, LININGS, WALLS OR DOORS SPECIALLY ADAPTED FOR COMBUSTION CHAMBERS, e.g. FIREBRIDGES; DEVICES FOR DEFLECTING AIR, FLAMES OR COMBUSTION PRODUCTS IN COMBUSTION CHAMBERS; SAFETY ARRANGEMENTS SPECIALLY ADAPTED FOR COMBUSTION APPARATUS; DETAILS OF COMBUSTION CHAMBERS, NOT OTHERWISE PROVIDED FOR
- F23M5/00—Casings; Linings; Walls
- F23M5/08—Cooling thereof; Tube walls
- F23M5/085—Cooling thereof; Tube walls using air or other gas as the cooling medium
Abstract
DOWNHOLE STEAM GENERATOR WITH IMPROVED
PREHEATING, COMBUSTION AND PROTECTION FEATURES
ABSTRACT OF THE DISCLOSURE
An apparatus for generation of steam in a bore-hole for penetration into an earth formation wherein feedback preheater means are provided for the fuel and water before entering the combustor assembly.
First, combustion gases are conducted from the com-bustion chamber to locations in proximity to the water and fuel supplies. Secondly, both hot combustion gases and steam are conducted from the borehole back to the water and fuel supply. The water used for conversion to steam is passed in a countercurrent manner through a plurality of annular water flow chan-nels surrounding the combustion chamber. In this manner, the water is preheated, and the combustion chamber is cooled simultaneously, thereby minimizing thermal stresses and deterioration of the walls of the combustion chamber. The water is injected through slotted inlets along the combustion chamber wall to provide an unstable boundary layer and stripping of the water from the wall for efficient steam genera-tion. Pressure responsive doors are provided at the steam outlet of the combustor assembly. The outlet doors and fluid flow functions may be controlled by a diagnostic/control module. The module is positioned in the water flow channel to maintain a relatively constant, controlled temperature.
PREHEATING, COMBUSTION AND PROTECTION FEATURES
ABSTRACT OF THE DISCLOSURE
An apparatus for generation of steam in a bore-hole for penetration into an earth formation wherein feedback preheater means are provided for the fuel and water before entering the combustor assembly.
First, combustion gases are conducted from the com-bustion chamber to locations in proximity to the water and fuel supplies. Secondly, both hot combustion gases and steam are conducted from the borehole back to the water and fuel supply. The water used for conversion to steam is passed in a countercurrent manner through a plurality of annular water flow chan-nels surrounding the combustion chamber. In this manner, the water is preheated, and the combustion chamber is cooled simultaneously, thereby minimizing thermal stresses and deterioration of the walls of the combustion chamber. The water is injected through slotted inlets along the combustion chamber wall to provide an unstable boundary layer and stripping of the water from the wall for efficient steam genera-tion. Pressure responsive doors are provided at the steam outlet of the combustor assembly. The outlet doors and fluid flow functions may be controlled by a diagnostic/control module. The module is positioned in the water flow channel to maintain a relatively constant, controlled temperature.
Description
DOWNHOLE STEAM GENERATOR WITH IMPROYED
PREHEATING, COMBUSTION AND PROTECTION FEATURES
Background of the Invention The invention is in the area of tertiary oil recovery techniques, in particular, an improved ap-paratus for downhole injection of steam into boreholes.
In the art of recovering oil from earth formations, tertiary methods are increasing in their importance.
Initially, oil flow from many wells is driven by the pressure due to natural gases trapped along with the liquid oil in the forma~ion. With the passage of time, natural gas pressures decrease. When gas pressure is insuffici~nt to drive oil to the surface, pumping methods are then employed. As time passes, pumping methods may be ineffective because the flow of oil underground out of porous formations into a well may be very slow. It is at this point that tertiary methods are sought to accelerate the flow of oil from the formation into the well. A particularly useful tertiary method employs the injection of steam. Steam serves to heat the oil in the formation, thereby re-ducing its vi-scosity and increasing its flow rate into the well for recovery.
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Methods employing downhole generation of steam within a well have proved to be particularly advan~ageous.
The prior art discloses representative methods and apparatus.
In U. S. Patent 3,456,721, Smith discloses a downhole burner for generating steam. Gaseous or liquid fuels are mixed with air and combusted in a burner with simultaneous spraying of water toward the flame. The water is sprayed from a cylindrical - 10 water jacket through a plurality of orifices. Steam ; is formed by the vaporization of the water as the water bombards ~he flame.
In U. S. Patent 3,980,147, Gray discloses a downhole steam injector employing the combustion of hydrogen with oxygen to generate heat to vaporize injected water to form steam. The water moves in a single direction through an annular preheater jacket surrounding the combustion chamber, and, after being preheated, enters the combustion chambex through a plurality of grooves or passages at the top o~ the combustion chamber near the ignitor and the hydrogen/
oxygen flame.
Hamrick et al in their related U. S. Patents 3,982,591 and 4,078,613 disclose downhole steam generators. In the first patent, in Figure 17, water is injected through a plurality of apertures
PREHEATING, COMBUSTION AND PROTECTION FEATURES
Background of the Invention The invention is in the area of tertiary oil recovery techniques, in particular, an improved ap-paratus for downhole injection of steam into boreholes.
In the art of recovering oil from earth formations, tertiary methods are increasing in their importance.
Initially, oil flow from many wells is driven by the pressure due to natural gases trapped along with the liquid oil in the forma~ion. With the passage of time, natural gas pressures decrease. When gas pressure is insuffici~nt to drive oil to the surface, pumping methods are then employed. As time passes, pumping methods may be ineffective because the flow of oil underground out of porous formations into a well may be very slow. It is at this point that tertiary methods are sought to accelerate the flow of oil from the formation into the well. A particularly useful tertiary method employs the injection of steam. Steam serves to heat the oil in the formation, thereby re-ducing its vi-scosity and increasing its flow rate into the well for recovery.
' ., .
O 1 7 ~
Methods employing downhole generation of steam within a well have proved to be particularly advan~ageous.
The prior art discloses representative methods and apparatus.
In U. S. Patent 3,456,721, Smith discloses a downhole burner for generating steam. Gaseous or liquid fuels are mixed with air and combusted in a burner with simultaneous spraying of water toward the flame. The water is sprayed from a cylindrical - 10 water jacket through a plurality of orifices. Steam ; is formed by the vaporization of the water as the water bombards ~he flame.
In U. S. Patent 3,980,147, Gray discloses a downhole steam injector employing the combustion of hydrogen with oxygen to generate heat to vaporize injected water to form steam. The water moves in a single direction through an annular preheater jacket surrounding the combustion chamber, and, after being preheated, enters the combustion chambex through a plurality of grooves or passages at the top o~ the combustion chamber near the ignitor and the hydrogen/
oxygen flame.
Hamrick et al in their related U. S. Patents 3,982,591 and 4,078,613 disclose downhole steam generators. In the first patent, in Figure 17, water is injected through a plurality of apertures
-2- .
., .
, ~ .
3L 17017~
directly into the flame in a hydrogen/oxygen com-bustion zone. In the second patent, in Fiqure 2B, water moves through a cooling annulus in a single direction before it is injectPd into a mixi~g zonè
spaced below the combustion zone. The mixing zone ~¦ , is de~ined by a cylindrical wall which has a plurality ¦ of apertures through which water from the cooling - annulus passes laterally into the mixing zone. A
heat-resistant liner is placed along the interior of the ~ombustion zone.
Several problems have been encountered with ~, these prior art downhole stea~ generators. A par-, . . .
ticularly serious problem relates to overheating of the boundary layer adjacent the inner wall of t 15 the combustion zone. A boundary layer which is thick and of low velocity leads to detexioration of combus-tion chamber walls and excessive thermal conduction from the combustion zone to pre-combustion areas.
A problem prevalent with the prior ar~ devices 20 employing heat-resistant combustion zone liners is ~hat the liners are not c0012d adequately by adjacent heat transfer jackets through which water flows in a .
; single direction. As a conse~uence, the liners cannot withstand th~ prolonged high temperatures of the combustion zone and undergo severe deterioration.
Problems are also encountered relative to the ~3~
,.
. ~ , ~:L7~174 efficient preheating of the fuels and water used in the downhole steam generatorO To explain, liquid fuels may be relatively cold at the surface prior to - pumping downhole. As a result, the combustion process itsel must give up heat to the liquid fuel to brin~
it up to combustion temperatures. Cool fuel, ~esults in production of,sbot, which is undesirable because ; of poor energy eficiency and clogging of pores in the earth formation. Similarly~ water may be rela-tively cold at the surface prior to pumping downhole.As a resalt, a considerable portion of the heat genera-ted by the combustion process is consumed in bringing the water up to the boiling point. Thus, less energy is available for driving high enthalpy st~am into the earth formation.
Conditions downhole may occasionally occur which tend to flood the combustioD chamber with reservoir fluids. This occurs particulaxly when a temporary interruption of combustion is ~ncountered.
.
¦ 20 A need ~or an efficient means for isolatiny and - protecting the combustion cham~er is thus indicated.
Summary of the Invention In view of the deficiencies and inadequacies - described above, it is an object of the invention to -4- .
. ~ .
.
~1701~4 .
provide an appara~us ~or downhole steam generation which provides for efficient counterflow cooling of the ~ombustion chamber walls and preheating of the fuel,and water.
, .
i 5 More particularly, an object of the invention is ¦ , to provide an apparatus for efficiently preheating and , injecting the water in the b~undary layer adjacent' ' the inner wall of the combustion zone and for providing an unstable boundary layer for more efficient stripping of the water into the hot combustion gas flow.
Another object of the invention is to provide a downhole steam generation apparatus which prevents : formation of soot to reduce attandant clogging of the rock formation pores, as well as pollution.
Another object of the invention is to provide an apparatus for downhole steam generati~n in which ' - the walls of the combustion zone are cooled more ef-' fectively to preclude deterioration.
An additional object of the invention is to provide an apparatus for eficiently preheating liquid fuels prior to combustion in the combustion chamber of the downhole steam generator.
- A further object of the invention is to provide I a downhole steam generator having unique apparatus for increasing the ability to preheat the water prior to volati:Lization to form steam.
_5 _ .
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Still anotheL object of the invention is to provide an apparatus for protecting the apparatus by monitoring and diagnosing critical parameters and controlling ~unctions such as closing doors to prevent fluids in the ea~th formation from flooding the combustion chamber in the event of flameout.
To achieve the foregoing and other objects and in accordance with the purposes described herein, the invention contemplates an apparatus for generation of steam in a borehole for penetration into an earth formation which comprises an oxidant supply means, a fuel supply means for supplying fuel, an ignitor means for ignitiny the fuel and o~idant, and a water supply means for providing water to be converted to steam by the heat of combustion. ~ combustor assembly has ~u~l inlet means, oxidant inlet means, a combustion chamber for generating hot combustion gas, water inlet means to provide steam upon contact with the hot gas, and steam outlet means.
Together with the foregoing the apparatus has a hot gas feed-back conduit from the combustion chamber to a preheat location adjacent the fuel supply means for conveying hot combustion gases from the combustion chamber for preheating the fuel.
Thereby, the combustor is cooled and heated water and fuel are supplied to the combustion process, resulting in more efficient combustion and less soot formation.
In another aspect the invention includes an apparatus for generating steam in a borehole which is a combustor assembly which comprises a combustion chamber, top cap header means attached to an upper end thereof and steam and hot gas outlet means at the lower end thereof; oxidant inlet means, fuel inlet means and igniter means in communication with the combustion chamber through the top cap header means for generating hot combustion gas. A water inlet means is in communication with the combustion chamber to provide steam upon contact with the hot gas, and a hot gas feedback conduit extends from the combustion chamber to a preheat location in the top cap header means in the proximity of the fuel inlet means for preheating the fuel.
~ 170 17~
In a further aspect of the present invention, in accordance with its purposes and objects, the apparatus ~or downhole steam generation includes a feedback conduit connected between the combustor and the water and fuel supply for conveyin~ hot combustion gases and, in addition, steam from the borehole for preheating the water and fuel prior to combustion. The presence of steam, which has a relatively high enthalpy, increases the efficiency of fuel preheating.
In a further aspect of the invention, the apparatus for downhole steam generation includes door means operably connected to the steam outlet means for closing and opening the steam outlet means in response to the pressure in the combustion chamber.
The steam generation apparatus can also be provided with a control module, transducer means in communciation with the combustion chamber for sensing the pressure in the chamber, with the transducer means being operably connected to the control module and including actuator means responsive to the control module to control the position of the door means responsive to the combustion chamber pressure for the purpose of optimizing combustion in the chamber and for preventing a backflow of liquid from the borehole when the pressure in the chamber is too low, thereby preventing flooding of the com-bustion chamber by the fluid~ such as water, in the borehole.
~5 The pressure responsive doors may be controlled by mechanical devices, such as springs, or by an electro-mechanical actuator having a pressure transducer adjacent the steam outlet.
A diagnostic and control circuit module for the actuators is housed in the water supply. The water supply serves to cool and provide a constant operating temperature for the module.
The control module is designed to be self-contained, but is connected by means of conductors to electric power and additional information processing apparatus outside the borehole. The module may also ,~;..~
., .~ ,.~
0 1 7 ~
. .
monitor additional temperatures and pressures, as well as other parameters, to provide fine-tuned control of such functions, as fuel supply and water flow.
In a further aspect of the invention, the downhole steam generator incluldes a combustor assembly having counter-flow annular channels for preheating - water prior to steam generation and for cooling the walls of the combustion chamber. Preferably, the wall of the combustion chamber has slots for injection of water of steam generation. The location and size of the slots provide an unstable boundary layer and provide efficient conversion of water into steam.
The combustor assembly has a cylindrical outer lS housing sleeve, a cylindrical inner sleeve, and the combustion chamber wall in concentric relationship with spaces therebetween. The space between the outer sleeve and the inner sleeve defines a first annular - water flow channel. The space between the inner sleeve and the combustor chamber wall defines a second annular wa~er flow channel. A passage connects the first and second flow channels resulting in a downward and upward or counter-flow of water through the channels.
The flow of water in this countercurrent manner serves three purposes: (1) more efficient cooling of the wall o the combustion chamber; (2) full preheating .
.
~ 1~01 ~4 , of the water and fuel prior to steam generation; and
., .
, ~ .
3L 17017~
directly into the flame in a hydrogen/oxygen com-bustion zone. In the second patent, in Fiqure 2B, water moves through a cooling annulus in a single direction before it is injectPd into a mixi~g zonè
spaced below the combustion zone. The mixing zone ~¦ , is de~ined by a cylindrical wall which has a plurality ¦ of apertures through which water from the cooling - annulus passes laterally into the mixing zone. A
heat-resistant liner is placed along the interior of the ~ombustion zone.
Several problems have been encountered with ~, these prior art downhole stea~ generators. A par-, . . .
ticularly serious problem relates to overheating of the boundary layer adjacent the inner wall of t 15 the combustion zone. A boundary layer which is thick and of low velocity leads to detexioration of combus-tion chamber walls and excessive thermal conduction from the combustion zone to pre-combustion areas.
A problem prevalent with the prior ar~ devices 20 employing heat-resistant combustion zone liners is ~hat the liners are not c0012d adequately by adjacent heat transfer jackets through which water flows in a .
; single direction. As a conse~uence, the liners cannot withstand th~ prolonged high temperatures of the combustion zone and undergo severe deterioration.
Problems are also encountered relative to the ~3~
,.
. ~ , ~:L7~174 efficient preheating of the fuels and water used in the downhole steam generatorO To explain, liquid fuels may be relatively cold at the surface prior to - pumping downhole. As a result, the combustion process itsel must give up heat to the liquid fuel to brin~
it up to combustion temperatures. Cool fuel, ~esults in production of,sbot, which is undesirable because ; of poor energy eficiency and clogging of pores in the earth formation. Similarly~ water may be rela-tively cold at the surface prior to pumping downhole.As a resalt, a considerable portion of the heat genera-ted by the combustion process is consumed in bringing the water up to the boiling point. Thus, less energy is available for driving high enthalpy st~am into the earth formation.
Conditions downhole may occasionally occur which tend to flood the combustioD chamber with reservoir fluids. This occurs particulaxly when a temporary interruption of combustion is ~ncountered.
.
¦ 20 A need ~or an efficient means for isolatiny and - protecting the combustion cham~er is thus indicated.
Summary of the Invention In view of the deficiencies and inadequacies - described above, it is an object of the invention to -4- .
. ~ .
.
~1701~4 .
provide an appara~us ~or downhole steam generation which provides for efficient counterflow cooling of the ~ombustion chamber walls and preheating of the fuel,and water.
, .
i 5 More particularly, an object of the invention is ¦ , to provide an apparatus for efficiently preheating and , injecting the water in the b~undary layer adjacent' ' the inner wall of the combustion zone and for providing an unstable boundary layer for more efficient stripping of the water into the hot combustion gas flow.
Another object of the invention is to provide a downhole steam generation apparatus which prevents : formation of soot to reduce attandant clogging of the rock formation pores, as well as pollution.
Another object of the invention is to provide an apparatus for downhole steam generati~n in which ' - the walls of the combustion zone are cooled more ef-' fectively to preclude deterioration.
An additional object of the invention is to provide an apparatus for eficiently preheating liquid fuels prior to combustion in the combustion chamber of the downhole steam generator.
- A further object of the invention is to provide I a downhole steam generator having unique apparatus for increasing the ability to preheat the water prior to volati:Lization to form steam.
_5 _ .
' : ' 0 1 7 ~
Still anotheL object of the invention is to provide an apparatus for protecting the apparatus by monitoring and diagnosing critical parameters and controlling ~unctions such as closing doors to prevent fluids in the ea~th formation from flooding the combustion chamber in the event of flameout.
To achieve the foregoing and other objects and in accordance with the purposes described herein, the invention contemplates an apparatus for generation of steam in a borehole for penetration into an earth formation which comprises an oxidant supply means, a fuel supply means for supplying fuel, an ignitor means for ignitiny the fuel and o~idant, and a water supply means for providing water to be converted to steam by the heat of combustion. ~ combustor assembly has ~u~l inlet means, oxidant inlet means, a combustion chamber for generating hot combustion gas, water inlet means to provide steam upon contact with the hot gas, and steam outlet means.
Together with the foregoing the apparatus has a hot gas feed-back conduit from the combustion chamber to a preheat location adjacent the fuel supply means for conveying hot combustion gases from the combustion chamber for preheating the fuel.
Thereby, the combustor is cooled and heated water and fuel are supplied to the combustion process, resulting in more efficient combustion and less soot formation.
In another aspect the invention includes an apparatus for generating steam in a borehole which is a combustor assembly which comprises a combustion chamber, top cap header means attached to an upper end thereof and steam and hot gas outlet means at the lower end thereof; oxidant inlet means, fuel inlet means and igniter means in communication with the combustion chamber through the top cap header means for generating hot combustion gas. A water inlet means is in communication with the combustion chamber to provide steam upon contact with the hot gas, and a hot gas feedback conduit extends from the combustion chamber to a preheat location in the top cap header means in the proximity of the fuel inlet means for preheating the fuel.
~ 170 17~
In a further aspect of the present invention, in accordance with its purposes and objects, the apparatus ~or downhole steam generation includes a feedback conduit connected between the combustor and the water and fuel supply for conveyin~ hot combustion gases and, in addition, steam from the borehole for preheating the water and fuel prior to combustion. The presence of steam, which has a relatively high enthalpy, increases the efficiency of fuel preheating.
In a further aspect of the invention, the apparatus for downhole steam generation includes door means operably connected to the steam outlet means for closing and opening the steam outlet means in response to the pressure in the combustion chamber.
The steam generation apparatus can also be provided with a control module, transducer means in communciation with the combustion chamber for sensing the pressure in the chamber, with the transducer means being operably connected to the control module and including actuator means responsive to the control module to control the position of the door means responsive to the combustion chamber pressure for the purpose of optimizing combustion in the chamber and for preventing a backflow of liquid from the borehole when the pressure in the chamber is too low, thereby preventing flooding of the com-bustion chamber by the fluid~ such as water, in the borehole.
~5 The pressure responsive doors may be controlled by mechanical devices, such as springs, or by an electro-mechanical actuator having a pressure transducer adjacent the steam outlet.
A diagnostic and control circuit module for the actuators is housed in the water supply. The water supply serves to cool and provide a constant operating temperature for the module.
The control module is designed to be self-contained, but is connected by means of conductors to electric power and additional information processing apparatus outside the borehole. The module may also ,~;..~
., .~ ,.~
0 1 7 ~
. .
monitor additional temperatures and pressures, as well as other parameters, to provide fine-tuned control of such functions, as fuel supply and water flow.
In a further aspect of the invention, the downhole steam generator incluldes a combustor assembly having counter-flow annular channels for preheating - water prior to steam generation and for cooling the walls of the combustion chamber. Preferably, the wall of the combustion chamber has slots for injection of water of steam generation. The location and size of the slots provide an unstable boundary layer and provide efficient conversion of water into steam.
The combustor assembly has a cylindrical outer lS housing sleeve, a cylindrical inner sleeve, and the combustion chamber wall in concentric relationship with spaces therebetween. The space between the outer sleeve and the inner sleeve defines a first annular - water flow channel. The space between the inner sleeve and the combustor chamber wall defines a second annular wa~er flow channel. A passage connects the first and second flow channels resulting in a downward and upward or counter-flow of water through the channels.
The flow of water in this countercurrent manner serves three purposes: (1) more efficient cooling of the wall o the combustion chamber; (2) full preheating .
.
~ 1~01 ~4 , of the water and fuel prior to steam generation; and
(3) providing a constant temperature for the entire apparatus, including the sensitive electronic control module.
, 5 By efficient cooling of the walls of the com-¦ bustion of the chamber, overheating of the boundary layer adjacent the inner wall of the cnmbustion zone is avoided thereby significantly improved steam j generation. In addition, the thickness of the boundary ; - 10 layer adjacent the inner wall of the combustion chamber -j is reduced, and he velocity of the bou~dary layer is I, increased. Also, deterioration of the walls is ... ~ . .
reduced considerably or eliminated by keeping the _ walls cooled ade~uately.
By conducting heat from combustion zone walls to the water, the water is preheated and ~rought to near the boiling point prior to injection into the hot combustion gases inside the comhustion chamber.
~, Thus, less heat is required to produce steam inside the combustion chamber, and more heat energy is available . . - .
- for driving the steam to pen~trate into the earth formation.
Diesel fuel is preferred for use in the genera-tor; however, light crude oii can also be successfully used. Depending on which fuel is used, and whether air or another form of oxidant is used, the combustion products include various!quantities of czrbon dioxide, sulfur oxides, and nitrogen oxides. The acids~formed when these products are cor~ined with water can increase .~ ~70174 . .
~ .
the porosity of the earth formation, enhance penetra-tion of the steam and thus enhance flow rate of oil - to a production well.
, Another benefit derivecl from preheating the ~ water is that preheated water exerts less of a cooling - effect on the combustion flar.~e and thereby reduces the tendency of soot formation and the attendant problems of air pollution ancl clogging of the pores of the earth formation.
Still other objects and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description, wherein I have sho~n and described only the preferred embodiment of the invention, simply by way of illus-~ 15 tration of the best modes contemplated for carrying out the invention.- As will be realized, the invention :. .
is capable of other and different embodiments and its everal details are capable of modification in various, obvious respects, all without departing from the invention. Accordingly, the drawingsand descrip-tion are to be regarded as 111ustrative in nature, and not as restrictive.
Brief Description of the Drawing The accompanying drawings, whlch are incorporated in and form a part of this specification, illustrate O 1 ~
several aspects of the present invention1 and, together with the description, serve to explain the principles of the invention. In the drawings-Figure 1 is a longitudinal cross-sectional view partially broken away illustrating a downhole steam generator of the invention;
Figure 2 is a lateral cross-sectional view of the steam generator taken along lines 2-2 of Figure l;
Figure 3 is a lateral cross-sectional view taken along lines 3-3 of Figure l; and Figure 4 is a schematic diagram of the diagnostic/
control system for the generator.
Detailed Description of the Invention : . :
With reference to Figure 1, in accordance with 1-5 the invention, the apparatus 1 for generation of steam in a borehole for penetration into an earth formation comprises: an oxidant supply line 4; a fuel supply line 8 for supplying fuel which is combusted when mixed with the oxidant; and ignitor 12, such as a glow plug for igniting the fuel and oxidant mixture; a water supply line 10 with entry tube 11 for providing water to be converted to steam by the heat of combustion of the fuel/oxidant; and a combustor assembly 16.
The combustor assembly 16 has a fuel injector nozzle 17, a plurality of oxidant inlet nozzles 18 -11- ..
.. _ _ _ . . , ... ~ _ , _ _ _ _ . , _ .:
` ' ` ' '' ' ~' ~7Vl ~4 lsee Fig. 2 also), a çombustion chamber 20, slotted water inlets 24 positioned a:Long combustion chamber . wall 21, and a steam outlet ;27. A first hot gas feedback conduit 22 with entry port 22a connects 5 the upper portion of the combustion chamber 20 with a heat transfer location for the line 8 (see Fig. 1).
¦ ~ In particular, the hot combustion gases ~rom the combustion ;chamber 20 are carried to the location in ! top cap 49 in proximity to the fuel supply fitting 10 51 for preheating the fuel.
In accordance with another aspect of the inven-tion, a second feedback conduit 23 conn~cts the lower ! borehole and the heat transfer location in top cap 49. Hot gases and steam from the lower borehole 15 adjacent the steam outlet 27 enter a plurality of ,! spaced inlets 25 ~see Fig. 3), and pass through ~he full loop of the annular cor,~uit 23. The feedback conduits 22,23 merge in the top cap 49 adjacent the t ' ' fuel heat transfer location to eff~ctively conduct , 20 heat to fitting 51 of fuel line 8. At the same ;¦ time incoming oxidant in line 4 is preheated in the gap around the fitti~g 51. A~ter transferring heat, ~:~ the borehole gases and steam exhaust through spaced outlet ports 25 (see Fig. 3) back to the lower 25 bor~hole. The feedback conduit 23 is formed by the two outer housing sleeves 47~8~ t~e top cap 49 (see Figs 1 and 2) and bottom cap 49a lsee FigsO 1 and 3).
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017~
The high pressur~ combustion gases in conduit 22 are injected into the exit leg of the conduit 23 at an angled exit port 22b. This injection toward the outlet port 26 creates a positive flow thxough the .
j 5 conduit 23 and insures a constant flow of heat transfer fluid.
In accordance with anot:her aspect of the invention, . the downhole steam generator is provided with pressure . .
/ responsive doors 28 capable of closing or opening .. . .
. 10 steam outlet 27 in esponse to the pressure sensed within the combustion chamber 20. Preferably, doors 28 (see Figs. 1 and 3) are provided.with hinges 29 for easy opening and closing. As best shown in Fig. 1, a nozzle shroud 30 may be provided to protect the -1 15 doors 28 from bumping against rock formations ox :~ other obstacles. In a simple case, the doors may be urged closed by mechanical springs or, preferably, : doors 28 are more closely controlled by an electro-~ mechanical door actuators 32 whose operation is in turn . ..
. 20 controlled by electronic diagnosticfcontrol module 31j as will be seen ~ore in detail below during the discussion of Fig. 4.
Preferably, the combustor assembly of the invention further includes a cylindrical outer housing sleeve 33, a cyl.indical inner sleeve 34, spaced between and concentric with respect to both the outer sleeve 33 and the combustion chamber wall 21.
The annular space between the outer sleeve 33-and ` : .
.
~ 1~0 17~. -.
the inner sleeve 34 is connected to the water supplylO and defines a first flow channel 36. The annular space between the inner sleeve 34 and the combustion chamber wall 21 defines a second ~low channel 37.` A
passage 39, defined by the lower edge of inner sleeve 34 interconnects the first and second water flow channels 36 and 37 adjacent the bottom of the genera~
tor. Thereby, downward and upward flow or counterflow of water through channels 36 and 37 cools the combus-tion chamber wall 21, and, in addition, preheatsthe water in a countercurrent manner prior to entry into the combustion cha~ber 20 for conversion into steam. The annular conduit 23 with the flow o~ hot combustion gases and steam inside is particularly efficient ln transferring preheat energy to the down-. ward annular channel 36 (see Fig. 1). The counter-current flow of water also advantageously serves to maintain the temperature of module 31 at a controlled level.
.. The more efficiently preheated water allows less heat of combustion to be.drained off for heating th~ water and thus allows more heat energy to be available for generating high enthalpy steam and driving the steam into the earth formationO As the preheated water enters combustion chamber 20 through downwardly directed slots 24 in combustion chamber . . . . ~
~170:~ ~4 .
wall 21, the ~luid boundary layer adjacent to wall 21 is stirred up and made highly unstabl~e~ As a result, the thickness of the boundary layer is re-duced considerably, and the velocity of its swirling i 5 movement is increased. The boundary layer of decreased thickness and increased velocity results ! in more efficient ~tripping of the water entering the combustion zone from the wall 21, and thus a better mixing of the fluids. A much enhanced r 10 ability to generate high enthalpy steam results.
' In addition to this optimization of the vaporization ~ . .
process, the combustion chamber wall 21 remains cool and thus the thermal stress is minimized.
With seference now to Figure 4, the diagnostic/
15 control system of the steam generator of the present invention can be described in more detail. The heaxt of the system i5 the self-contained electronic module 31 housed in a water-tight jacket and positioned adjacent the bottom of the generator within the water 20 flow channels 36,37, and particularly at the connecting ~low passage 39 (See Fig. 1). With this concept, the self-contained module can be positi~ned in the downhole -steam generator and maintained at a carefully controlled working temperature. The module 31 is preferably 25 constructed of microelectronic components and elimi-nates the need for above-ground computers.
1 ~7()174 . .
The module 31 receives power from cable 60 and can also be provided with control cables 61 to the above-ground control slte for the steam generatox.
It will be understood that these cables 6~,61 are grouped with the delivery string of the generator.
, The output signals from the control cable 61 can ! be used f~r readout of the various functions of the steam generator and can al~o be utilized to provide manual input or correction vf functions as required.
As briefly described above, the actuators 32 for the doors 28 are controlled by the module 31.
These actuators can be of any selected electromechani-cal devices that are available. Prefer~bly, the actuators 32 are designed to be connected to the , 15 doors 28 by extendable linkage and are capable of ~arying'the position between the fully open position (see Fig. 1) and the closed position. Thus, the actuators 32 can close the doors 28 when a flameout .. . .
'~ ' occurs in order to protect'the combustion cham~er, ii , 20 but also the actuators 32 can be utilized through ,i , analog control by the module'31 to regulate the ' opening at the nozzle outlet 27.' This regulation i can provide better control of the combustion due to ' maintaining the most efficient operating pressure and temperature within the combustion chamber 20 regardless of the conditions,in the borehole or variations in the 0 1 '7 4 .
supply of the ~luids to the generator.
In order to sense the condition of combustion within the combustion chamber 20, suitable pressure and temperature transducers 65,66, respectively, are provided on the combustion chamber wall 21 (see Fig. 4).
`~ The pressure transducer 65 can be any suitable high pressure measuring device available commercially, and the temperature transducer 66 can be a simple thermocouple. The signals are provided to the module 31 through lines 67,68, respectively. With these parameters being monitored in the combustion chamber 20, the electronics in the module 31 can diagnose any problem, provide output signals to make necessary adjustments to correct the problem and at the same time provide a signal through control cables 61 indicating to the operator above ground the action being taken.
Similarly, the water temperature in the f~ow channels 36,37 ean be monitored by pressure and tem-perature transducers 70,71, respectively, positionedin inner sleeve 34 ~see Fig. 4~. The signals, as before, are transmitted to the module 31 over suitable control lines 72~73. Of coùrse, additional parameters and different locations can be monitored in the genera-tor as desired depending on the degree of diagnosisand control of the operation of the generator 1 that is desired.
7 ~
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When the module 31 senses a variation in the combu~tion process, or in the flow of the cooling water, _ regulation of ~he supplies oE fuel, oxidant and water ~ can be effected. A control ~alve 75 in the fuel line ;,~ 5 B is ~esigned to regulate the flow of fuel in the event that the module 31 determines that this is desired. Similarly, a valve 76 regulates the flow o~ oxidant entering through the oxidant supply line
, 5 By efficient cooling of the walls of the com-¦ bustion of the chamber, overheating of the boundary layer adjacent the inner wall of the cnmbustion zone is avoided thereby significantly improved steam j generation. In addition, the thickness of the boundary ; - 10 layer adjacent the inner wall of the combustion chamber -j is reduced, and he velocity of the bou~dary layer is I, increased. Also, deterioration of the walls is ... ~ . .
reduced considerably or eliminated by keeping the _ walls cooled ade~uately.
By conducting heat from combustion zone walls to the water, the water is preheated and ~rought to near the boiling point prior to injection into the hot combustion gases inside the comhustion chamber.
~, Thus, less heat is required to produce steam inside the combustion chamber, and more heat energy is available . . - .
- for driving the steam to pen~trate into the earth formation.
Diesel fuel is preferred for use in the genera-tor; however, light crude oii can also be successfully used. Depending on which fuel is used, and whether air or another form of oxidant is used, the combustion products include various!quantities of czrbon dioxide, sulfur oxides, and nitrogen oxides. The acids~formed when these products are cor~ined with water can increase .~ ~70174 . .
~ .
the porosity of the earth formation, enhance penetra-tion of the steam and thus enhance flow rate of oil - to a production well.
, Another benefit derivecl from preheating the ~ water is that preheated water exerts less of a cooling - effect on the combustion flar.~e and thereby reduces the tendency of soot formation and the attendant problems of air pollution ancl clogging of the pores of the earth formation.
Still other objects and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description, wherein I have sho~n and described only the preferred embodiment of the invention, simply by way of illus-~ 15 tration of the best modes contemplated for carrying out the invention.- As will be realized, the invention :. .
is capable of other and different embodiments and its everal details are capable of modification in various, obvious respects, all without departing from the invention. Accordingly, the drawingsand descrip-tion are to be regarded as 111ustrative in nature, and not as restrictive.
Brief Description of the Drawing The accompanying drawings, whlch are incorporated in and form a part of this specification, illustrate O 1 ~
several aspects of the present invention1 and, together with the description, serve to explain the principles of the invention. In the drawings-Figure 1 is a longitudinal cross-sectional view partially broken away illustrating a downhole steam generator of the invention;
Figure 2 is a lateral cross-sectional view of the steam generator taken along lines 2-2 of Figure l;
Figure 3 is a lateral cross-sectional view taken along lines 3-3 of Figure l; and Figure 4 is a schematic diagram of the diagnostic/
control system for the generator.
Detailed Description of the Invention : . :
With reference to Figure 1, in accordance with 1-5 the invention, the apparatus 1 for generation of steam in a borehole for penetration into an earth formation comprises: an oxidant supply line 4; a fuel supply line 8 for supplying fuel which is combusted when mixed with the oxidant; and ignitor 12, such as a glow plug for igniting the fuel and oxidant mixture; a water supply line 10 with entry tube 11 for providing water to be converted to steam by the heat of combustion of the fuel/oxidant; and a combustor assembly 16.
The combustor assembly 16 has a fuel injector nozzle 17, a plurality of oxidant inlet nozzles 18 -11- ..
.. _ _ _ . . , ... ~ _ , _ _ _ _ . , _ .:
` ' ` ' '' ' ~' ~7Vl ~4 lsee Fig. 2 also), a çombustion chamber 20, slotted water inlets 24 positioned a:Long combustion chamber . wall 21, and a steam outlet ;27. A first hot gas feedback conduit 22 with entry port 22a connects 5 the upper portion of the combustion chamber 20 with a heat transfer location for the line 8 (see Fig. 1).
¦ ~ In particular, the hot combustion gases ~rom the combustion ;chamber 20 are carried to the location in ! top cap 49 in proximity to the fuel supply fitting 10 51 for preheating the fuel.
In accordance with another aspect of the inven-tion, a second feedback conduit 23 conn~cts the lower ! borehole and the heat transfer location in top cap 49. Hot gases and steam from the lower borehole 15 adjacent the steam outlet 27 enter a plurality of ,! spaced inlets 25 ~see Fig. 3), and pass through ~he full loop of the annular cor,~uit 23. The feedback conduits 22,23 merge in the top cap 49 adjacent the t ' ' fuel heat transfer location to eff~ctively conduct , 20 heat to fitting 51 of fuel line 8. At the same ;¦ time incoming oxidant in line 4 is preheated in the gap around the fitti~g 51. A~ter transferring heat, ~:~ the borehole gases and steam exhaust through spaced outlet ports 25 (see Fig. 3) back to the lower 25 bor~hole. The feedback conduit 23 is formed by the two outer housing sleeves 47~8~ t~e top cap 49 (see Figs 1 and 2) and bottom cap 49a lsee FigsO 1 and 3).
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017~
The high pressur~ combustion gases in conduit 22 are injected into the exit leg of the conduit 23 at an angled exit port 22b. This injection toward the outlet port 26 creates a positive flow thxough the .
j 5 conduit 23 and insures a constant flow of heat transfer fluid.
In accordance with anot:her aspect of the invention, . the downhole steam generator is provided with pressure . .
/ responsive doors 28 capable of closing or opening .. . .
. 10 steam outlet 27 in esponse to the pressure sensed within the combustion chamber 20. Preferably, doors 28 (see Figs. 1 and 3) are provided.with hinges 29 for easy opening and closing. As best shown in Fig. 1, a nozzle shroud 30 may be provided to protect the -1 15 doors 28 from bumping against rock formations ox :~ other obstacles. In a simple case, the doors may be urged closed by mechanical springs or, preferably, : doors 28 are more closely controlled by an electro-~ mechanical door actuators 32 whose operation is in turn . ..
. 20 controlled by electronic diagnosticfcontrol module 31j as will be seen ~ore in detail below during the discussion of Fig. 4.
Preferably, the combustor assembly of the invention further includes a cylindrical outer housing sleeve 33, a cyl.indical inner sleeve 34, spaced between and concentric with respect to both the outer sleeve 33 and the combustion chamber wall 21.
The annular space between the outer sleeve 33-and ` : .
.
~ 1~0 17~. -.
the inner sleeve 34 is connected to the water supplylO and defines a first flow channel 36. The annular space between the inner sleeve 34 and the combustion chamber wall 21 defines a second ~low channel 37.` A
passage 39, defined by the lower edge of inner sleeve 34 interconnects the first and second water flow channels 36 and 37 adjacent the bottom of the genera~
tor. Thereby, downward and upward flow or counterflow of water through channels 36 and 37 cools the combus-tion chamber wall 21, and, in addition, preheatsthe water in a countercurrent manner prior to entry into the combustion cha~ber 20 for conversion into steam. The annular conduit 23 with the flow o~ hot combustion gases and steam inside is particularly efficient ln transferring preheat energy to the down-. ward annular channel 36 (see Fig. 1). The counter-current flow of water also advantageously serves to maintain the temperature of module 31 at a controlled level.
.. The more efficiently preheated water allows less heat of combustion to be.drained off for heating th~ water and thus allows more heat energy to be available for generating high enthalpy steam and driving the steam into the earth formationO As the preheated water enters combustion chamber 20 through downwardly directed slots 24 in combustion chamber . . . . ~
~170:~ ~4 .
wall 21, the ~luid boundary layer adjacent to wall 21 is stirred up and made highly unstabl~e~ As a result, the thickness of the boundary layer is re-duced considerably, and the velocity of its swirling i 5 movement is increased. The boundary layer of decreased thickness and increased velocity results ! in more efficient ~tripping of the water entering the combustion zone from the wall 21, and thus a better mixing of the fluids. A much enhanced r 10 ability to generate high enthalpy steam results.
' In addition to this optimization of the vaporization ~ . .
process, the combustion chamber wall 21 remains cool and thus the thermal stress is minimized.
With seference now to Figure 4, the diagnostic/
15 control system of the steam generator of the present invention can be described in more detail. The heaxt of the system i5 the self-contained electronic module 31 housed in a water-tight jacket and positioned adjacent the bottom of the generator within the water 20 flow channels 36,37, and particularly at the connecting ~low passage 39 (See Fig. 1). With this concept, the self-contained module can be positi~ned in the downhole -steam generator and maintained at a carefully controlled working temperature. The module 31 is preferably 25 constructed of microelectronic components and elimi-nates the need for above-ground computers.
1 ~7()174 . .
The module 31 receives power from cable 60 and can also be provided with control cables 61 to the above-ground control slte for the steam generatox.
It will be understood that these cables 6~,61 are grouped with the delivery string of the generator.
, The output signals from the control cable 61 can ! be used f~r readout of the various functions of the steam generator and can al~o be utilized to provide manual input or correction vf functions as required.
As briefly described above, the actuators 32 for the doors 28 are controlled by the module 31.
These actuators can be of any selected electromechani-cal devices that are available. Prefer~bly, the actuators 32 are designed to be connected to the , 15 doors 28 by extendable linkage and are capable of ~arying'the position between the fully open position (see Fig. 1) and the closed position. Thus, the actuators 32 can close the doors 28 when a flameout .. . .
'~ ' occurs in order to protect'the combustion cham~er, ii , 20 but also the actuators 32 can be utilized through ,i , analog control by the module'31 to regulate the ' opening at the nozzle outlet 27.' This regulation i can provide better control of the combustion due to ' maintaining the most efficient operating pressure and temperature within the combustion chamber 20 regardless of the conditions,in the borehole or variations in the 0 1 '7 4 .
supply of the ~luids to the generator.
In order to sense the condition of combustion within the combustion chamber 20, suitable pressure and temperature transducers 65,66, respectively, are provided on the combustion chamber wall 21 (see Fig. 4).
`~ The pressure transducer 65 can be any suitable high pressure measuring device available commercially, and the temperature transducer 66 can be a simple thermocouple. The signals are provided to the module 31 through lines 67,68, respectively. With these parameters being monitored in the combustion chamber 20, the electronics in the module 31 can diagnose any problem, provide output signals to make necessary adjustments to correct the problem and at the same time provide a signal through control cables 61 indicating to the operator above ground the action being taken.
Similarly, the water temperature in the f~ow channels 36,37 ean be monitored by pressure and tem-perature transducers 70,71, respectively, positionedin inner sleeve 34 ~see Fig. 4~. The signals, as before, are transmitted to the module 31 over suitable control lines 72~73. Of coùrse, additional parameters and different locations can be monitored in the genera-tor as desired depending on the degree of diagnosisand control of the operation of the generator 1 that is desired.
7 ~
. .
When the module 31 senses a variation in the combu~tion process, or in the flow of the cooling water, _ regulation of ~he supplies oE fuel, oxidant and water ~ can be effected. A control ~alve 75 in the fuel line ;,~ 5 B is ~esigned to regulate the flow of fuel in the event that the module 31 determines that this is desired. Similarly, a valve 76 regulates the flow o~ oxidant entering through the oxidant supply line
4 and the valve 77 reyulates ~he cooling and steam generating water entering through the water supply line 10. As shown, each of these valves 75-77 is connected through a suitable control line (not numbered) with the module 31.
In operation of the steam generator 1 of the present invention, the results and advantages of the various aspects of the invention should now be apparent.
The~water entering the suppl~ line 10 flows through the counter10w channels 36,37 where the water is preheated and cools the combustion chamber wall 21 at the same time and is ejected through the slotted inlets 24 into the-combustion chamber 20. Fuel ~rom the nozzle 17 is sprayed into the top of the combustion chamber 20 sur-rounded by oxidant orifices 18 positioned in a con-centric arrangement. The glow plug 12 ignites the mixture and turns the water into high enthalpy steam ejected from the nozzle outlet ~7 at the bottom of the . ; .
-11701 74 ~, . .
generator l. The doors 28 are openeZ and regulated by the actuators 32 in order to optimize the c~mbus-tion process.
The preheating function of t;he water and the 1 5 fuel is carried out in a unique manner. The feedback , conduits 22,23, merge at a location in the top cap 49.
¦ The fuel is heated in the supply fitting 51 at a loca-tion directly adjacent the merging point. The hot combustion gases flowing through the conduit 2~ and the steam and other hot gases flowing from the borehole ~' through the conduit 23 provide a highly efficient pre-heater for the fuel. As an incident to this preheating function, the oxidant in the supply line 4 is also hèated as it flows around the fitting 51~ The incoming ~ 15 water fxom supply line lO as it travels through entry ;i tube 11 and then thro~gh downward channel 36 is efficiently heated by this preheater arrangement.
¦ As the water is ejected through the thermally directed slotted inlets 24, it has been preheated to ~¦ 20 substantially a boiling point and is ready to be quickly converted to steam in the combustion chamber 20. The ¦ boundary layer along the combustion cham~er wall 21 I is maintained in an unstable condition so that the - stripping of any water occurring along the wall is accomplished. A thorough mixing and swirling of .
~1~017 . ' ' ' ' ,, , ' hot gaseous fluids and the water and water vapor is optimized. At the same time the thermal stress on the wall 21 is minimized since the walls are kept cool by the regulated flow of water through the channels 36,37.
In the event that a flameout or loss of combus-tion occurs, the doors 28 are immediately closed sealing the combustion chamber 20 from the fluid within the borehole. Furthermore, under the control of the diagnostic/control module 31, the doors may be modula-ted in order to maintain the desired temperature and pressure within the combustion chamber 20.
- Also during the operation the control module 31 regulates the supply of fluids, namely fuel, oxidant and water in order to maintain the optimum operating conditions. The control signals to provide this function can be taken from transducers within the i - combustion chamber, the water channels or other loca-tions. Nost importantly, the diagnosticjcontrol module 31 is protected in the downhole environment by mounting within the watsr flow channels 36,37 where the tempera- -ture of the sensitive electronics can be closely con-trolled.
Thus, in summary, it will now be realized that the downhole steam generator 1 of the present invention provides substantial results and advantages over prior art devices. Substantially more e~ficient pxeheating , ' .
.
01~
of the fuel and water is accomplished by the fe~dbackheating conduits 22,23. The counterflow water through ' the channels 36,37 allows the preheating water function to occur and at the same time main~ains a constant, ~ . . .l~ , 5 relatively cool temperature for the combustion chamher - ~ w,all 21 in order to relieve the thermal stresses that ~''j would otherwise occur. At the same time, the control ' ' module 31 is advantageously cooled by the flow of water ', in the channels 36,37.
i: .
,"; 10 The combustion chamber 20 of the combustor of - the invention is designed with the downwardly directed slotted inlets 24 a~d the flow rate of the water is ' 'so regulated so as to provide an unstable boundary - layer,along the combustion chamber wall 21. This - 15 assures an enhanced mixing of the hot gases with the water~entering the chamber to be converted into steam and a continuous stripping action of water from the ~' wall,'21, as desired.
' The foregoing descriptio~ of the preferred ~, - ~
~,~ ' 20 embodimant of the apparatus of the'invention has been ~ . .
provided for purposes of illustration and description.
,It is not intended to be exhaustive or to limit the ' i,nvention to the precise form disclosed. Obvious modifications and variations are possible in light of the above teaching.
-21- , ..
. " . ' . .
' :~
.
117017~
The embodiment was chosen and descxibed in order to best explain the principles of the invention and its - practical application to thereby enable others skilled in the art to best utilize the invention in various ¦ S embodiments and with various modifications as are - sulted to the particular use contemplated. It is intended that the scope of t:he invention be defined by the claims appended hereto.
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i' ' ' ' ' .
.
, ;~'' ' , ' ' ,' ' "' ,' ' ' ' ~ r .:~, , ~, .
.i , ' , ' , . .
. . -22- .;
In operation of the steam generator 1 of the present invention, the results and advantages of the various aspects of the invention should now be apparent.
The~water entering the suppl~ line 10 flows through the counter10w channels 36,37 where the water is preheated and cools the combustion chamber wall 21 at the same time and is ejected through the slotted inlets 24 into the-combustion chamber 20. Fuel ~rom the nozzle 17 is sprayed into the top of the combustion chamber 20 sur-rounded by oxidant orifices 18 positioned in a con-centric arrangement. The glow plug 12 ignites the mixture and turns the water into high enthalpy steam ejected from the nozzle outlet ~7 at the bottom of the . ; .
-11701 74 ~, . .
generator l. The doors 28 are openeZ and regulated by the actuators 32 in order to optimize the c~mbus-tion process.
The preheating function of t;he water and the 1 5 fuel is carried out in a unique manner. The feedback , conduits 22,23, merge at a location in the top cap 49.
¦ The fuel is heated in the supply fitting 51 at a loca-tion directly adjacent the merging point. The hot combustion gases flowing through the conduit 2~ and the steam and other hot gases flowing from the borehole ~' through the conduit 23 provide a highly efficient pre-heater for the fuel. As an incident to this preheating function, the oxidant in the supply line 4 is also hèated as it flows around the fitting 51~ The incoming ~ 15 water fxom supply line lO as it travels through entry ;i tube 11 and then thro~gh downward channel 36 is efficiently heated by this preheater arrangement.
¦ As the water is ejected through the thermally directed slotted inlets 24, it has been preheated to ~¦ 20 substantially a boiling point and is ready to be quickly converted to steam in the combustion chamber 20. The ¦ boundary layer along the combustion cham~er wall 21 I is maintained in an unstable condition so that the - stripping of any water occurring along the wall is accomplished. A thorough mixing and swirling of .
~1~017 . ' ' ' ' ,, , ' hot gaseous fluids and the water and water vapor is optimized. At the same time the thermal stress on the wall 21 is minimized since the walls are kept cool by the regulated flow of water through the channels 36,37.
In the event that a flameout or loss of combus-tion occurs, the doors 28 are immediately closed sealing the combustion chamber 20 from the fluid within the borehole. Furthermore, under the control of the diagnostic/control module 31, the doors may be modula-ted in order to maintain the desired temperature and pressure within the combustion chamber 20.
- Also during the operation the control module 31 regulates the supply of fluids, namely fuel, oxidant and water in order to maintain the optimum operating conditions. The control signals to provide this function can be taken from transducers within the i - combustion chamber, the water channels or other loca-tions. Nost importantly, the diagnosticjcontrol module 31 is protected in the downhole environment by mounting within the watsr flow channels 36,37 where the tempera- -ture of the sensitive electronics can be closely con-trolled.
Thus, in summary, it will now be realized that the downhole steam generator 1 of the present invention provides substantial results and advantages over prior art devices. Substantially more e~ficient pxeheating , ' .
.
01~
of the fuel and water is accomplished by the fe~dbackheating conduits 22,23. The counterflow water through ' the channels 36,37 allows the preheating water function to occur and at the same time main~ains a constant, ~ . . .l~ , 5 relatively cool temperature for the combustion chamher - ~ w,all 21 in order to relieve the thermal stresses that ~''j would otherwise occur. At the same time, the control ' ' module 31 is advantageously cooled by the flow of water ', in the channels 36,37.
i: .
,"; 10 The combustion chamber 20 of the combustor of - the invention is designed with the downwardly directed slotted inlets 24 a~d the flow rate of the water is ' 'so regulated so as to provide an unstable boundary - layer,along the combustion chamber wall 21. This - 15 assures an enhanced mixing of the hot gases with the water~entering the chamber to be converted into steam and a continuous stripping action of water from the ~' wall,'21, as desired.
' The foregoing descriptio~ of the preferred ~, - ~
~,~ ' 20 embodimant of the apparatus of the'invention has been ~ . .
provided for purposes of illustration and description.
,It is not intended to be exhaustive or to limit the ' i,nvention to the precise form disclosed. Obvious modifications and variations are possible in light of the above teaching.
-21- , ..
. " . ' . .
' :~
.
117017~
The embodiment was chosen and descxibed in order to best explain the principles of the invention and its - practical application to thereby enable others skilled in the art to best utilize the invention in various ¦ S embodiments and with various modifications as are - sulted to the particular use contemplated. It is intended that the scope of t:he invention be defined by the claims appended hereto.
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Claims (21)
1. An apparatus for generation of steam in a borehole for penetration into an earth formation, comprising:
an oxidant supply means;
a fuel supply means for supplying fuel;
an ignitor means for igniting the fuel and oxidant;
a water supply means for providing water to be converted to steam by the heat of combustion;
a combustor assembly having fuel inlet means, oxidant inlet means, a combustion chamber for generating hot combustion gas, water inlet means to provide steam upon contact with the hot gas, and steam outlet means; and a hot gas feedback conduit from said combustion chamber to a preheat location adjacent said fuel supply means for conveying hot combustion gases from said combustion chamber for preheating the fuel.
an oxidant supply means;
a fuel supply means for supplying fuel;
an ignitor means for igniting the fuel and oxidant;
a water supply means for providing water to be converted to steam by the heat of combustion;
a combustor assembly having fuel inlet means, oxidant inlet means, a combustion chamber for generating hot combustion gas, water inlet means to provide steam upon contact with the hot gas, and steam outlet means; and a hot gas feedback conduit from said combustion chamber to a preheat location adjacent said fuel supply means for conveying hot combustion gases from said combustion chamber for preheating the fuel.
2. The steam generation apparatus of claim 1 wherein the water supply means is located adjacent said hot gas feedback conduit for preheating said water.
3. The steam generation apparatus of claim 2 wherein said combustion chamber has slotted inlets in the wall for injection of the preheated water for steam generation.
4. An apparatus for generation of steam in a borehole for penetration into an earth formation, comprising:
an oxidant supply means;
a fuel supply means for supplying fuel;
an ignitor means for igniting the fuel and oxidant mixture;
a water supply means for providing water to be converted to steam by the heat of combustion;
a combustor assembly having fuel inlet means, oxidant inlet means, a combustion chamber for generating hot combustion gas, water inlet means to provide steam upon contact with the hot gas and steam outlet means; and a hot gas and steam feedback conduit from the borehole below said steam outlet means to a preheat location adjacent said fuel supply means for conveying hot combustion gases and steam from the borehole for preheating the fuel.
an oxidant supply means;
a fuel supply means for supplying fuel;
an ignitor means for igniting the fuel and oxidant mixture;
a water supply means for providing water to be converted to steam by the heat of combustion;
a combustor assembly having fuel inlet means, oxidant inlet means, a combustion chamber for generating hot combustion gas, water inlet means to provide steam upon contact with the hot gas and steam outlet means; and a hot gas and steam feedback conduit from the borehole below said steam outlet means to a preheat location adjacent said fuel supply means for conveying hot combustion gases and steam from the borehole for preheating the fuel.
5. The steam generation apparatus of claim 4 wherein is provided a hot gas feedback conduit connected to said combustion chamber and feeding into said hot gas steam feedback conduit to further enhance the preheat function.
6. The steam generation apparatus of claim 5 wherein said feedback conduits merge adjacent said preheat location.
7. The steam generation apparatus of claim 6 wherein said hot gas feedback conduit merges at an angle to said hot gas and steam conduit to drive said hot gas and steam.
8. An apparatus for generation of steam in a borehole for penetration into an earth formation, comprising:
an oxidant supply means;
a fuel supply means for supplying fuel;
an ignitor means for igniting the fuel and oxidant mixture;
a water supply means for providing water to be converted to steam by the heat of combustion;
a combustor assembly having fuel inlet means, oxidant inlet means, a combustion chamber for generating hot combustion gas, water inlet means to provide steam upon contact with the hot gas and steam outlet means; and door means operably connected to said steam outlet means for closing and opening said steam outlet means in response to the pressure in said combustion chamber.
an oxidant supply means;
a fuel supply means for supplying fuel;
an ignitor means for igniting the fuel and oxidant mixture;
a water supply means for providing water to be converted to steam by the heat of combustion;
a combustor assembly having fuel inlet means, oxidant inlet means, a combustion chamber for generating hot combustion gas, water inlet means to provide steam upon contact with the hot gas and steam outlet means; and door means operably connected to said steam outlet means for closing and opening said steam outlet means in response to the pressure in said combustion chamber.
9. The steam generation apparatus of claim 8 wherein is provided a control module, transducer means in communication with said combustion chamber for sensing the pressure in said chamber, said transducer means being operably connected to said control module and including actuator means responsive to said control module to control the position of said door means responsive to the combustion chamber pressure for the purpose of optimizing combustion in said chamber and for preventing a backflow of liquid from the borehole when the pressure in said chamber is too low.
10. An apparatus for generation of steam in a borehole for penetration into an earth formation, comprising:
an oxidant supply means;
a fuel supply means for supplying fuel;
an ignitor means for igniting the fuel and oxidant mixture;
a water supply means for providing water to be converted to steam by the heat of combustion;
a combustor assembly having fuel inlet means, oxidant inlet means, a combustion chamber defined by a chamber wall for generating hot combustion gas, water inlet means to provide steam upon contact with the hot gas and steam outlet means;
and a cylindrical outer housing sleeve, a cylindrical inner sleeve spaced between and concentric with respect to both said outer sleeve and the wall defining said combustion chamber, the space between said outer sleeve and said inner sleeve connected to said water supply means and defining a first annular water flow channel, the space between said inner sleeve and said combus-tion chamber wall connected to said water inlet means and defining a second annular water flow channel, and passage means interconnecting said first and sec-ond flow channels, whereby downward and upward flow of water through said channels cools said combustion chamber and preheats the water in a countercurrent manner.
an oxidant supply means;
a fuel supply means for supplying fuel;
an ignitor means for igniting the fuel and oxidant mixture;
a water supply means for providing water to be converted to steam by the heat of combustion;
a combustor assembly having fuel inlet means, oxidant inlet means, a combustion chamber defined by a chamber wall for generating hot combustion gas, water inlet means to provide steam upon contact with the hot gas and steam outlet means;
and a cylindrical outer housing sleeve, a cylindrical inner sleeve spaced between and concentric with respect to both said outer sleeve and the wall defining said combustion chamber, the space between said outer sleeve and said inner sleeve connected to said water supply means and defining a first annular water flow channel, the space between said inner sleeve and said combus-tion chamber wall connected to said water inlet means and defining a second annular water flow channel, and passage means interconnecting said first and sec-ond flow channels, whereby downward and upward flow of water through said channels cools said combustion chamber and preheats the water in a countercurrent manner.
11. The steam generation apparatus of claim 10 wherein is provided a hot gas and steam feedback conduit from the borehole below said steam outlet means to a preheat location adjacent said fuel supply means for conveying hot combustion gases and steam from the borehole for preheating the fuel, said feedback conduit extending concentrically along the length of said generator and positioned adjacent said first annular water flow channel for enhanced preheating of said water.
12. An apparatus for generation of steam in a bore-hole for penetration into an earth formation, com-prising:
an oxidant supply means;
a fuel supply means for supplying fuel;
an ignitor means for igniting the fuel and oxidant mixture;
a water supply means for providing water tore converted to steam by the heat of combustion;
a combustor assembly having fuel inlet means, oxidant inlet means, a combustion chamber for generating hot combustion gases, water inlet means to provide steam upon contact with the hot gas and steam outlet means;
a control module comprising pressure and temperature transducer means for sensing parameters in said generator connected to said control module; and actuator means responsive to said control module to control the operation of said generator, said actuator means being operable connected to said door means for adjusting the position of said door means responsive to the combustion chamber pressure.
an oxidant supply means;
a fuel supply means for supplying fuel;
an ignitor means for igniting the fuel and oxidant mixture;
a water supply means for providing water tore converted to steam by the heat of combustion;
a combustor assembly having fuel inlet means, oxidant inlet means, a combustion chamber for generating hot combustion gases, water inlet means to provide steam upon contact with the hot gas and steam outlet means;
a control module comprising pressure and temperature transducer means for sensing parameters in said generator connected to said control module; and actuator means responsive to said control module to control the operation of said generator, said actuator means being operable connected to said door means for adjusting the position of said door means responsive to the combustion chamber pressure.
13. The steam generation apparatus of claim 12 wherein is provided valve means on at least one of said supply means and said actuator means is provided on at least one of said valve means to control the flow of fluid to said generator.
14. The steam generation apparatus of claim 10 wherein said chamber wall is provided with a plurality of spaced downwardly directed slotted inlets for injecting the water into said combustion chamber, the injection of the water being such as to provide an unstable boundary layer along the wall and stripping of water for efficient steam generation.
15. An apparatus for generating steam in a borehole comprising a combustor assembly which comprises a combustion chamber, top cap header means attached to an upper end thereof and steam and hot gas outlet means at the lower end thereof;
oxidant inlet means, fuel inlet means and igniter means in communication with said combustion chamber through said top cap header means for generating hot combustion gas; water inlet means in communication with said combustion chamber to provide steam upon contact with said hot gas; and a hot gas feedback conduit extending from the combustion chamber to a preheat location in said top cap header means in the proximity of said fuel inlet means for preheating the fuel.
oxidant inlet means, fuel inlet means and igniter means in communication with said combustion chamber through said top cap header means for generating hot combustion gas; water inlet means in communication with said combustion chamber to provide steam upon contact with said hot gas; and a hot gas feedback conduit extending from the combustion chamber to a preheat location in said top cap header means in the proximity of said fuel inlet means for preheating the fuel.
16. The steam generation apparatus of claim 15 wherein a portion of said water inlet means is located adjacent said hot gas feedback conduit for preheating said water.
17. The steam generation apparatus of claim 15 wherein said water inlet means comprises slotted inlets in the wall of the combustion chamber for injection of the water for steam generation.
18. The steam generation apparatus of claim 15 and including a combination steam and hot gas feedback conduit extending from below said steam and hot gas outlet means to said preheat location for enhancement of fuel preheating.
19. The steam generation apparatus of claim 18 wherein the hot gas feedback conduit is connected to said combination steam and hot gas feedback conduit to enhance circulation of the steam and hot gas therethrough.
20. The steam generation apparatus of claim 19 wherein said feedback conduits merge adjacent said preheat location.
21. The steam generation apparatus of claim 20 wherein said hot gas feedback conduit merges at an angle to said combustion steam and hot gas feedback conduit to drive said hot gas and steam.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US06/222,855 US4385661A (en) | 1981-01-07 | 1981-01-07 | Downhole steam generator with improved preheating, combustion and protection features |
| US222,855 | 1981-01-07 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1170174A true CA1170174A (en) | 1984-07-03 |
Family
ID=22833995
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000393351A Expired CA1170174A (en) | 1981-01-07 | 1981-12-29 | Downhole steam generator with improved preheating, combustion and protection features |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US4385661A (en) |
| CA (1) | CA1170174A (en) |
| MX (1) | MX157626A (en) |
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- 1981-01-07 US US06/222,855 patent/US4385661A/en not_active Expired - Lifetime
- 1981-12-29 CA CA000393351A patent/CA1170174A/en not_active Expired
-
1982
- 1982-01-07 MX MX190901A patent/MX157626A/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| MX157626A (en) | 1988-12-07 |
| US4385661A (en) | 1983-05-31 |
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