Self-Powered Spiral Heating Elements for Viscous Hydrocarbon Flow
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Solution Overview
Problem
Current methods face challenges in economically and efficiently extracting high-viscosity hydrocarbons from subsurface rock formations and transporting them through pipelines without the assistance of heated steam or solvents, as they do not flow in sufficient quantities to be economically viable.
Innovation Solution
The use of self-generated high-temperature steam and hot fluids, produced by metal sheathed heating elements in a spiral configuration within production tubing and pipelines, to fracture rock formations and enhance the flow of viscous hydrocarbons to the surface and through pipelines, with optional pumping capabilities to aid in continuous flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heated steam or solvents are used to assist flow of high-viscosity hydrocarbons, then flow rate increases, but extraction and transportation costs increase
Solution Approach 1:
The heating elements are powered by the hydrocarbon flow itself through a motor-generator system, making the heating process self-sustaining without external energy input. The flowing hydrocarbons drive the motor, which generates electricity to power the heating elements, creating a closed-loop system that eliminates the need for external steam or solvent injection.
Solution Approach 2:
The patent replaces the traditional mechanical/thermal system of external steam injection with an electromagnetic heating system. Electric heating elements embedded in the production tubing provide direct thermal energy to the hydrocarbons, eliminating the need for complex steam generation and injection infrastructure.
2Use of energy by stationary object
If high-viscosity hydrocarbons are extracted without assistance, then extraction costs are reduced, but flow rate becomes insufficient for economic viability
Solution Approach 1:
The system uses the kinetic energy of the flowing hydrocarbons to power the heating elements through a motor-generator, making the heating process self-sustaining. This eliminates the need for external energy sources while maintaining continuous heating to reduce viscosity and enhance flow.
Solution Approach 2:
The patent dynamically adjusts the temperature of the hydrocarbons by controlling the heating elements, changing the physical parameter of viscosity to enable flow. The system maintains optimal temperature to keep viscosity low enough for economic extraction without requiring excessive external energy input.
3Temperature
If external steam injection is used to heat hydrocarbons, then viscosity is reduced and flow improves, but system complexity and energy input requirements increase
Solution Approach 1:
The patent replaces the complex mechanical system of steam generation, storage, and injection with a simple electrical heating system. Heating elements embedded in the production tubing provide direct thermal energy to the hydrocarbons, eliminating the need for steam boilers, pipelines, and injection equipment.
Solution Approach 2:
The production tubing acts as an intermediary heat transfer medium, with heating elements embedded in its wall. This allows direct thermal coupling between the heating elements and the hydrocarbons flowing through the tubing, providing efficient heating without complex external steam injection infrastructure.
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 significantly increases the flow rate and economic viability of high-viscosity hydrocarbon extraction and transportation by maintaining constant high temperatures and promoting continuous flow, overcoming viscosity-based flow impediments and reducing extraction and transportation times.
Implementation Method 1
metal sheathed heating elements in a spiral configuration within production tubing and pipelines
Implementation Method 2
When the hot fluids and high temperature steam levels are reached in the heating area, the superheated steam and/or hot fluids pass through rock fissures
Implementation Method 3
superheated steam and other hot fluids contemplated hereunder are transferred through the annulus formed between production pipe and surrounding outermost casing
Data Source
AI summary
Apparatus and methodology for self-generating high-temperature water and superheated steam for recovering embedded heavy-viscosity hydrocarbons from subterranean rock, shale, bitumen, sand formations and enabling continuous flow of released heavy-viscosity hydrocarbons using four successive spiral trough-like flowpaths, and optionally comprising an internal elongated pump member. Another embodiment promotes continuous flow of heavy-viscosity hydrocarbons through surface pipelines to tanks, railway tankcars, ships, refineries. A plurality of high-temperature, sheathed insertion heaters sustains constant high temperature to assure continuous flow of such hydrocarbons.