Downhole Heater Cables for Oil Shale Recovery

Downhole heaters capable of long-term high-temperature operation are needed to assist in oil shale recovery. However, currently available, mineral insulated (MI) cables are not capable of surviving the temperature or other downhole environmental conditions encountered in this application. This project will develop high-performance downhole heater cables, based on high-performance composite insulation, to assist in oil shale recovery. In Phase I, prototype heater cables with composite insulation were produced using a readily-scalable manufacturing process and their performance was characterized. High-temperature high-voltage performance was demonstrated for long-term application in the downhole environment. Phase II will continue the development of materials and manufacturing processes for the heater cables. The initial focus will be on the further optimization of the composite insulation system. Then, the heater cable fabrication process will be scaled-up to levels suitable for the commercialization of the composite insulated heater cables. Commercial Applications and other Benefits as described by the awardee: It is estimated that the United States possesses approximately two-thirds of the world¿s oil shale deposits. The new heater cables should allow this valuable resource to be exploited. These heater cables would be: (1) capable of extended operation at elevated temperatures, (2) able to withstand the downhole environmental conditions, and (3) produced using a process that is scalable to meet end-user production requirements