RF Conductor Wellbore Heating for Hydrocarbon Recovery

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Solution Overview

Problem

The hydrocarbon upgrading process, particularly in the FCC process, has limited efficiency, produces coke residues that stop the process and pose safety risks, and results in high reactant emissions and poor molecular selectivity, with catalysts having short lifespans and requiring additional resources like natural gas for hydrogen.

Innovation Solution

A method involving the use of radio frequency (RF) energy to heat hydrocarbon resources in situ within subterranean formations using a laterally extending injector well with a tubular conductor and an RF conductor, allowing for RF energy to be supplied into the formation to enhance hydrocarbon recovery and upgrading, potentially reusing existing infrastructure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If FCC process is used for hydrocarbon cracking, then synthetic crude oil can be produced, but the process efficiency is limited to about 70% and produces coke residues that stop the process

Engineering Contradiction:

Improvehydrocarbon cracking efficiencyVSAvoidcoke residue production

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the thermal catalytic cracking mechanism with RF electromagnetic heating to break hydrocarbon molecules. The RF energy directly heats the bitumen and natural gas mixture, enabling cracking without requiring catalysts that produce coke residues. This substitution of heating mechanism eliminates the harmful coke formation while maintaining cracking efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the heating method from conventional thermal heating to RF electromagnetic heating, altering the energy delivery parameter. This parameter change enables more efficient and uniform heating of the hydrocarbon mixture, improving cracking efficiency while avoiding the catalyst deactivation issues that limit conventional processes to 70% efficiency.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If FCC process is used for hydrocarbon cracking, then synthetic crude oil can be produced, but the catalyst has a relatively short lifespan and requires additional resources like natural gas for hydrogen

Engineering Contradiction:

Improvesynthetic crude oil productionVSAvoidcatalyst lifespan

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The patent eliminates the catalyst-based system entirely by using RF electromagnetic heating to provide the activation energy for cracking. This substitution removes the catalyst lifespan limitation and eliminates the need for continuous catalyst replacement, while also reducing the need for additional hydrogen sources like natural gas.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If FCC process is used for hydrocarbon cracking, then synthetic crude oil can be produced, but the process has poor molecular selectivity and produces high reactant emissions

Engineering Contradiction:

Improvesynthetic crude oil productionVSAvoidmolecular selectivity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent changes the energy delivery parameter from thermal conduction through catalyst to direct RF electromagnetic heating. This parameter change enables more precise control over the cracking process, improving molecular selectivity by allowing controlled breakdown of specific hydrocarbon bonds without the uncontrolled side reactions that occur with catalytic processes.

Inventive Principle:

Principle #35Parameter changes

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 method increases the efficiency of hydrocarbon resource recovery and upgrading by heating the formation, reducing the need for additional resources and extending the life of existing wells, while minimizing coke production and emissions, and improving molecular selectivity.

Implementation Method 1

supplying RF energy into adjacent portions of the subterranean formation from the RF conductor

Methodology Applied

Scientific EffectDielectric heating: Dielectric Heating

Data Source

PatentUS8960285B2Method of processing a hydrocarbon resource including supplying RF energy using an extended well portion

Publication Date: 2015.02.24 HARRIS CORP

AI summary

A method for hydrocarbon resource recovery in a subterranean formation including a laterally extending injector well having a tubular conductor therein, and a laterally extending producer well adjacent the injector well, may include drilling outwardly from a distal end of the injector well beyond a distal end of the tubular conductor to define an extended injector well portion. The method may further include advancing a radio frequency (RF) conductor through the tubular conductor so as to extend beyond the distal end of the tubular conductor and into the extended injector well portion. The method may further include supplying RF energy into adjacent portions of the subterranean formation from the RF conductor, and recovering hydrocarbon resources utilizing the producer well.