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WO2014099407A1 - Chauffage pour ébullition indirecte - Google Patents

Chauffage pour ébullition indirecte Download PDF

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Publication number
WO2014099407A1
WO2014099407A1 PCT/US2013/073485 US2013073485W WO2014099407A1 WO 2014099407 A1 WO2014099407 A1 WO 2014099407A1 US 2013073485 W US2013073485 W US 2013073485W WO 2014099407 A1 WO2014099407 A1 WO 2014099407A1
Authority
WO
WIPO (PCT)
Prior art keywords
solid particulate
vessel
water
steam
heating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2013/073485
Other languages
English (en)
Inventor
David W. Larkin
Scott D. Love
Scott Macadam
Peter N. Slater
Edward G. Latimer
Richard B. Miller
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ConocoPhillips Co
Original Assignee
ConocoPhillips Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US14/097,496 external-priority patent/US20140165930A1/en
Application filed by ConocoPhillips Co filed Critical ConocoPhillips Co
Priority to CA2894864A priority Critical patent/CA2894864A1/fr
Publication of WO2014099407A1 publication Critical patent/WO2014099407A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22—STEAM GENERATION
    • F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B1/00—Methods of steam generation characterised by form of heating method
    • F22B1/02—Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers
    • F22B1/04—Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being hot slag, hot residues, or heated blocks, e.g. iron blocks
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22—STEAM GENERATION
    • F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B27/00—Instantaneous or flash steam boilers
    • F22B27/16—Instantaneous or flash steam boilers involving spray nozzles for sprinkling or injecting water particles on to or into hot heat-exchange elements, e.g. into tubes

Definitions

  • Embodiments of the invention relate to methods and systems for generating steam which may be utilized in applications such as bitumen production.
  • Costs associated with building a complex, large, sophisticated facility to process water and generate steam contributes to economic challenges of oil sands production operations. Such a facility represents much of the capital costs of these operations. Chemical and energy usage of the facility also contribute to operating costs.
  • a method of vaporizing water includes introducing a gaseous fluid into a first vessel and in contact with solid particulate within the first vessel to transfer heat from the gaseous fluid to the solid particulate.
  • the gaseous fluid Upon recovering and then reheating the gaseous fluid from the first vessel, the gaseous fluid circulates back into the first vessel for continued heating of the solid particulate that is circulating between the first vessel and a second vessel.
  • the water introduced into the second vessel contacts the solid particulate heated to a temperature that results in vaporizing the water into steam, which is then separated from the solid particulate.
  • a system for vaporizing water includes a first vessel having an inlet and an outlet for a gaseous fluid and containing solid particulate in contact with the gaseous fluid that passes from the inlet to the outlet for transference of heat from the gaseous fluid to the solid particulate.
  • a heater coupled to the inlet and the outlet of the first vessel reheats the gaseous fluid that is recovered from the outlet of the first vessel and circulated back to the inlet of the first vessel for sustained heating of the solid particulate.
  • a second vessel couples to the first vessel by conduits through which the solid particulate is circulated between the first vessel and the second vessel.
  • An injection line coupled to the second vessel supplies the water into the second vessel and in contact with the solid particulate heated to a temperature that results in vaporization of the water into steam.
  • a steam output line coupled to the second vessel conveys the steam that is separated from the solid particulate.
  • Figure 1 is a schematic of a steam generating system that includes dual vessels arranged to alternate between heating and steam generation cycles, according to one embodiment of the invention.
  • Figure 2 is a schematic of a steam generating system with an exemplary heating vessel through which solid particulate circulates to regain thermal energy used to vaporize water, according to one embodiment of the invention.
  • Figure 3 is a schematic of a steam generating system with a heating vessel in which heat is transferred to solid particulate via recycled gaseous fluid, according to one embodiment of the invention.
  • Figure 4 is a schematic of a steam generating system with a heating vessel in which heat is transferred to solid particulate via recycled gaseous fluid that is condensed before reheating, according to one embodiment of the invention.
  • Figure 5 is a schematic of a steam generating system with a heating vessel having an internal heat exchanger to transfer heat to solid particulate from hot fluids without direct contact, according to one embodiment of the invention.
  • FIG. 6 is a schematic of a steam generating system with a single vessel for vaporizing water upon contact with fluidized solid particulate disposed in the vessel and in thermal contact with a heat exchanger, according to one embodiment of the invention.
  • Figure 7 is a schematic of the steam generating system shown in Figure 3 and in a side -by-side vessel configuration, according to one embodiment of the invention.
  • Embodiments of the invention relate to systems and methods for vaporizing water into steam, which may be utilized in applications such as bitumen production.
  • the methods rely on indirect boiling of the water by contact with a substance such as solid particulate heated to a temperature sufficient to vaporize the water. Heating of the solid particulate may utilize pressure isolated heat exchanger units or a hot gas recirculation circuit at a pressure corresponding to that desired for the steam.
  • the water may form part of a mixture that contacts the solid particulate and includes a solvent for the bitumen in order to limit vaporization energy requirements and facilitate the production.
  • the water may come from separated production fluid associated with a steam assisted gravity drainage (SAGD) bitumen recovery operation.
  • SAGD steam assisted gravity drainage
  • the water at time of being generated into the steam may still contain: at least about 1000 parts per million (ppm), at least 10,000 ppm or at least 45,000 ppm total dissolved solids; at least 100 ppm, at least 500 ppm, at least 1000 ppm or at least 15,000 ppm organic compounds or organics; and at least 1000 ppm free oil.
  • ppm parts per million
  • Figure 1 illustrates a steam generating system that includes a first vessel 101 and a second vessel 102 that each contains solid particulate.
  • the solid particulate include sand, metal spheres, cracking catalyst and mixtures thereof.
  • fluidization of the solid particulate keeps the solid particulate moving within the vessels 101, 102 during operation to generate steam. Such fluidization may involve circulation of the solid particulate and may rely on addition of supplemental steam.
  • Each of the vessels 101, 102 couples to a water injection line 104 and a heat source line 106.
  • a manifold system controls flow through the vessels 101, 102 to a steam output 108 and an exhaust 110 and includes first through eighth valves 111-118.
  • the valves 111-118 alternate between heating and steam generation cycles with the first vessel 101 being shown in the steam generation cycle while the second vessel 102 is in the heating cycle.
  • the first and fifth valves 111, 115 on the water injection line 104 and the steam output 108 thus remain open to flow of the water through the first vessel 101 to generate the steam while the third and seventh valves 113, 117 block flow of the water through the second vessel 102.
  • the steam exits the first vessel 101 through the steam output 108, which may couple to the injection well, and is separated from the solid particulate that remains in the first vessel 101 and may be trapped by filters or cyclones.
  • the second and sixth valves 112, 116 block flow from the heat source line 106 to the first vessel 101 at this time while the fourth and eighth valve 114, 118 are open to flow of oxygen and fuel, such as methane, from the heat source line 106 through the second vessel 102 to the exhaust 110.
  • oxygen and fuel such as methane
  • the oxygen and fuel passing through the second vessel 102 combusts to reheat the solid particulate.
  • contaminants such as organic compounds deposited on the solid particulate from the water, may partially or fully convert into carbon dioxide and water, and some salts deposited on the solid particulate from the water may come off and be swept out of the second vessel 102.
  • the combustion heats the solid particulate to a temperature that results in vaporizing the water upon contact therewith in the steam generation cycle that follows.
  • the heat source line 106 can supply the oxygen and fuel without compression to pressures desired for the steam to be injected into the formation. This relative lower pressure combustion facilitates economic production of the steam. Alternating each of the vessels 101, 102 between the steam generation cycle and the heating cycle also eliminates need for conveying the solid particulate to units dedicated to one particular cycle.
  • the water mixes with a solvent 120 for the bitumen prior to vaporization due to contact with the solid particulate.
  • the solvent 120 (common reference number depicted in all figures) thus may flow as a liquid into the water supply line 104 to form a resulting mixture of the water with the solvent 120. Vaporization of the water along with the solvent 120 results in the steam output 108 also containing both water and solvent vapors, as may be desired for injection into the formation.
  • the solvent 120 may include hydrocarbons having between 3 and 30 carbon atoms, such as butane, pentane, naphtha and diesel. Temperatures associated with the indirect boiling described herein limit potential problems of cracking the hydrocarbons, which can tend to occur if passed through direct fired boilers that may thus require injection of any wanted solvents into steam rather than boiler feed. Such injection of the solvent into the steam instead of the water feed may either cause loss of some steam due to condensation or require superheating of the steam. Conventional superheating of the steam also suffers from fouling problems. Therefore, the solvent 120 may flow into steam superheated by steam generation methods described herein in some embodiments since the fouling issues from the superheating are overcome in the same manner as those associated with steam generation.
  • the mixture in the water supply line 104 may include between 5 and 30 percent of the liquid hydrocarbon by volume.
  • the mixture may further provide an energy requirement for vaporization that is at least 10 percent lower than water alone. For example, a 28:72 ratio of butane to water reduces steam generator duty by 22 percent as compared to water alone.
  • FIG. 2 shows a steam generating system with a steam generating riser 200 and/or vessel 201 and a heating vessel 202 through which solid particulate are circulated.
  • a heat source line 206 supplies reactants for combustion within the heating vessel 202 in order regain thermal energy used to vaporize water. Flue gases from the combustion exit the heating vessel 202 through exhaust 210 following any filtering to retain the solid particulate.
  • Multiple alternating heating vessels with flow control similar to Figure 1 or lockhoppers may enable operation of the heating vessel 202 at a lower pressure than the steam generating riser 200 and/or vessel 201.
  • the solid particulate heated in the heating vessel 202 transfers to the steam generating vessel 201 by gravity since the heating vessel 202 is disposed above the steam generating vessel 201.
  • a water supply line 204 then inputs the water into contact with the solid particulate that is heated to result in vaporizing the water and providing a steam output 208.
  • Some of the steam output 208 may provide lift for the solid particulate being returned up the riser 200 to the heating vessel 202.
  • the water vaporizes in the riser 200 such that the steam generating vessel 201 is not even required and the steam is recovered at a riser output 209.
  • Figure 3 illustrates a steam generating system with a heating vessel 302 in which heat is transferred to solid particulate via recycled gaseous fluid circulating in a circuit. Similar to systems in other figures, the solid particulate once heated transfers to a steam generating vessel 301 where water 304 is input to contact the solid particulate and generate steam 308. Embodiments may therefore implement various features and attributes explained in detail with respect to another particular figure or elsewhere herein without being repeated in order to be as succinct as possible. [0031] The gaseous fluid that exits the heating vessel 302 through an outlet 310 passes through heat exchanger(s) 350 and a fin-fan cooler 352, if necessary.
  • the heat exchanger 350 may transfer heat with the gaseous fluid post compression boosting and/or with the water 304 being input into the steam generating vessel 301. Such heat exchange helps maintain efficiency while bringing the temperature of the gaseous fluid below temperature limits of a compressor 358 through which the gaseous fluid is sent downstream in the circuit.
  • a purge 354 allows removal of a portion of the gaseous fluid, which may pick up contaminants, such as from cracking or entrainment.
  • Makeup gas 356 combines with the gaseous f uid to replace that purged.
  • the gaseous fluid includes an inert gas such as nitrogen and may also include air or oxygen for burning of the deposits. Methane may provide the gaseous fluid for some embodiments and may be desired due to its relative higher thermal capacity.
  • the compressor 358 only boosts pressure of the gaseous fluid circulating through the circuit.
  • the compressor may provide between 50 and 150 kilopascals (kPa) boost in pressure, which is achievable without making steam generation uneconomical by requiring levels of compression needed to increase atmospheric pressure to above 2500 kPa.
  • the gaseous fluid in the circuit may thus always remain above 2500 kPa, in some embodiments.
  • the gaseous fluid from the compressor 358 then flows through the circuit to a furnace 360.
  • the furnace 360 burns fuel to reheat the gaseous fluid that reenters the heating vessel 302 through a heat source line 306 for sustained heating of the solid particulate within the heating vessel 302.
  • the heating vessel 302 may include multiple (e.g., 6 as shown) bed stages 362 or trays such that the solid particulate passing through the heating vessel 302 counter current with the gaseous fluid achieves efficient heat cross exchange.
  • Pressure of the steam desired for injection into the formation dictates pressure inside the steam generating vessel 301.
  • both the steam generating vessel 301 and the heating vessel 302 may operate at this pressure, such as above 2500 kPa, provided there may be sufficient differences in pressure in the vessels 301, 302 or other such arrangements described herein to maintain fluid flows.
  • a slipstream 364 of the gaseous fluid also at necessary pressure provides lift for transporting the solid particulate from the steam generating vessel 301 to the heating vessel 302.
  • FIG 4 shows a steam generating system with a heating vessel 402 in which heat is transferred to solid particulate via recycled gaseous fluid that is circulating in a circuit and condensed before reheating. While shown as being recycled, the gaseous fluid in some embodiments passes once through the vessel 402 and may then be utilized in another application. Like the system in Figure 3, the solid particulate once heated transfers to a steam generating vessel 401 where water 404 is input to contact the solid particulate and generate steam 408. The gaseous fluid that exits the heating vessel 402 through an outlet 410 passes through heat exchanger(s) 450 that transfer heat from flow along the circuit post pumping and/or with the water 404 being input into the steam generating vessel 401.
  • heat exchanger(s) 450 that transfer heat from flow along the circuit post pumping and/or with the water 404 being input into the steam generating vessel 401.
  • the heat exchange 450 condenses the gaseous fluid, such as propane, butane or naphtha, to a liquid phase for pressurization by a pump 458.
  • a separator 454 may enable venting off gasses that are not condensed, such as may result from cracking of the gaseous fluid.
  • Outflow from the pump 458 and any makeup 456 then flows through the circuit to a furnace 460.
  • the furnace 460 burns fuel to vaporize and reheat the gaseous fluid that reenters the heating vessel 402 through a heat source line 406 for sustained heating of the solid particulate within the heating vessel 402.
  • the pump 458 may influence efficiency if used in place of compression.
  • Use of the pump 458 with the gaseous fluid that is condensed may further enable economic once through heating (i.e., without the circuit) at the desired pressure similar to approaches depicted in Figures 1 or 2 (i.e. replace oxygen and methane for combustion with a higher hydrocarbon pumped and then heated as in Figure 4) except that resulting exhaust may have further application for its energy content.
  • FIG. 5 illustrates a steam generating system with a heating vessel 502 having an internal heat exchanger 562 to transfer heat to solid particulate from hot fluids without direct contact. Similar again to systems in other figures, the solid particulate once heated transfers to a steam generating vessel 501 where water 504 is input to contact the solid particulate and generate steam 508. Both the steam generating vessel 501 and the heating vessel 502 may operate in open pressure communication with one another at an internal pressure desired for injection of the steam into a formation while pressure isolated flow through the heat exchanger 562 may be at a lower pressure.
  • oxygen and fuel react in a combustor 560 to generate a flue gas conveyed to the heat exchanger 562 by a heat source line 506.
  • the flue gas passes through the heat exchanger 562 and exits via an exhaust 510.
  • a thermally conductive material forms the heat exchanger 562 such that heat from the flue gas transfers to the solid particulate in the heating vessel 502.
  • the thermally conductive material forms a tube of the heat exchanger.
  • the tube may coil within the heating vessel 510 to provide the heat exchanger 562 with either the solid particulate flowing through an inside of the tube or the flue gas flowing through the inside of the tube.
  • a fluidization gas such as air, passes through the inside of the heating vessel 502. This gas may help remove contaminants from the solid particulate as well. Use of the gas for only fluidization while relying on heating by the heat exchanger 562 limits quantity and compression requirements for the gas whether the gas is used once through or circulated in a circuit.
  • FIG. 6 shows a steam generating system with a single vessel 600 for vaporizing water upon contact with fluidized solid particulate disposed in the single vessel 600 and in thermal contact with a heat exchanger 662.
  • the solid particulate heated by the heat exchanger 662 contacts water 604 that is input into the single vessel to generate steam 608.
  • a circulating liquid such as sodium or sodium and potassium, passes through the heat exchanger 662, exits the heat exchanger via an outlet 610 and is pumped by an pump 658 to a furnace 660 that reheats the circulating liquid prior flowing back to the heat exchanger 662 via inlet 606.
  • the heat exchanger 662 transfers heat from the circulating liquid to the solid particulate and may have a design such as described with respect to the heat exchanger 562 shown in Figure 5. Vaporization of the water 604 still occurs upon contacting the solid particulate that is heated. While the solid particulate thus should receive deposits from the water 604, movement of the solid particulate along the heat exchanger 662 provides abrasion to ensure that the heat exchanger 662 does not become fouled.
  • the heat exchangers 562, 662 in Figures 5 and 6 may each operate with either the flue gas or the circulating liquid as described herein providing hot fluid thereto.
  • systems may incorporate both the heat exchanger 662 where the steam is being generated along with additional heating of the solid particulate such as provided in the heating vessel 302 shown in Figure 3. Sharing this thermal load may enable efficient operation.
  • FIG. 7 shows the system illustrated in Figure 3 with the steam generating vessel 301 disposed at a common elevation with the heating vessel 302 as opposed to a stacked vertical arrangement.
  • This side -by-side configuration limits or eliminates need to use lift gas for transfer of the solid particulate.
  • the solid particulate transfers between the steam generating vessel 301 and the heating vessel 302 via dense phase gravity drain as a result of such at least partial overlapping height.
  • an upper outlet of the steam generating vessel 301 couples to a relative lower inlet of the heating vessel 302 for flow from the steam generating vessel 301 to the heating vessel 302.
  • a bottom outlet of the heating vessel 302 couples to a relative lower inlet of the steam generating vessel 301 for flow from the heating vessel 302 to the steam generating vessel 301.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)

Abstract

L'invention concerne des systèmes et méthodes de vaporisation d'eau en vapeur, lesquels peuvent être utilisés dans des applications telles que la production de bitume. Les procédés reposent sur l'ébullition indirecte de l'eau par un contact avec une substance telle qu'une matière particulaire solide chauffée à une température suffisante pour vaporiser l'eau. Le chauffage de la matière particulaire solide peut faire appel à des unités d'échangeur thermique isolées en pression ou à un circuit de recirculation de gaz chaud à une pression correspondant à celle souhaitée pour la vapeur. En outre, l'eau peut faire partie d'un mélange qui vient en contact avec la matière particulaire solide et comprend un solvant pour le bitume afin de limiter les exigences en énergie de vaporisation et faciliter la production.
PCT/US2013/073485 2012-12-17 2013-12-06 Chauffage pour ébullition indirecte Ceased WO2014099407A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA2894864A CA2894864A1 (fr) 2012-12-17 2013-12-06 Chauffage pour ebullition indirecte

Applications Claiming Priority (8)

Application Number Priority Date Filing Date Title
US201261737948P 2012-12-17 2012-12-17
US201261737973P 2012-12-17 2012-12-17
US201261737967P 2012-12-17 2012-12-17
US61/737,967 2012-12-17
US61/737,973 2012-12-17
US61/737,948 2012-12-17
US14/097,496 US20140165930A1 (en) 2012-12-17 2013-12-05 Heating for indirect boiling
US14/097,496 2013-12-05

Publications (1)

Publication Number Publication Date
WO2014099407A1 true WO2014099407A1 (fr) 2014-06-26

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CA (1) CA2894864A1 (fr)
WO (1) WO2014099407A1 (fr)

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5442919A (en) * 1993-12-27 1995-08-22 Combustion Engineering, Inc. Reheater protection in a circulating fluidized bed steam generator
US20060107587A1 (en) * 2004-10-12 2006-05-25 Bullinger Charles W Apparatus for heat treatment of particulate materials
US20100037835A1 (en) * 2008-02-26 2010-02-18 Ex-Tar Technologies Direct contact rotating steam generator using low quality water with zero liquid discharge
CA2676717A1 (fr) * 2008-08-28 2010-02-28 Maoz Betzer-Zilevitch Processus et systeme de production de vapeur par contact direct avec le lit fluidise
US20100212894A1 (en) * 2009-02-20 2010-08-26 Conocophillips Company Steam generation for steam assisted oil recovery
US20110120673A1 (en) * 2009-09-17 2011-05-26 Xiaodong Xiang Systems and methods of thermal transfer and/or storage
US20110259586A1 (en) * 2010-04-23 2011-10-27 Conocophillips Company Water treatment using a direct steam generator
WO2011114127A9 (fr) * 2010-03-18 2011-12-15 William Curle Developments Limited Échangeur de chaleur pour produits solides
US20120111109A1 (en) * 2010-11-05 2012-05-10 ThermoChem Recovery International Solids Circulation System and Method for Capture and Conversion of Reactive Solids
US20120241375A1 (en) * 2010-07-01 2012-09-27 Alexander Fassbender Wastewater treatment
CA2776389A1 (fr) * 2011-05-06 2012-11-06 Maoz Betzer Systeme de generation de vapeur a contact indirect

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5442919A (en) * 1993-12-27 1995-08-22 Combustion Engineering, Inc. Reheater protection in a circulating fluidized bed steam generator
US20060107587A1 (en) * 2004-10-12 2006-05-25 Bullinger Charles W Apparatus for heat treatment of particulate materials
US20100037835A1 (en) * 2008-02-26 2010-02-18 Ex-Tar Technologies Direct contact rotating steam generator using low quality water with zero liquid discharge
CA2676717A1 (fr) * 2008-08-28 2010-02-28 Maoz Betzer-Zilevitch Processus et systeme de production de vapeur par contact direct avec le lit fluidise
US20100050517A1 (en) * 2008-08-28 2010-03-04 Maoz Betzer Tsilevich Fluid bed direct contact steam generator system and process
US20100212894A1 (en) * 2009-02-20 2010-08-26 Conocophillips Company Steam generation for steam assisted oil recovery
US20110120673A1 (en) * 2009-09-17 2011-05-26 Xiaodong Xiang Systems and methods of thermal transfer and/or storage
WO2011114127A9 (fr) * 2010-03-18 2011-12-15 William Curle Developments Limited Échangeur de chaleur pour produits solides
US20110259586A1 (en) * 2010-04-23 2011-10-27 Conocophillips Company Water treatment using a direct steam generator
US20120241375A1 (en) * 2010-07-01 2012-09-27 Alexander Fassbender Wastewater treatment
US20120111109A1 (en) * 2010-11-05 2012-05-10 ThermoChem Recovery International Solids Circulation System and Method for Capture and Conversion of Reactive Solids
CA2776389A1 (fr) * 2011-05-06 2012-11-06 Maoz Betzer Systeme de generation de vapeur a contact indirect

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