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WO2014107159A1 - Système d'élimination de co2 par générateur direct de vapeur - Google Patents

Système d'élimination de co2 par générateur direct de vapeur Download PDF

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Publication number
WO2014107159A1
WO2014107159A1 PCT/US2013/020349 US2013020349W WO2014107159A1 WO 2014107159 A1 WO2014107159 A1 WO 2014107159A1 US 2013020349 W US2013020349 W US 2013020349W WO 2014107159 A1 WO2014107159 A1 WO 2014107159A1
Authority
WO
WIPO (PCT)
Prior art keywords
steam
recited
combustion chamber
potable water
downstream
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/US2013/020349
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English (en)
Inventor
Kenneth M. Sprouse
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.)
Aerojet Rocketdyne of DE Inc
Original Assignee
Pratt and Whitney Rocketdyne Inc
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
Application filed by Pratt and Whitney Rocketdyne Inc filed Critical Pratt and Whitney Rocketdyne Inc
Priority to PCT/US2013/020349 priority Critical patent/WO2014107159A1/fr
Publication of WO2014107159A1 publication Critical patent/WO2014107159A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K25/00—Plants or engines characterised by use of special working fluids, not otherwise provided for; Plants operating in closed cycles and not otherwise provided for
    • F01K25/005—Plants or engines characterised by use of special working fluids, not otherwise provided for; Plants operating in closed cycles and not otherwise provided for the working fluid being steam, created by combustion of hydrogen with oxygen

Definitions

  • the present disclosure relates to a Steam Assisted Gravity Drain System, and more particularly to a direct steam generator (DSG) that minimizes Carbon Dioxide production.
  • DSG direct steam generator
  • bitumen can be economically recovered in many areas by recently developed in-situ recovery methods such as SAGD (Steam Assisted Gravity Drain) or other variants of gravity drain technology which can mobilize the bitumen or heavy oil.
  • SAGD Steam Assisted Gravity Drain
  • SAGD horizontal drilling technology is used to drill two closely spaced horizontal wells near the bottom of the ore deposits.
  • the upper horizontal well i.e., the injection well
  • the heated bitumen then flows downward by gravity and is collected in the lower horizontal well (i.e., the production well) and delivered to the surface under pressure.
  • the bitumen is then processed and sent to an upgrader facility.
  • SAGD requires enormous amounts of energy to generate steam to heat the underground deposits to the point where the bitumen can flow and be pumped. Typically, 20% to 30%) of the energy recovered from a barrel of bitumen must be used to produce the steam required to recover the next barrel of bitumen in the SAGD process.
  • SAGD also requires enormous amounts of water, usage of which is often subjected to extreme regulatory requirements which constrain recovery.
  • FIG 1 is a schematic view of one disclosed non-limiting embodiment of a direct steam generator (DSG) for Steam Assisted Gravity Drain (SAGD) that minimizes Carbon Dioxide production.
  • DSG direct steam generator
  • SAGD Steam Assisted Gravity Drain
  • FIG. 1 schematically illustrates a direct steam generator (DSG) system 20 for a Steam Assisted Gravity Drain (SAGD) 22.
  • the DSG system 20 generally includes a combustor 24, a candle filter 26, a waste ash recovery subsystem 28, a calciner 30, a slaker 32 and a slurry pump 34.
  • the combustor 24 in one disclosed non-limiting embodiment is a nominal 2,000 psia oxy-fired natural gas combustor that is cooled and quenched with subterranean "produced water" from the tar/oil sands field.
  • This non-potable brine water is a basic solution containing both dissolved and suspended solids. Hence, it is highly corrosive and will produce detrimental solid deposits (or scale) on heat exchanger surfaces during boiling which may lead to fouling and burnout.
  • the combustor 24 generally includes a combustion chamber 36, a convergent nozzle zone 38, a divergent nozzle zone 40 downstream of the convergent nozzle zone 38 and a quench zone 42 downstream of the divergent nozzle zone 40. That is, the convergent nozzle zone 38 and the divergent nozzle zone 40 form a convergent-divergent nozzle upstream of the quench zone 42.
  • the combustion chamber 36 receives propellants which, in the disclosed non- limiting embodiment, includes a carbonaceous fuel such as methane CH 4 (g) or other hydrocarbon natural gas, an oxidizer such as oxygen, 0 2 (g) and the non-potable produced water.
  • a carbonaceous fuel such as methane CH 4 (g) or other hydrocarbon natural gas
  • an oxidizer such as oxygen, 0 2 (g) and the non-potable produced water.
  • the oxygen 0 2 (g) may be high-purity oxygen from, for example, a cryogenic air separation unit (ASU), ion transport membrane (ITM) or other subsystem.
  • ASU cryogenic air separation unit
  • ITM ion transport membrane
  • the non-potable "produced water” is injected directly into the combustion chamber 36 as well as into the quench zone 42.
  • the combustor 24 generates steam at 700 - 900 F (371-482 C) without the use of a downstream boiler.
  • the steam effluent H 2 0(g) (to be subsequently injected down hole) will contain carbon dioxide gas, C0 2 (g), together with micron and submicron size solid particles. The solid particles are readily removed with the candle filter 26 and or other filters.
  • g is the gravitational acceleration constant (32.2 ft/s 2 );
  • D s is the steam bubble diameter
  • pf is density of the near stagnant chamber fluid (nominally a multi-phase mixture/emulsion of water, crude oil, and non-condensible gases such as carbon dioxide and methane);
  • p s is the density of the hot injected steam (which may include carbon dioxide gas).
  • the steam bubble diameter will most likely be set by the throat diameter of the smallest pores within the porous rock or sandstone.
  • the vertical riser velocity of the steam bubble is directly proportional to the relative density difference between the surrounding chamber fluid and the well's injected steam— i.e., ( 1 - p s /pf ).
  • the reservoir fluid pressures are typically less than 2,000 psia (136 ATM) with injected steam temperatures near 700 F (371 C). This means that the injected steam density, p s , is less than 3.2 1bm/ft 3 .
  • the reservoir fluid density, pf will be in the 40 to 50 lbm/ft 3 (640-800 kg/m 3 ) range.
  • the injected steam contains carbon dioxide
  • a third fluid that contains mostly carbon dioxide gas will accumulate within the reservoir above the stagnant water/oil zone.
  • this carbon dioxide fluid will contain about 12 vol% steam at saturated conditions and have a fluid density, pf , of approximately 8.8 lbm/ft 3 (140 kg/m 3 ).
  • the kinematic viscosities, Of for both the water/oil and carbon dioxide/steam fluid mixtures at 400 F (204 C) and 2,000 psia (136 ATM) are about 1.8 x 10 "6 ft 2 /s.
  • Equation 1 shows that the vertically upward hot steam bubble velocity, v s , is on the order of 0.42 ft/s (0.128 m/s 2 ) as the steam travels through the surrounding stagnant water/oil fluid.
  • this hot steam bubble breaks into the lighter carbon dioxide/steam zone sitting on top of the heavier water/oil region, its velocity will slow to 0.28 ft/s (0.085 m/s 2 ) according to Equation 1.
  • the carbon dioxide gas C0 2 (g) being delivered to the reservoir through the SAGD's upper injection well separates from the 400 F (204 C) product water/oil mixture traveling downward towards the SAGD's lower production well and remains in the upper regions of the steam chamber.
  • the C0 2 (g) accumulates to increase the overall reservoir fluid pressure while completely filling the SAGD steam chamber voids with low density C0 2 rather than higher density water/oil mixtures ⁇ thus reducing the direct heating of the upper SAGD steam chamber via steam condensation.
  • C0 2 may also produce phase interfaces within the reservoir whose interfacial surface tensions effectively increase the flow resistance of the condense water/oil product flow. This increased flow resistance from C0 2 interfacial surface tension is particularly significant in smaller pore areas of the reservoir which may prevent the draining of the water/oil product entirely.
  • the DSG system 20 provides a dusty gas product containing high pressure (to 2,000 psia; 136 ATM) steam, H 2 0(g), and fly ash at approximately 700 F (371 C) together with a chemical recycle process for operating the combustor 24 with slaked lime [i.e., calcium hydroxide, Ca(OH) 2 ] slurries.
  • slaked lime i.e., calcium hydroxide, Ca(OH) 2
  • Both the combustion and recycle process operate on the earth's surface (not down hole) and utilize produced water from the oil field that typically contains both suspended and dissolved solids. The produced water may be initially filtered to remove most of the larger suspended particles.
  • the combustor 24 burns methane, CH 4 (g), and oxygen, 0 2 (g), at a stoichiometric mixture and at pressures to 2,000 psia (136 ATM) to produce a high temperature (> 5,000 F; 2760 C) gas containing steam, H 2 0(g); carbon dioxide, C0 2 (g); hydrogen, H 2 (g); carbon monoxide, CO(g); and other gaseous species— such as atomic hydrogen, H(g); atomic oxygen, 0(g); and the hydroxyl radical, OH(g), to name a few.
  • the convergent nozzle zone 38 accelerates the high temperature combustion gas to near supersonic velocities approaching 1,000 ft/s (304 m/s).
  • the balance of the calcium hydroxide water slurry is injected perpendicularly into the near Mach 1.0 high velocity gas flow through, for example, a plurality of injection orifices.
  • the size of the orifices are as small as reasonably achievable to prevent solids plugging— usually about 0.100-in. (2.54 mm) diameter.
  • the near sonic gas velocities and small orifice sizes are required for atomization of the slurry jet into droplets having diameters below 0.008-in. (200-microns) for maximum droplet surface area production and rapid vaporization.
  • the divergent nozzle zone 40 decelerates the gas stream to velocities below 150 ft/s (46 m/s) while the droplet vaporization process cools the gas to its design 700 F requirement.
  • all disassociated gases combine to form steam, H 2 0(g), and carbon dioxide, C0 2 (g).
  • the carbon dioxide gas, C0 2 within the combustor 24 reacts with the aqueous and solid calcium hydroxide, Ca(OH) 2 , to form solid limestone, CaC0 3 (s) according to the following reaction:
  • Solid particulate material from the candle filter 26 may be subsequently conveyed by gravity to a solids splitter whereby an amount of solids equal in weight to the mass of suspended and dissolved solids within the produced water fed to the slaker 32 - and make-up limestone fed to the calciner 30 - is removed from the bulk solids recycle steam.
  • the slaker 32 such as that manufacture by Merrick Industries Inc., converts calcium oxide (CaO), which is also known as quicklime or pebblelime, into a calcium hydroxide (Ca(OH)2) slurry.
  • the calciner 30, such as that manufactured by Heyl & Patterson Inc., may be a furnace or reactor of various designs including shaft furnaces, rotary kilns, multiple hearth furnaces, and fluidized bed reactors among others.
  • the removed solids may be subsequently lock hoppered to atmospheric pressure and disposed of.
  • the bulk of the recycle solids is dense phase fed into the calciner 30 along with the make-up limestone and endothermically decomposed into calcium oxide and carbon dioxide gas at atmospheric pressure and 1,650 F (899 C) temperature via the following reaction:
  • the product lime, CaO(s) from the calciner 30 is sent to the slaker 32 whereby the dry lime may be pulverized to particle sizes below, for example, 0.003 in (70-microns) before mixing with the oil field's produced water - that was previously filtered for removal of all suspended solids greater than 0.0004 (10-microns) in size.
  • the lime and water react exothermically to produce a dilute calcium hydroxide aqueous slurry, Ca(OH) 2 , according to the following reaction:
  • the dilute water calcium hydroxide slurry is finally sent to a commercial slurry pump 34, such as, for example, a GEHO Piston Diaphragm pump or a Moyno Progressive Cavity pump - whereby the slurry is pumped to high pressure conditions exceeding 2,500 psia (170 ATM) for subsequent injection into the combustor 24.
  • a commercial slurry pump 34 such as, for example, a GEHO Piston Diaphragm pump or a Moyno Progressive Cavity pump - whereby the slurry is pumped to high pressure conditions exceeding 2,500 psia (170 ATM) for subsequent injection into the combustor 24.
  • the DSG system 20 thereby supplies high-temperature (700 F; 371 C), high-pressure (to 2,000 psia; 136 ATM) carbon dioxide free steam to a SAGD injection well using non-potable oil field produced water.
  • the product steam is free from potentially detrimental carbon dioxide gas and limestone dust for subsequent use in SAGD operations.
  • dirty (but filtered) oil field produced non-potable water is utilized rather than potable or boiler feed quality water.
  • the DSG system 20 beneficially provide a low cost C0 2 free steam source for injection wells where non-condensable gases such as carbon dioxide may present a problem in reservoirs having fluid pressure below 2,000 psia (136 ATM).

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)

Abstract

La présente invention concerne un système de drainage par gravité assisté à la vapeur, et plus particulièrement un générateur direct de vapeur (DSG) qui minimise la production de dioxyde de carbone. Le système comprend une chambre de combustion qui fonctionne avec un carburant carboné, un oxydant et une eau non potable et une tuyère convergente-divergente en aval de ladite chambre de combustion. Diverses caractéristiques deviendront apparentes à l'homme de l'art à la lecture de la description détaillée suivante du mode de réalisation non limitatif décrit.
PCT/US2013/020349 2013-01-04 2013-01-04 Système d'élimination de co2 par générateur direct de vapeur Ceased WO2014107159A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2013/020349 WO2014107159A1 (fr) 2013-01-04 2013-01-04 Système d'élimination de co2 par générateur direct de vapeur

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PCT/US2013/020349 WO2014107159A1 (fr) 2013-01-04 2013-01-04 Système d'élimination de co2 par générateur direct de vapeur

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11110370B2 (en) 2016-11-20 2021-09-07 XDI Holdings, LLC Dirty water distillation and salt harvesting system, method, and apparatus
US11242772B2 (en) 2017-02-17 2022-02-08 XDI Holdings, LLC Large scale cost effective direct steam generator system, method, and apparatus
US11262022B2 (en) 2016-08-31 2022-03-01 XDI Holdings, LLC Large scale cost effective direct steam generator system, method, and apparatus

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4884529A (en) * 1987-11-12 1989-12-05 Blower Engineering, Inc. Steam generator
US5814288A (en) * 1996-03-08 1998-09-29 Mcdermott Technology, Inc. Flue gas desulfurization method and apparatus
US20040101470A1 (en) * 2000-07-20 2004-05-27 Rosenberg Steven P Process for filter aid production in alumina refineries
US20110259586A1 (en) * 2010-04-23 2011-10-27 Conocophillips Company Water treatment using a direct steam generator
US20120125610A1 (en) * 2010-11-22 2012-05-24 Advanced Combustion Energy Systems, Inc. Combustion Thermal Generator and Systems and Methods for Enhanced Oil Recovery

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4884529A (en) * 1987-11-12 1989-12-05 Blower Engineering, Inc. Steam generator
US5814288A (en) * 1996-03-08 1998-09-29 Mcdermott Technology, Inc. Flue gas desulfurization method and apparatus
US20040101470A1 (en) * 2000-07-20 2004-05-27 Rosenberg Steven P Process for filter aid production in alumina refineries
US20110259586A1 (en) * 2010-04-23 2011-10-27 Conocophillips Company Water treatment using a direct steam generator
US20120125610A1 (en) * 2010-11-22 2012-05-24 Advanced Combustion Energy Systems, Inc. Combustion Thermal Generator and Systems and Methods for Enhanced Oil Recovery

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11262022B2 (en) 2016-08-31 2022-03-01 XDI Holdings, LLC Large scale cost effective direct steam generator system, method, and apparatus
US11802662B2 (en) 2016-08-31 2023-10-31 XDI Holdings, LLC Large scale cost effective direct steam generator system, method, and apparatus
US11110370B2 (en) 2016-11-20 2021-09-07 XDI Holdings, LLC Dirty water distillation and salt harvesting system, method, and apparatus
US12343658B2 (en) 2016-11-20 2025-07-01 Heat Ip Holdco, Llc Dirty water distillation and salt harvesting system, method, and apparatus
US11242772B2 (en) 2017-02-17 2022-02-08 XDI Holdings, LLC Large scale cost effective direct steam generator system, method, and apparatus
US11624299B2 (en) 2017-02-17 2023-04-11 XDI Holdings, LLC Large scale cost effective direct steam generator system, method, and apparatus

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