U.S. patent application number 14/468073 was filed with the patent office on 2014-12-11 for articulated conduit linkage system.
The applicant listed for this patent is Red Leaf Resources, Inc.. Invention is credited to Todd Dana, James W. Patten.
Application Number | 20140360615 14/468073 |
Document ID | / |
Family ID | 42558866 |
Filed Date | 2014-12-11 |
United States Patent
Application |
20140360615 |
Kind Code |
A1 |
Patten; James W. ; et
al. |
December 11, 2014 |
ARTICULATED CONDUIT LINKAGE SYSTEM
Abstract
An articulating conduit linkage system for maintaining a fluid
connection between a fluid source and displaceable conduit that has
been buried in a subsiding permeable body. A fluid source can
supply a working fluid through a source outlet. A displaceable
conduit can receive the working fluid through a conduit inlet, and
be buried at a depth within a subsiding permeable body that is
contained within a permeability control infrastructure. A plurality
of articulating conduit segments can include, an outer conduit
segment coupled to the source outlet, an inner conduit segment
coupled to the conduit inlet, and at least one middle conduit
segment coupled to the outer and inner segments. In the event of a
subsidence, the plurality of articulating conduit segments are
configured so the outer and inner conduit segments extend the
conduit linkage system while maintaining a working fluid connection
between the source outlet and the conduit inlet.
Inventors: |
Patten; James W.; (South
Jordan, UT) ; Dana; Todd; (South Jordan, UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Red Leaf Resources, Inc. |
South Jordan |
UT |
US |
|
|
Family ID: |
42558866 |
Appl. No.: |
14/468073 |
Filed: |
August 25, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12704440 |
Feb 11, 2010 |
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14468073 |
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61152180 |
Feb 12, 2009 |
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Current U.S.
Class: |
138/120 ;
137/15.01 |
Current CPC
Class: |
Y10T 137/8807 20150401;
F16L 27/082 20130101; C10G 9/36 20130101; Y10T 137/0402 20150401;
C10G 1/02 20130101; F16L 9/22 20130101; C10G 9/38 20130101; C10G
2300/4037 20130101; F16L 27/0861 20130101; F16L 55/00 20130101;
Y10T 29/49826 20150115; F16L 27/0816 20130101; Y10T 29/4984
20150115 |
Class at
Publication: |
138/120 ;
137/15.01 |
International
Class: |
F16L 9/22 20060101
F16L009/22; F16L 55/00 20060101 F16L055/00 |
Claims
1. An articulated conduit linkage system for maintaining a fluid
connection between a fluid source and displaceable conduit buried
within a subsiding permeable body, comprising: a fluid source for
supplying a working fluid through a source outlet and being located
outside the permeable body; a displaceable conduit for receiving
the working fluid through a conduit inlet and being buried at a
depth within the subsiding permeable body; and a plurality of
articulating conduit segments comprising: an outer conduit segment
operably coupled to the source outlet with a first single-axis
swivel joint; an inner conduit segment operably coupled to the
conduit inlet with a second single-axis swivel joint; and at least
one middle conduit segment operably connecting the outer and inner
segments, respectively, with at least one single-axis swivel joint,
to establish a working fluid connection between the fluid source
and the displaceable conduit, wherein a subsidence of the permeable
body causes a relative displacement between the source outlet and
the conduit inlet that is perpendicular to the longitudinal axes of
both the outlet and the inlet, causing the outer and inner conduit
segments to rotate in opposite directions to extend the conduit
linkage system while maintaining the working fluid connection
between the source outlet and the conduit inlet.
2. The conduit linkage system of claim 1, wherein the single-axis
swivel joints further comprises threaded pipe joints.
3. The conduit linkage system of claim 1, wherein the subsiding
permeable body is selected from the group consisting of oil shale,
tar sands, coal, lignite, bitumen, and peat.
4. The conduit linkage system of claim 1, wherein the working fluid
is a heat transfer fluid, the fluid source is a heat source for
supplying the heat transfer fluid, and the displaceable conduit is
a heating conduit for receiving the heat transfer fluid.
5. The conduit linkage system of claim 4, wherein the heat transfer
fluid is selected from the group consisting of a heated exhaust
gas, heated air, steam, hydrocarbon vapors, and a heated
liquid.
6. The conduit linkage system of claim 4, wherein the heat transfer
fluid is heated to a temperature between 200 degrees and 1000
degrees Fahrenheit.
7. The conduit linkage system of claim 1, wherein the direction of
flow of the working fluid is reversed, and a displaceable conduit
outlet buried at a depth within the subsiding permeable body
supplies the working fluid through the plurality of articulating
conduit segments to a collection system inlet located outside the
constructed permeability control infrastructure.
8. The conduit linkage system of claim 7, wherein the permeable
body is a hydrocarbonaceous material and the working fluid is a
produced hydrocarbon gas recovered from the permeable body of
hydrocarbonaceous material.
9. The conduit linkage system of claim 7, wherein the permeable
body is a hydrocarbonaceous material and the working fluid is
produced hydrocarbon liquid recovered from the permeable body of
hydrocarbonaceous material.
10. A method of operably coupling a fluid source and displaceable
conduit buried with a subsiding permeable body contained within a
constructed permeability control infrastructure, comprising:
providing a fluid source for supplying a working fluid through a
source outlet and being located outside the constructed
permeability control infrastructure; providing a displaceable
conduit for receiving the working fluid through a conduit inlet and
being buried at a depth within the subsiding permeable body
contained within the control infrastructure; establishing a fluid
connection between the heat source and the heating conduit with a
plurality of articulating conduit segments comprising: an outer
conduit segment operably coupled to the source outlet with a first
single-axis swivel joint; an inner conduit segment operably coupled
to the conduit inlet with a second single-axis swivel joint; and at
least one middle conduit segment operably connecting the outer and
inner segments, respectively, with at least one single-axis swivel
joint, to establish a working fluid connection between the fluid
source and the displaceable conduit, wherein a subsidence of the
permeable body causes a relative displacement between the source
outlet and the conduit inlet that is perpendicular to the
longitudinal axes of both the outlet and the inlet, causing the
outer and inner conduit segments to rotate in opposite directions
to extend the conduit linkage system while maintaining the working
fluid connection between the source outlet and the conduit
inlet.
11. The method of claim 10, wherein the single-axis swivel joints
further comprises threaded pipe joints.
12. The method of claim 10, wherein the subsiding permeable body is
selected from the group consisting of oil shale, tar sands, coal,
lignite, bitumen, and peat.
13. The method of claim 10, wherein the working fluid is a heat
transfer fluid, the fluid source is a heat source for supplying the
heat transfer fluid, and the displaceable conduit is a heating
conduit for receiving the heat transfer fluid.
14. The method of claim 13, wherein the heat transfer fluid is
selected from the group consisting of a heated exhaust gas, heated
air, steam, hydrocarbon vapors, and a heated liquid.
15. The method of claim 13, wherein the heat transfer fluid is
heated to a temperature between 200 degrees and 1000 degrees
Fahrenheit.
16. The method of claim 10, wherein the direction of flow of the
working fluid is reversed, and a displaceable conduit outlet buried
at a depth within the subsiding permeable body supplies the working
fluid through the plurality of articulating conduit segments to a
collection system inlet located outside the constructed
permeability control infrastructure.
17. The method of claim 16, wherein the permeable body includes a
hydrocarbonaceous material and the working fluid is a produced
hydrocarbon gas recovered from the permeable body of
hydrocarbonaceous material.
18. The method of claim 16, wherein the permeable body includes a
hydrocarbonaceous material and the working fluid is produced
hydrocarbon liquid recovered from the permeable body of
hydrocarbonaceous material.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 12/704,440, filed Feb. 11, 2010, which claims
the benefit of U.S. Provisional Application No. 61/152,180, filed
Feb. 12, 2009, each of which is incorporated by reference in its
entirety herein.
BACKGROUND
[0002] Global and domestic demand for fossil fuels continues to
rise despite price increases and other economic and geopolitical
concerns. As such demand continues to rise, research and
investigation into finding additional economically viable sources
of fossil fuels correspondingly increases. Historically, many have
recognized the vast quantities of energy stored in oil shale, coal
and tar sand deposits, for example. However, these sources remain a
difficult challenge in terms of economically competitive recovery.
Canadian tar sands have shown that such efforts can be fruitful,
although many challenges still remain, including environmental
impact, product quality, production costs and process time, among
others.
[0003] Estimates of world-wide oil shale reserves range from two to
almost seven trillion barrels of oil, depending on the estimating
source. Regardless, these reserves represent a tremendous volume
and remain a substantially untapped resource. A large number of
companies and investigators continue to study and test methods of
recovering oil from such reserves. In the oil shale industry,
methods of extraction have included underground rubble chimneys
created by explosions, in-situ methods such as In-Situ Conversion
Process (ICP) method (Shell Oil), and heating within steel
fabricated retorts. Other methods have included in-situ radio
frequency methods (microwaves), and "modified" in-situ processes
wherein underground mining, blasting and retorting have been
combined to make rubble out of a formation to allow for better heat
transfer and product removal.
[0004] Among typical oil shale processes, all face tradeoffs in
economics and environmental concerns. No current process alone
satisfies economic, environmental and technical challenges.
Moreover, global warming concerns give rise to additional measures
to address carbon dioxide (CO.sub.2) emissions which are associated
with such processes. Methods are needed that accomplish
environmental stewardship, yet still provide a high-volume
cost-effective oil production.
[0005] Below ground in-situ concepts emerged based on their ability
to produce high volumes while avoiding the cost of mining. While
the cost savings resulting from avoiding mining can be achieved,
the in-situ method requires heating a formation for a longer period
of time due to the extremely low thermal conductivity and high
specific heat of solid oil shale. Perhaps the most significant
challenge for any in-situ process is the uncertainty and long term
potential of water contamination that can occur with underground
freshwater aquifers. In the case of Shell's ICP method, a "freeze
wall" is used as a barrier to keep separation between aquifers and
an under-ground treatment area. Although this is possible, no long
term analysis has proven for extended periods to guarantee the
prevention of contamination. Without guarantees and with even fewer
remedies should a freeze wall fail, other methods are desirable to
address such environmental risks.
[0006] For this and other reasons, the need remains for methods and
systems which can provide improved recovery of hydrocarbons from
suitable hydrocarbon-containing materials, which have acceptable
economics and avoid the drawbacks mentioned above.
SUMMARY
[0007] Disclosed and described is an articulating conduit linkage
system for maintaining a fluid connection between a fluid source
and displaceable conduit that has been buried in a subsiding
permeable body of hydrocarbonaceous material. The system includes a
fluid source for supplying a working fluid through a source outlet,
and which is located outside of the boundaries of a constructed
permeability control infrastructure. The system also includes a
displaceable conduit that receives the working fluid through a
conduit inlet, and which is being buried at a depth within the
subsiding permeable body of hydrocarbonaceous material that is
contained within the control infrastructure. The linkage system
further includes a plurality of articulating conduit segments which
comprise: an outer conduit segment that is operably coupled to the
source outlet with a first single-axis swivel joint, an inner
conduit segment that is operably coupled to the conduit inlet with
a second single-axis swivel joint, and at least one middle conduit
segment that operably connects the outer and inner segments,
respectively, with at least one single-axis swivel joint to
establish a working fluid connection between the fluid source and
the displaceable conduit. In the event of a subsidence of the
permeable body which causes a relative displacement between the
source outlet and the conduit inlet that is perpendicular to the
longitudinal axes of both the outlet and the inlet, the plurality
of articulating conduit segments are configured so the outer and
inner conduit segments rotate in opposite directions to extend the
conduit linkage system while maintaining the working fluid
connection between the source outlet and the conduit inlet.
[0008] A method of operably coupling a fluid source and
displaceable conduit that has been buried in a subsiding permeable
body of hydrocarbonaceous material contained within a constructed
permeability control infrastructure can include providing a fluid
source for supplying a working fluid through a source outlet. The
source outlet can be located outside of the boundaries of the
constructed permeability control infrastructure. The method also
includes providing a displaceable conduit for receiving the working
fluid through a conduit inlet, and which is buried at a depth
within a subsiding permeable body of hydrocarbonaceous material
contained within the control infrastructure. The method further
includes establishing a fluid connection between the heat source
and the heating conduit with a plurality of articulating conduit
segments that comprise: an outer conduit segment operably coupled
to the source outlet with a first single-axis swivel joint, an
inner conduit segment operably coupled to the conduit inlet with a
second single-axis swivel joint, and at least one middle conduit
segment operably connecting the outer and inner segments,
respectively, with at least one single-axis swivel joint, to
establish a working fluid connection between the fluid source and
the displaceable conduit. In the event of a subsidence of the
permeable body which causes a relative displacement between the
source outlet and the conduit inlet that is perpendicular to the
longitudinal axes of both the outlet and the inlet, the plurality
of articulating conduit segments are configured so that the outer
and inner conduit segments to rotate in opposite directions to
extend the conduit linkage system while maintaining the working
fluid connection between the source outlet and the conduit
inlet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Features and advantages of the invention will be apparent
from the detailed description that follows, and which taken in
conjunction with the accompanying drawings, together illustrate
features of the invention. It is understood that these drawings
merely depict exemplary embodiments and are not, therefore, to be
considered limiting of its scope. And furthermore, it will be
readily appreciated that the components of the present invention,
as generally described and illustrated in the figures herein, could
be arranged and designed in a wide variety of different
configurations. Nonetheless, the invention will be described and
explained with additional specificity and detail through the use of
the accompanying drawings, in which:
[0010] FIG. 1 illustrates a partial cutaway, side schematic view of
a constructed permeability control infrastructure that includes a
permeable body of hydrocarbonaceous material, a heat source, and
interconnecting piping, in accordance with one embodiment;
[0011] FIG. 2 illustrates a side sectional view of a subsiding
permeable body of hydrocarbonaceous material contained within a
constructed permeability control infrastructure, in accordance with
one embodiment;
[0012] FIG. 3 illustrates a side sectional view of the subsiding
permeable body of FIG. 2 having a displaceable heating conduit
buried therein, in accordance with one embodiment;
[0013] FIGS. 4a-4c together illustrate a perspective side, plan and
front elevation views of an articulating conduit linkage system and
box enclosure, in accordance with an exemplary embodiment;
[0014] FIG. 5a through 5c illustrate side sectional views of
several swivel joints for use in the linkage system, in accordance
with one embodiment; and
[0015] FIG. 6 illustrates a perspective side view a sliding vane
panel device mounted to the box enclosure, in accordance with an
exemplary embodiment.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0016] Reference will now be made to exemplary embodiments and
specific language will be used herein to describe the same. It will
nevertheless be understood that no limitation of the scope of the
invention is thereby intended. Alterations and further
modifications of the inventive features described herein, and
additional applications of the principles of the invention as
described herein, which would occur to one skilled in the relevant
art and having possession of this disclosure, are to be considered
within the scope of the invention. Further, before particular
embodiments of the present invention are disclosed and described,
it is to be understood that this invention is not limited to the
particular process and materials disclosed herein as such may vary
to some degree. It is also to be understood that the terminology
used herein is used for the purpose of describing particular
embodiments only and is not intended to be limiting, as the scope
of the present invention will be defined only by the appended
claims and equivalents thereof.
Definitions
[0017] In describing and claiming the present invention, the
following terminology will be used.
[0018] The singular forms "a," "an," and "the" include plural
references unless the context clearly dictates otherwise. Thus, for
example, reference to "a wall" includes reference to one or more of
such structures, "a permeable body" includes reference to one or
more of such materials, and "a heating step" refers to one or more
of such steps.
[0019] As used herein, "conduits" refers to any passageway along a
specified distance which can be used to transport materials and/or
heat from one point to another point. Although conduits can
generally be circular pipes, other non-circular conduits can also
be useful. Conduits can advantageously be used to either introduce
fluids into or extract fluids from the permeable body, convey heat
transfer, and/or to transport radio frequency devices, fuel cell
mechanisms, resistance heaters, or other devices.
[0020] As used herein, "longitudinal axis" refers to the long axis
or centerline of a conduit or passage.
[0021] As used herein, "transverse" refers to a direction that cuts
across a referenced plane or axis at an angle ranging from
perpendicular to about 45 degrees off the referenced plane or
axis.
[0022] As used herein, "conformably bend" refers to bending which
at least partially follows subsidence movement of the permeable
body during heating. Such bending allows for lateral deflection of
the conduit while reducing the risk of rupturing the walls of the
conduit.
[0023] As used herein, "longitudinal axis thermal expansion" refers
to an accordion-like effect along the length of the corrugated
conduit. When corrugations are circumferential, e.g. spiral or
circular, as the conduit material expands the corrugations allow
the overall length of the conduit to increase if the conduit is
free to move at one or both ends. If the conduit is fixed along its
length, however, the corrugations allow the longitudinal expansion
to be absorbed at the individual corrugations. Thus, a corrugated
conduit can be designed to eliminate linear expansion or at least
reduce the stresses associated with restrained linear expansion by
allowing corrugations to permit flexing without loss of conduit
wall integrity.
[0024] As used herein, "apertures" refers to holes, slots, pores or
openings, etc., in the walls or joints of the conduit which allow
the flow of fluid, whether gases or liquids, between the interior
of conduit and the immediately adjacent environment. The flow can
be outwards towards the adjacent environment if the pressure inside
the conduit is greater than the outside pressure. The flow can also
be inwards toward the interior of the conduit if the pressure
inside the conduit is less than the outside pressure.
[0025] As used herein, "constructed infrastructure" refers to a
structure which is substantially entirely man made, as opposed to
freeze walls, sulfur walls, or other barriers which are formed by
modification or filling pores of an existing geological
formation.
[0026] The constructed permeability control infrastructure is often
substantially free of undisturbed geological formations, although
the infrastructure can be formed adjacent or in direct contact with
an undisturbed formation. Such a control infrastructure can be
unattached or affixed to an undisturbed formation by mechanical
means, chemical means or a combination of such means, e.g. bolted
into the formation using anchors, ties, or other suitable
hardware.
[0027] As used herein, "comminuted" refers to breaking a formation
or larger mass into pieces. A comminuted mass can be rubbilized or
otherwise broken into fragments.
[0028] As used herein, "hydrocarbonaceous material" refers to any
hydrocarbon-containing material from which hydrocarbon products can
be extracted or derived. For example, hydrocarbons may be extracted
directly as a liquid, removed via solvent extraction, directly
vaporized or otherwise removed from the material. However, many
hydrocarbonaceous materials contain kerogen or bitumen which is
converted to a hydrocarbon through heating and pyrolysis. Hydro
carbonaceous materials can include, but is not limited to, oil
shale, tar sands, coal, lignite, bitumen, peat, and other organic
materials.
[0029] As used herein, "impoundment" refers to a structure designed
to hold or retain an accumulation of fluid and/or solid moveable
materials. An impoundment generally derives at least a substantial
portion of foundation and structural support from earthen
materials. Thus, the control walls do not always have independent
strength or structural integrity apart from the earthen material
and/or formation against which they are formed.
[0030] As used herein, "permeable body" refers to any mass of
comminuted hydrocarbonaceous material having a relatively high
permeability which exceeds permeability of a solid undisturbed
formation of the same composition. Suitable permeable bodies can
have greater than about 10% void space and typically have void
space from about 30% to 45%, although other ranges may be suitable.
Allowing for high permeability facilitates, for example, through
the incorporation of large irregularly shaped particles, heating of
the body through convection as the primary heat transfer while also
substantially reducing costs associated with crushing to very small
sizes, e.g. below about 1 to about 0.5 inch.
[0031] As used herein, "wall" refers to any constructed feature
having a permeability control contribution to confining material
within an encapsulated volume defined at least in part by control
walls. Walls can be oriented in any manner such as vertical,
although ceilings, floors and other contours defining the
encapsulated volume can also be "walls" as used herein.
[0032] As used herein, "mined" refers to a material which has been
removed or disturbed from an original stratographic or geological
location to a second and different location or returned to the same
location. Typically, mined material can be produced by rubbilizing,
crushing, explosively detonating, or otherwise removing material
from a geologic formation.
[0033] As used herein, "bulk convective flow pattern" refers to
convective heat flow which spans a majority of the permeable body.
Generally, convective flow is generated by orienting one or more
conduits or heat sources in a lower or base portion of a defined
volume. By orienting the conduits in this manner, heated fluids can
flow upwards and cooled fluids flow back down along a substantial
majority of the volume occupied by the permeable body of
hydrocarbonaceous material in a re-circulating pattern.
[0034] As used herein, "substantially stationary" refers to nearly
stationary positioning of materials with a degree of allowance for
subsidence, expansion, and/or settling as hydrocarbons are removed
from the hydrocarbonaceous material from within the enclosed volume
to leave behind lean material. In contrast, any circulation and/or
flow of hydrocarbonaceous material such as that found in fluidized
beds or rotating retorts involves highly substantial movement and
handling of hydrocarbonaceous material. As used herein,
"substantial" when used in reference to a quantity or amount of a
material, or a specific characteristic thereof, refers to an amount
that is sufficient to provide an effect that the material or
characteristic was intended to provide. The exact degree of
deviation allowable may in some cases depend on the specific
context. Similarly, "substantially free of" or the like refers to
the lack of an identified element or agent in a composition.
Particularly, elements that are identified as being "substantially
free of" are either completely absent from the composition, or are
included only in amounts which are small enough so as to have no
measurable effect on the composition.
[0035] As used herein, "about" refers to a degree of deviation
based on experimental error typical for the particular property
identified. The latitude provided the term "about" will depend on
the specific context and particular property and can be readily
discerned by those skilled in the art. The term "about" is not
intended to either expand or limit the degree of equivalents which
may otherwise be afforded a particular value. Further, unless
otherwise stated, the term "about" shall expressly include
"exactly," consistent with the discussion below regarding ranges
and numerical data.
[0036] Concentrations, dimensions, amounts, and other numerical
data may be presented herein in a range format. It is to be
understood that such range format is used merely for convenience
and brevity and should be interpreted flexibly to include not only
the numerical values explicitly recited as the limits of the range,
but also to include all the individual numerical values or
sub-ranges encompassed within that range as if each numerical value
and sub-range is explicitly recited. For example, a range of about
1 to about 200 should be interpreted to include not only the
explicitly recited limits of 1 and 200, but also to include
individual sizes such as 2, 3, 4, and sub-ranges such as 10 to 50,
20 to 100, etc.
[0037] As used herein, a plurality of items, structural elements,
compositional elements, and/or materials may be presented in a
common list for convenience. However, these lists should be
construed as though each member of the list is individually
identified as a separate and unique member. Thus, no individual
member of such list should be construed as a de facto equivalent of
any other member of the same list solely based on their
presentation in a common group without indications to the
contrary.
Articulated Conduit Linkage System
[0038] Illustrated in FIGS. 1-6 are several representative
embodiments of an articulated conduit linkage system which can be
used to maintain a fluid connection between a source of heat
transfer fluid and a displaceable heating conduit buried within a
subsiding permeable body. The permeable body can be a
hydrocarbonaceous material, although other subsiding materials can
be used. The hydrocarbonaceous material can include mined materials
such as oil shale, tar sands, coal, etc., that are placed within a
suitable structure (e.g. a constructed permeability control
infrastructure, an impoundment, or other structure) with the intent
to extract or otherwise liberate hydrocarbon products therefrom.
The hydrocarbons can be liberated by passing a heat transfer fluid,
such as hot air, hot exhaust gases, steam, hydrocarbon vapors
and/or hot liquids, into or through the buried heating conduit to
heat the hydrocarbonaceous material to temperature levels
sufficient to remove hydrocarbons therefrom.
[0039] Exemplary embodiments of one alternative constructed
permeability control infrastructure, and the permeable body of
hydrocarbonaceous material contained within its substantially
encapsulated volume, are described in more detail in commonly-owned
and co-pending U.S. patent application Ser. No. 12/028,569, filed
Feb. 8, 2008, and entitled "Methods Of Recovering Hydrocarbons From
Hydrocarbonaceous Material Using A Constructed Infrastructure And
Associated Systems," which application is incorporated by reference
in its entirety herein. However, other structures can also be used
which provide at least some control or containment of materials
within the structure. For example, the articulated conduit linkage
system can also be suitable for use whenever conduits are embedded
in a material which subsides over time. Subsidence can be the
result of removal of hydrocarbons, deterioration of the permeable
body, or other processes.
[0040] In order for the extraction process to be effective, it may
be desirable to raise the temperature of the permeable body to
between 200 degrees and 900 degrees Fahrenheit to initiate
pyrolysis. It has been discovered that during the heating process
the permeable body of hydrocarbonaceous material can remain
substantially stationary in the lateral directions, but over time
can undergo significant vertical subsidence and settling as the
hydrocarbons are released to flow downwards as a liquid or upwards
as a gas. Subsidence of the permeable body can cause the embedded
heating conduit to displace downwardly as well. Small relative
displacements between adjacent conduit segments that are both
subsiding can be accommodated by providing the heating conduit with
flexible joints, seams or corrugations which can absorb localized
bending. However, large displacements between adjacent conduit
segments, where one segment is subsiding and the other is fixed,
may create sheer stresses that cannot be accommodated or absorbed
simply by providing flexible joints, seams or corrugations.
[0041] Such a situation can exist between the outlet piping of the
heat source that provides heat transfer fluid to the permeable body
(which outlet is fixed in space) and the inlet to the heating
conduit (which inlet can displace downwards with the rest of the
displaceable heating conduit). If the relative motion between the
source outlet and conduit inlet is great enough, the resulting
transverse sheer stresses can exceed the material limits of the
conduit walls and joints and result in a rupture that allows the
heating fluid to escape. It is desirable, therefore, to maintain
the structural integrity and working fluid connection between the
source outlet and conduit inlet, regardless of the amount of
vertical displacement brought on by subsidence, so that the conduit
system can maintain its structural integrity and continue to
function throughout the process.
[0042] FIG. 1 provides a partial cutaway, side schematic view of a
constructed permeability control infrastructure or impoundment 10,
a permeable body 30 of hydrocarbonaceous material 32, a heat source
40, and interconnecting piping 62, 64, 66 and 68. In the embodiment
shown, the existing grade 4 is used primarily as support for an
impermeable floor layer 16. Exterior capsule impoundment side walls
12 can provide containment and can, but need not be, subdivided by
interior walls 14. Subdividing can create separate containment
capsules 22 within a greater capsule containment 20 of the
impoundment 10 which can be any geometry, size or subdivision.
[0043] The sidewalls 12 and 14, as well as the impermeable cap 18
and impermeable floor 16 layers, can comprise the permeability
control impoundment 10 that defines the encapsulated volume 20, and
can be formed of any suitable material. For instance, the sidewalls
12 and 14 of the impoundment 10 can also be self-supporting,
wherein the tailings berms, walls, and floors can be compacted and
engineered for structure as well as substantial impermeability
(e.g. sufficient to prevent uncontrolled escape of fluids from the
impoundment). Furthermore, the impermeable cap layer 18 can be used
to prevent uncontrolled escape of volatiles and gases, and to
direct the gases and vapors to appropriate gas collection outlets
66. Similarly, an impermeable floor layer 16 can be used to contain
and direct collected liquids to a suitable outlet such the drain
system 26 to remove liquid products from lower regions of the
impoundment. Although impermeable side walls can be desirable in
some embodiments, such are not always required. Having permeable
side walls may allow some small egress of gases and/or liquids from
the impoundment.
[0044] Once side wall structures 12 and 14 have been constructed
above a constructed and impermeable floor layer 16, which commences
from ground surface 6, the mined hydrocarbonaceous material 32
(which may be crushed or classified according to size or
hydrocarbon richness), can be placed in layers upon (or next to)
placed tubular heating pipes or conduit 62, fluid drainage pipes 64
and/or gas gathering or injection pipes 66. These pipes can be
oriented and designed in any optimal flow pattern, angle, length,
size, volume, intersection, grid, wall sizing, alloy construction,
perforation design, injection rate, and extraction rate. In some
cases, pipes such as those used for heat transfer can be connected
to, recycled through or derive heat from a heat source 40.
Alternatively, or in combination with, recovered gases can be
condensed by a condenser 42. Heat recovered by the condenser can be
optionally used to supplement heating of the permeable body or for
other process needs.
[0045] Heat source 40 can derive or create heat from any suitable
heat source including, but not limited to, fuel cells (e.g. solid
oxide fuel cells, molten carbonate fuel cells and the like), solar
sources, wind sources, hydrocarbon liquid or gas combustion
heaters, geothermal heat sources, nuclear power plant, coal fired
power plant, radio frequency generated heat, wave energy, flameless
combustors, natural distributed combustors, or any combination
thereof. In some cases, electrical resistive heaters or other
heaters can be used, although fuel cells and combustion-based
heaters are very effective. In some locations, geothermal water can
be circulated to the surface and directed into the infrastructure
in adequate amounts to heat the permeable body.
[0046] In one embodiment, heating of the permeable body 30 can be
accomplished by convective heating from hydrocarbon combustion. Of
particular interest is hydrocarbon combustion performed under
stoichiometric conditions of fuel to oxygen. Stoichiometric
conditions can allow for significantly increased heat gas
temperatures. Stoichiometric combustion can employ but does not
generally require a pure oxygen source which can be provided by
known technologies including, but not limited to, oxygen
concentrators, membranes, electrolysis, and the like. In some
embodiments oxygen can be provided from air with stoichiometric
amounts of oxygen and hydrogen. Combustion off gas can be directed
to an ultra-high temperature heat exchanger, e.g. a ceramic or
other suitable material having an operating temperature above about
2500.degree. F. Air obtained from ambient or recycled from other
processes can be heated via the ultra high temperature heat
exchanger and then sent to the impoundment for heating of the
permeable body. The combustion off gases can then be sequestered
without the need for further separation, i.e. because the off gas
is predominantly carbon dioxide and water.
[0047] A liquid or gas heat transfer fluid can transfer heat from
the heat source 40, through heating conduit 62 and into the
permeable body 30 of hydrocarbonaceous material 32. In order to
raise the temperature of the permeable body to between 200 degrees
and 900 degrees Fahrenheit to initiate pyrolysis, as stated above,
the temperature of the heat transfer fluid within the heating
conduit can be elevated to even higher temperatures, such as 1000
degrees Fahrenheit or above, to maintain a constant flow of heat
from the heat transfer fluid into the permeable body.
[0048] The liquids or gases extracted from capsule impoundment
treatment area 20 or 22 can be stored in a nearby holding tank 44
or within a capsule containment 20 or 22. For example, the
impermeable floor layer 16 can include a sloped area 24 which
directs liquids towards drain system 26, from which liquids are
directed to the holding tank 44 through drain piping 64.
[0049] As placed hydrocarbonaceous rubble material 32 fills the
capsule treatment area 20 or 22, permeable body 30 becomes the
ceiling support for engineered impermeable cap layer 18, which may
include an engineered fluid and gas barrier. Above cap layer 18,
fill material 28 can be added to form a top layer that can create
lithostatic pressure upon the capsule treatment areas 20 or 22.
Covering the permeable body 30 with a compacted fill layer 28
sufficient to create an increased lithostatic pressure within the
permeable body 30 can be useful in further increasing hydrocarbon
product quality. The compacted fill layer 28 can substantially
cover the permeable body 30, while the permeable body 30 in return
can substantially support the compacted fill layer 28.
[0050] FIG. 2 is an illustration of the permeable body 30 of
hydrocarbonaceous material 32 contained within the constructed
permeability control infrastructure or impoundment 10. The
permeable body can substantially fill the containment capsule or
volume 20 defined by the side walls 12, the impermeable floor layer
16 and the impermeable cap layer (not shown). For instance, during
the filling stage and prior to commencement of the heating process,
the encapsulated volume 20 can be substantially filled with
hydrocarbonaceous material 32 so that top surface t.sub.o of the
permeable body 30 is substantially level with the top of the side
walls 12 to maximize the amount of hydrocarbonaceous material
included in the batch process.
[0051] As stated above, it has been discovered that during the
heating process that the permeable body of hydrocarbonaceous
material can undergo significant vertical subsidence movement and
settling as the hydrocarbons are released. This process is a result
of the temperature gradients that can begin to develop with the
introduction of heat into the permeable body, with the center and
upper regions becoming hotter than the side and bottom edges
adjacent the unheated boundaries of the containment capsule 20.
Naturally, hydrocarbons can begin to flow more readily from the
hotter regions, resulting in the initial subsidence having the
greatest movement in the center region of the top surface, to the
t.sub.1 position.
[0052] The period of time necessary to reach the t.sub.1 position
can fluctuate significantly, depending on the composition and
configuration of the hydrocarbonaceous material 32, the size of the
permeable body 30, the method of heating and heat rate provided by
the heating conduit system, the ambient environment and insulating
boundary conditions, etc., and can range from a few days to a few
months. It has been observed that the hydrocarbons can begin to
remove when hydrocarbonaceous material 32 reaches a temperature of
about 600 degrees Fahrenheit.
[0053] As the higher temperatures spread towards the edges of the
containment capsule 20, the top surface of the permeable body 30
can continue to subside through the t.sub.2 and t.sub.3 positions,
following a pattern in which the center region can still experience
more vertical movement than the edges. However, continuous heating
can eventually raise the temperature throughout the entire
permeable body 30 to the critical extraction point, causing even
the material adjacent the boundaries of the impoundment 10 to
release its hydrocarbons. At that point the outer regions can also
undergo significant vertical subsidence until the top surface
reaches the t.sub.4 position.
[0054] The amount of vertical subsidence experienced by the
permeable body 30 can vary greatly, depending upon composition of
the hydrocarbonaceous material 32 and its initial configuration.
Although exaggerated in FIG. 2 for illustrative purposes, the
amount of vertical movement of the top surface can range between 5%
and 25% of the initial vertical height of the body, with a
subsidence of 12%-16% being common. Small relative displacements
between adjacent conduit segments that are both embedding with the
subsiding body can be accommodated by providing the heating conduit
with flexible joints, seams or corrugations 76 which can absorb
localized bending. (see FIG. 3). However, maintaining the
structural integrity and heat transfer fluid connection of the
conduit joints that connect the displaceable heating conduit with
the stationary heat source located outside the constructed
permeability control structure, can be challenging.
[0055] One system for maintaining the fluid connection between the
source outlet 72 and the conduit inlet 74 is an articulated conduit
linkage system, illustrated in one specific embodiment at 80 in
FIG. 3. The source outlet 72 can be a stationary conduit or pipe
that extends from a fluid source (not shown) located outside the
constructed permeability control infrastructure 10, through the
side walls 12 of the impoundment, and into the containment capsule
20 where it is coupled to the conduit linkage system 80. The fluid
source can supply a working fluid to the displaceable conduit 70
embedded or buried with the permeable body 30 of hydrocarbonaceous
material 32. If the permeable body 30 subsides from position
t.sub.0 to t.sub.4, the inlet 74' of the displaced conduit 70' can
displace to a location that is substantially lower than its
original position. As described above, the conduit linkage system
80 can continue to operate both during the subsidence and after its
completion to maintain the fluid connection between the stationary
and displaceable segments of conduit.
[0056] In one embodiment, the working fluid can be a heat transfer
fluid, the fluid source can be a heat source for supplying the heat
transfer fluid, and the displaceable conduit 70 can be a heating
conduit for receiving the heat transfer fluid and conveying it
throughout the containment capsule 20 for the purpose of heating
the permeable body.
[0057] However, the conduit linkage system 80 is not limited to the
heating system of the constructed permeability control
infrastructure 10, and can also be used to couple fluid sources (or
collection systems) and displaceable conduits that operate a
working fluid other than the heat transfer fluid.
[0058] For example, the gas gathering or injection pipes
(identified as 66 in FIG. 1) can be configured with the conduit
linkage system 80, as the gathering or injection pipes may also be
embedded in the subsiding permeable body 30. Other applications
include liquids gathering or injection pipes (not shown). For
injection systems the direction of flow of the working fluid can be
as described above, with the working fluid flowing from the fluid
source outside the impoundment 10, through the conduit linkage
system 80 and into the displaceable conduit 70 buried at a depth
within the subsiding permeable body. For collection systems,
however, the direction of flow of the working fluid can be
reversed, and the outlet 74 of the displaceable conduit 70 buried
at a depth within the subsiding permeable body can supply the
working fluid, through the conduit linkage system 80, to a
collection system inlet 72 that extends outside the control
infrastructure.
[0059] An exemplary embodiment of the conduit linkage system 80 is
shown in FIGS. 4a-4c, and can include a plurality of articulating
conduit segments 82, 84, 86 coupled together with conduit joints
88. For instance, the linkage system can include an outer conduit
segment 82 that can be coupled to the source outlet 72 with a first
single-axis swivel joint, and an inner conduit segment 84 can be
coupled to the conduit inlet 74, 74' with a second swivel joint.
The linkage system can also include at least one middle or
intermediate conduit segment 86 that operably connects the outer
and inner segments, respectively, with at least one single-axis
swivel joint, to establish a working fluid connection between the
fluid source (not shown) and the displaceable conduit 70, 70'.
[0060] The plurality of articulating conduit segments 82, 84, 86
and the conduit joints 88 can be surrounded by a protective,
motion-free box enclosure 90 that can prevent the encroachment of
hydrocarbonaceous material into the articulating linkage's
operating space. The stationary source outlet 72 can enter the box
enclosure 90 through a single circular opening in the outer face of
the enclosure, which can be adjacent the side wall 12 of the
impoundment 10. In contrast, the moveable conduit inlet 74, 74' can
enter the box enclosure through an elongated slot 92 or window that
can extend the vertical length of inner wall of the box enclosure
to allow for the unrestricted movement of the conduit inlet as it
displaces downward. As discussed in more detail below, a sliding
vane panel device or similar structure can be mounted into the
elongated slot 92 to cover and protect the exposed portions of the
opening and allow for the displaceable conduit 70' to travel
downwards.
[0061] In their initial, non-extended position, the articulating
conduit segments 82, 84, 86 can be arranged in a substantially
horizontal position, and with the longitudinal axes of the source
outlet 72 and the conduit inlet 74 substantially aligned with one
another. (see FIG. 4c). It can be appreciated by one of skill in
the art that a subsequent subsidence of the permeable body can
cause a relative displacement between the source outlet 72 and the
conduit inlet 74' that is perpendicular (in this case downward) to
the longitudinal axes. To accommodate this motion, the plurality of
articulating conduit segments can be configured in a toggle
orientation, so that any subsidence within the permeable body that
causes the inlet 74' of the displaceable conduit to move downwards,
can in turn cause the outer 82 and inner 84 conduit segments to
rotate in opposite directions to extend the conduit linkage system
80, thus maintaining the structural integrity and working fluid
connection between the stationary and displaceable segments of
conduit. (see FIG. 4b).
[0062] Although the conduit linkage system 80 can operate if any
three of the four conduit joints 88 connecting the three conduit
segments 82, 84, 86 with the source outlet 72 and conduit inlet 74,
74' allow for rotation movement, it is assumed that the source
outlet and conduit inlet are rotationally fixed within their
respective support structures (e.g. the side wall 12 of the
impoundment 10 and the subsiding permeable body 30). Therefore, the
conduit joints 88 connecting the outer and inner rotating conduits
82, 84 with the non-rotating outlet 72 and inlet 74, 74' can be
single-axis swivel joints. One or both of the conduit joints 88
connecting the intermediate conduit 86 with the outer 82 and inner
84 rotating conduits, consequently, can also be single-axis swivel
joints.
[0063] As the amount of hydro carbonaceous material contained
within the constructed permeability control infrastructure can be
quite large, the volume of working fluid, as well as the diameter
of the associated piping or conduit system, needed to affect the
mass properties of the permeable body can also be quite large. For
instance, the heat source outlet and heating conduit inlet can be
from several inches up to 36 inches or more in diameter to allow a
sufficient volume of heat transfer fluid to enter and heat the
permeable body. Additionally, the associated piping or conduit
system can experience extreme operating conditions, such as heavy
side loading created by the weight of overlying material and
operating temperatures as high as 900 degree to 1000 degrees
Fahrenheit. Providing a swivel or rotating conduit joint of large
enough size and which can operated in the severe operating
conditions may be difficult. One type of swivel joint that can be
particularly suitable for such large diameter piping and extreme
operating conditions is the threaded pipe joint. Threaded pipe
joints can effectively seal the conduit joints against fluid
leakage while still allowing the pipe to rotate through a limited
range of motion, e.g. up to 90.degree..
[0064] Other types of high-temperature swivel joints, however, can
also be suitable. For example, as shown schematically in FIG. 5a, a
stationary conduit segment 102 that is anchored or fixed with
anchor system 106 can be operably coupled and sealed to rotating a
conduit segment 104 with a high-temperature carbon-to-carbon face
seal 110. The carbon-to-carbon face seal can include two annular
carbon discs 114 that are mounted to adjacent inside faces of
conduit flanges 112, which can then be held together with an outer
retaining ring or device 116. The extreme hardness and heat
resistance of the carbon discs can provide a high-temperature
friction contact interface that does not easily wear or degrade
with rotation of conduit segment 104, and can thus maintain a
reliable mechanical seal for the life of the conduit swivel
joint.
[0065] Alternative types of high-temperature seals can include
labyrinth mechanical seals 120 having metal rings 122 alternately
extending from the inner rotating surface and the outer stator
surface, and which act as "teeth" to form a tortuous sealing
passage for gases and liquids (FIG. 5b). Another suitable joint can
include slip joints 130 having interlocking annular protrusions or
rings 132, 134 extending axially from the flanges of the stationary
102 and rotating 104 conduit segments, respectively, and which can
interconnect to form another type of passage which seals against
the flow of high-temperature fluids (FIG. 5c). Moreover, other
types of mechanical seals and/or swivel joint connections, etc.,
for facilitating the relative rotation of one conduit segment
relative to another conduit segment while preventing the escape of
high-temperature gases or liquids through the stationary/rotating
interface can be used.
[0066] The embodiment illustrated in FIGS. 4a-4c can comprise of
two rotating conduit segments 82, 84 that each rotate about an axis
perpendicular to the longitudinal axis of that conduit segment
(which in this case is coincident with the longitudinal axis of the
source outlet 72 or conduit inlet 74, 74'), as well as one
intermediate conduit segment 86 that both translates and spins
about its own longitudinal axis. It is to be appreciated, moreover,
that additional intermediate conduit segments (in pairs of one
rotating and one spinning conduit segments) can be added to
increase the range of motion of the conduit linkage system 80.
[0067] Shown in FIG. 6 is the second swivel joint 88 that connects
the conduit inlet 74 with the inner conduit segment 84, along with
one example of the sliding vane panel device 94 that can seal the
elongated slot opening of the box enclosure 90 to prevent the
encroachment of hydrocarbonaceous material into the articulating
linkage's operating space. The sliding vane panel device 94 can
include a series of upper sliding vane panels 96 that are each
coupled to adjacent vane panels at an upper or lower edge, but
which can slide relative to each other so that all of the vane
panels can be grouped together when the articulated conduit linkage
system is set into its initial position. Downward movement of the
conduit inlet 74 brought on by the subsidence of the permeable body
can allow the upper group of sliding vane panels 96 to drop
downwards, sequentially leaving panels behind to cover the exposed
opening. The panel device 94 can also include a series of lower
sliding vane panels 98 which operate in much the same way, with the
exception that the lower vane panels are extended in the initial
position and become sequentially grouped together as the conduit
inlet 74 descends. Other similar sliding panels can be used to
prevent solid debris from entering the box enclosure.
[0068] The foregoing detailed description describes the invention
with reference to specific exemplary embodiments. However, it will
be appreciated that various modifications and changes can be made
without departing from the scope of the present invention as set
forth in the appended claims. The detailed description and
accompanying drawings are to be regarded as merely illustrative,
rather than as restrictive, and all such modifications or changes,
if any, are intended to fall within the scope of the invention as
described and set forth herein.
[0069] More specifically, while illustrative exemplary embodiments
of the invention have been described herein, the present invention
is not limited to these embodiments, but includes any and all
embodiments having modifications, omissions, combinations (e.g., of
aspects across various embodiments), adaptations and/or alterations
as would be appreciated by those skilled in the art based on the
foregoing detailed description. The limitations in the claims are
to be interpreted broadly based on the language employed in the
claims and not limited to examples described in the foregoing
detailed description or during the prosecution of the application,
which examples are to be construed as non-exclusive. Any steps
recited in any method or process claims may be executed in any
order and are not limited to the order presented in the claims.
Means-plus-function or step-plus-function limitations will only be
employed where for a specific claim limitation all of the following
conditions are present in that limitation: a) "means for" or "step
for" is expressly recited; and b) a corresponding function is
expressly recited. The structure, material or acts that support the
means-plus function are expressly recited in the description
herein. Accordingly, the scope of the invention should be
determined solely by the appended claims and their legal
equivalents, rather than by the descriptions and examples given
above.
* * * * *