Induction Heater Layout for Deep Subsurface Formation Heating
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Solution Overview
Problem
Current methods for producing hydrocarbons and hydrogen from hydrocarbon-containing formations are often economically unfeasible, particularly due to the impermeable nature of oil shale and the high operating costs associated with methods like hydraulic fracturing and in situ combustion.
Innovation Solution
The use of a heating system comprising an elongated electrical conductor and a ferromagnetic conductor in a subsurface formation, where the electrical conductor induces electrical current flow in the ferromagnetic conductor to resistively heat the formation, thereby mobilizing hydrocarbons, and the system can include multiple heaters arranged in a configuration to provide superpositioned heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydraulic fracturing or in situ combustion is used to produce hydrocarbons from impermeable formations, then hydrocarbon production is achieved, but operating costs become excessively high
Solution Approach 1:
The patent replaces mechanical hydraulic fracturing systems with an electromagnetic induction heating system. An elongated ferromagnetic conductor is inserted into the formation and heated via electromagnetic induction from a surface-based power source, causing thermal expansion and natural fracturing of the impermeable formation without requiring high-pressure mechanical injection
Solution Approach 2:
The patent changes the physical state of the formation by heating it to elevated temperatures through electromagnetic induction. This temperature parameter change causes thermal expansion, reduces fluid viscosity, and creates pressure differentials that enable hydrocarbon mobilization and flow without mechanical fracturing
2Temperature
If conventional heating methods are used in subsurface formations, then some heating effect is achieved, but heat distribution is insufficient to maintain temperatures above 300°C throughout the formation
Solution Approach 1:
The patent divides the heating system into multiple discrete elongated ferromagnetic conductors that can be independently positioned at different locations within the formation. Each conductor acts as an independent heat source, and their collective arrangement creates a distributed heating network that covers a larger volumetric area
Solution Approach 2:
The patent introduces an elongated ferromagnetic conductor as an intermediary between the surface-based electromagnetic power source and the target hydrocarbon-bearing formation. This intermediary efficiently transfers electromagnetic energy to thermal energy at the precise location where heating is needed, enabling deep formation heating without direct surface contact
3Productivity
If the ferromagnetic conductor is heated to high temperatures, then hydrocarbon mobilization is achieved, but the conductor may become structurally compromised
Solution Approach 1:
The patent employs a composite conductor structure consisting of a ferromagnetic material core providing electromagnetic heating capability, surrounded by a protective outer layer or coating that maintains structural integrity at high temperatures. This composite design combines the thermal generation properties of ferromagnetic materials with the thermal stability of heat-resistant materials
Solution Approach 2:
The patent applies a protective coating or outer layer to the ferromagnetic conductor before insertion into the formation. This pre-applied protective layer acts as a barrier that prevents excessive temperature damage, oxidation, or mechanical degradation during the high-temperature heating operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for efficient heating of subsurface formations, enhancing permeability and facilitating the production of hydrocarbons and hydrogen by maintaining temperatures above 300°C, thus overcoming the challenges of impermeable formations and high operating costs.
Implementation Method 1
the electrical conductor induces electrical current flow in the ferromagnetic conductor
Implementation Method 2
the ferromagnetic conductor resistively heats to a temperature of at least about 300° C.
Data Source
AI summary
A heating system for a subsurface formation includes an elongated electrical conductor located in the subsurface formation. The electrical conductor extends between at least a first electrical contact and a second electrical contact. A ferromagnetic conductor at least partially surrounds and at least partially extends lengthwise around the electrical conductor. The electrical conductor, when energized with time-varying electrical current, induces sufficient electrical current flow in the ferromagnetic conductor such that the ferromagnetic conductor resistively heats to a temperature of at least about 300° C.