FIELD OF THE INVENTION
[0001] The invention relates to a method and system for producing fracturing of shale and
oil sands, and mineral containing material to release natural gases and oil utilizing
CO
2 and a steam process without using other chemical contaminants.
BACKGROUND OF THE INVENTION
[0002] Most fracturing processes use various chemicals in their process to recover gas and
oil. For example,
U.S. Patent 8,733,439 uses CO
2, but also used H
2O
2 (hydrogen peroxide) which, when used medically in small amounts, is considered a
mild antiseptic, and can be used as a bleaching agent. Hydrogen peroxide can be used
for certain industrial or environmental purposes as well, because it can provide the
effects of bleaching without the potential damage of chlorine-based agents. Because
this substance can be unstable in high concentrations, it must be used with care.
In higher concentrations, it can create strong chemical reactions when it interacts
with other agents, and it can damage the skin or eyes of persons working with it.
The use in wells may contaminate underground water if there is seepage into ground
water. This patent also uses other chemicals such as Fe, Co, Ni and similar chemicals.
[0003] Other processes also use various chemicals, particulate material, and other catalysts
which can contaminate water sources such as wells and aquifers. These processes utilize
a large amount of water which often is not or cannot be recycled because of the toxic
chemicals contained therein.
SUMMARY OF THE INVENTION
[0004] An object of the invention is to provide a clean, noncontaminating process for producing
fracturing of shale, limestone, sands, and other geological and mining formations
to release natural gas and oil within a well, and to break up any mineral containing
material.
[0005] Another object of the invention is to provide a system to produce on site the energy
required to induce fracturing, removing natural gas and oil, and to recycle fluids
used in fracturing for additional use.
[0006] Another object of the invention is to provide for movable storage of fracturing liquids
for additional use at one or more sites.
[0007] The technical advance represented by the invention as well as the objects thereof
will become apparent from the following description of a preferred embodiment of the
invention when considered in conjunction with the accompanying drawings, and the novel
features set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008]
FIGURE 1 illustrates a diagram of the basis system of the invention and the process
associated therewith.
FIGURE 2 illustrates additional features which may be utilized with the present invention.
Figure 3 illustrates a well configuration in which frozen CO2 is inserted into a well and then expanded by pressurized steam to cause fracturing
of the walls of the well.
Figures 4a and 4b illustrate two types of insertion tubes.
DESCRIPTION OF A PREFERRED EMBODIMENT
[0009] Figure 1 illustrates the system and method for producing clean fracturing in a natural
gas and oil well. The well has a vertical drill bore and or pipe casing 1a and a horizontal
drill bore or pipe casing 1b extending horizontally from the lower end of vertical
drill bore and or pipe casing 1a. This is the standard method of drilling wells. Inserted
in the well is vertical pipe or tube 2a which extends the length of vertical well
bore 1a and then extends horizontally, 2b, into the horizontal well bore 1b. Well
bore 1a is then caped at the top with seal 15. This is to prevent any gasses or other
material from escaping out into the atmosphere and surrounding area. This system is
an example that can be used with the claimed fracturing process. Modification of the
system and other configurations may be used with the fracturing process.
[0010] The rest of the system is described as follows. Clean water is supplied through input
14 through a processing system 8, which includes a three way valve. The water is directed
through 23 into pipe 9 and then in to storage container 5, which carbonates the water,
using the CO
2 from portable storage container 6.
[0011] The carbonated water from container 5 is then directed, through pipe 10 and valve
10b, into the well at opening 10a. This carbonated water flows downward into the well
and fills the horizontal portion 1b with carbonated water. The carbonated water in
container 5 may be refrigerated to keep the carbonated water cool, or partially frozen
so as to prevent vaporization of the CO
2 from the water while it is being injected into the well. The carbonated water may
be lightly frozen to provide an icy slush. Sand can be injected into the wellbore
alone, or with the carbonated water to aid in the fracturing process.
[0012] Once the well, particularly the horizontal portion 1b is filled with the carbonated
water, then high pressure steam, generated in steam generator 4, is injected into
the well though valve 3 into pipes or tubes 2a and 2b. Pipe/tube 2b has openings 16
around it periphery and along its length to distribute the steam throughout horizontal
well bore 1b. The high pressure steam causes the carbonated water to literally explode
creating, a great pressure in the well causing fracturing of the walls of the well
bore, thus releasing natural gas/oil from the underground sources. To keep all of
the pressurized steam from exiting though the first holes at the beginning 2c of horizontal
pipe 2b, there are fewer holes at the start of horizontal pipe 2c to prevent exiting
of a large quantity of pressurized gas. The number of holes increases towards the
2d end of the horizontal pipe. This progressive increasing of holes helps to evenly
distribute the pressurized gas throughout the horizontal portion 1b of the well.
[0013] After the fracturing process, the remaining carbonated water, any loose sand, and
the gas/oil is then pumped upward though well bore 1a and pipe 2a through pipes 11a
and 11b to valve 11c and though pipe 11 into processing unit 7, which may have storage
capacity. Processing unit 7 filters out any particulate material and separates the
gas/oil and CO
2 from the remaining water. The CO
2 can be returned through pipe 28 to the CO
2 storage tank 6 for reuse. The gas/oil is then stored or directed out pipe 13 for
storage and/or transportation to another storage facility.
[0014] To prevent the particulate filter 7 from becoming clogged with particulate material,
there could be at least two parallel particulate filters. One would be used at a time.
When the flow of gas/petroleum/CO2 decreases to a lower determined level through the
particulate filter, a sensor would detect this lower level and would switch the flow
through a parallel filter. There would be a notification of this change, and the clogged
filter could be cleaned to remove the particulate for use again.
[0015] The separated water is then passed through pipe 12 into processing system 8. The
water can be directed back into the system though valve 21 for reuse, as needed, for
additional fracturing of the well. The water can also be processed to clean it, removing
any and all chemical and/or foreign matter from the well and then sent thought pipe
14 for storage and/or another use.
[0016] All of the units, Steam generator 4, carbonated water unit 5, CO
2 unit 6, separator 7 and processing system may all be portable units for use at other
locations. The units may be incorporated in one movable unit for movement to other
drilling sites.
[0017] To prevent excess pressure that would cause over fracturing in the well, a pressure
sensor 30 measures the pressure. If the pressure exceeds a predetermined amount, then
release valve 31 would open, and stay open, as long as the pressure exceeds the predetermined
amount. When the pressure is reduced, then value 31 would close.
[0018] As an alternative to using carbonated water, refrigerated CO
2 can be injected into the well bore and then expanded with the pressurized steam.
This would limit the amount of carbonated water needed in the well bore. Since steam
is vaporized water, after the steam is injected into the refrigerated CO
2, it would cool and become carbonated water. Additional steam injected into the refrigerated
CO
2 would cause it to expand and cause fracturing. This would limit the amount of carbonated
water to be removed from the well for cleaning and future use.
[0019] Figure 2 illustrates the system and method for producing clean fracturing in a natural
gas and oil well as in Figure 1 with the following differences in the system and method.
In the vertical part of the wellbore 1a, a isolation plug 19 is placed near the bottom
of the vertical portion 1a of the well bore, or in any part of horizontal well bore
1b. The location of the isolation plug is determined where the fracturing of the well
is to begin. Since carbonated water cannot be inserted into the well after the isolation
plug seal 19 is in place, the valve 3 of Figure 1 is replaced with valve 20. The carbonated
water is then passed through pipe 17 into valve 20 into pipe 2a to insert the carbonated
water into the well bore. The carbonated water will flow downward through pipe 2a
and horizontal pipe 2b and into the well out openings 16 and out the end 2d of horizontal
pipe 2b into the well bore. The pressurized steam from steam generator 4 is directed
through valve 20 into pipe 2a and 2b. The steam is then evenly distributed into horizontal
well bore 1b through openings 16, as in Figure 1, providing pressure to producing
the fracturing required to release the natural gas or oil from the surrounding areas.
The advantage of using isolation plug 19 is that the pressure cannot pass upward into
vertical well bore 1a, or unwanted areas of 1b, providing a greater pressure in the
localized horizontal portion of 1b of the well bore, increasing the fracturing pressure
and increasing the result of the fracturing, releasing more natural gas and/or oil.
[0020] Isolation plug 19 could include a pressure sensor 38 and release valve 39 to prevent
the pressure from exceeding a predetermined amount, to prevent over fracturing. The
isolation plug can be later removed or drilled out to allow flow in well bore 1a.
[0021] After the fracturing process, the remaining carbonated water, any loose sand or other
particulate material, and the gas/oil may be pumped upward though pipe 2a and well
bore 1a through pipes 11a and 11b to valve 11c, and then through pipe 11 into processing
unit 7.
[0022] Figure 3 illustrates a well configuration in which frozen CO
2 is inserted into a pipe 45 and then expanded by pressurized steam to cause fracturing
of the walls of the well bore 1b. This configuration involves cooling CO
2 in unit 50 to below its freezing temperature of 109.3 degrees F and injecting a snow
like compound into well bore 1b. This is achieved through a flexible composite material
or metal alloy insertion hose or tube 51 and 45, which can be the same as tube 2a,
Figure 2, attached via a delivery hose or tubing from the surface. The cooled CO
2 is released into the well bore through the perforations 43 in the insertion tube
42, or by use of, or with a perforating gun. When sufficient amounts of cooled CO
2 are achieved, a CO
2 sensor and release valve 41 immediately closes off the CO
2 induction and triggers a steam pressure sensor and release valve 40 for high pressure
steam to immediately be injected through the same flexible perforated composite or
metal alloy insertion tube 45. A pressure containment plate 46 seals the lower portion
of the well to prevent pressure from rising upward to the top of the well. This process
creates a catalytic reaction that rapidly heats and expands the cooled CO
2 causing the fracturing of the shale or other geological formation being addressed.
This process can be carried out in one large stage or in multiple stages, depending
upon the specific characteristics of the geological formation being fractured, and
can be repeated until the required desire of fracturing is achieved. This configuration
can be used in combination with the basic system shown in Figure 2 where the assembly
in Figure 3 replaces the structure at the lower end of tube 2a, or any part of horizontal
1b of Figure 2.
[0023] Pipe 45, in Figure 3 may have several configurations and partitions for inserting
the fracturing materials into the well. Figures 4a and 4b below, shows two possible
configurations. Other configurations are possible to individually insert the fracturing
materials in the order necessary to provide the fracturing.
[0024] The carbonated water, frozen CO
2, and steam are alternately inserted though valve 20a.
[0025] The system of Figure 1 could be used to extract minerals other than gas and oil.
In this configuration, there would be extreme fracturing to break up the mineral containing
soil/rock in the structure. The mineral containing soil/rock would be vacuumed up
out of the structure where the minerals could be separated from the soil/rock. This
process would use a vacuum system similar to that used to mine minerals from the sea
bottom. In this instance, the pressure system and release valves would not be used.
[0026] Figures 4a and 4b illustrate two types of insertion tubes. Figures 4a and 4b are
cross sectional views taken at A-A in Figure 3.
[0027] Figure 4a shows concentric used to insert particulate frozen CO
2, pressurized steam and carbonated water and fracking sand as needed. The outer structure
is the well bore structure into which the concentric tubes are inserted.
[0028] Figure 4b shows parallel tubes into which pressurized steam, carbonated water and
particulate frozen CO
2 are injected into the well bore structure.
[0029] These two configurations are examples for inducing the fracturing material. Other
configurations may be used, for example some of the tubes may be used for more than
one insertion path, different injection materials may be switched between the injection
paths.
[0030] The valves 3, 20, 20a, 10b and 11c and tubes 2a and 2b in Figures 1, 2 and 3 may
remain onsite for future use.
1. A method of providing fracturing in a well bore, to produce at least one of natural
gas and oil, having vertical and horizontal well bore regions,
injecting carbonated water into the well bore; and
injecting high pressure steam into the carbonated water to cause fracturing of the
walls of the well.
2. The method according to Claim 1, wherein the well bore has vertical and horizontal
portions and a pipe in the well extends into the vertical and horizontal portions
of the well bore;
Wherein, pressurized steam is injected into the horizontal region of the well bore
though peripheral openings in the pipe in the horizontal region of the well bore;
and
Fracking sand is inserted as needed.
3. The method according to Claim 1 wherein the carbonated water is refrigerated prior
to injecting it into the well.
4. The method according to Claim 1, wherein at least one of natural gas and oil, the
carbonated water, and any released CO2 are removed from the well, the carbonated water and CO2 being separated from at least one of natural gas and oil, and processed for further
use.
5. The method according to Claim 1, wherein a seal is placed in the well bore to limit
the pressurized region of the well bore to increase the pressure therein, thereby
increasing the fracturing pressure; and
at least one pressure sensor and pressure release valve is placed in the well to prevent
the pressure produced by the carbonated water and pressured steam from exceeding a
predetermined value.
6. A method of providing fracturing in a well bore, to produce at least one of natural
gas and oil;
injecting at least one of refrigerated carbonized water and frozen CO2 into the well bore;
injecting pressurized steam into a region of the well bore though peripheral openings
in a pipe extending downward into the well bore and into the horizontal region of
the well bore.
7. The method according to Claim 6, wherein the peripheral openings in the pipe are spaced
apart to maximize the insertion of the pressurized steam in equal portions along the
length of the horizontal portion of the pipe.
8. The method according to Claim 6 wherein the CO2 is cooled below its freezing temperature to produce a snow like material which is
injected into the well bore through a tube and is released into the well bore through
perforations in the tube; and
injecting pressurized steam after a sufficient amount of cooled CO2 is released into the well to create a catalytic reaction that heats and expands the
cooled CO2 causing the fracturing of shale and other geological formations in the well.
9. The method according to Claim 8 including the triggering of a sensor valve when a
sufficient amount of cooled CO2 has been released into the well bore to close off the insertion of cooled CO2 and opening a second valve to allow pressurized steam to be injected into the well
to rapidly expand the cooled CO2.
10. A system for producing fracturing in a well bore utilizing only carbonated water,
sand as needed, and pressurized steam, comprising:
a well bore having a vertical and horizontal region;
a pipe extending downward in the vertical region and horizontally in the horizontal
region;
a storage unit for holding carbonated water for injection into the well;
a steam generator for injecting pressurized steam into the carbonated water for producing
fracturing in the well; and
means for removing at least one of gas and oil released during the fracturing process.
11. The system according to Claim 10, including a unit for refrigerating the carbonated
water prior to being injecting into the well bore.
12. The system according to Claim 10, wherein the pipe extending into the well bore has
perforated openings spaced apart along the horizontal portion of the pipe to evenly
distribute the pressurized steam equally along the length of the horizontal portion
of the pipe.
13. The system according to Claim 10, including an isolation plug to prevent the pressurized
steam, contaminates and carbonated water from moving up the vertical portion of the
well, increasing the pressure in any portion of the well bore to produce greater fracturing
in the well.
14. The system according to Claim 10, including a seal at the top of the well to prevent
any gases and other materials from leaving the well and entering the atmosphere, and
a system for freezing CO2 for injecting into the well bore.
15. The method according to claim 1, where in CO2 is injected into the well bore instead of carbonated water, and the CO2 is expanded by the pressurized steam to cause fracturing.