DE102007004526A1 - Conveyer device for in-situ-extraction of crude oil or crude oil containing material particularly with sand-containing material mixture, comprises unit for injection or flow through of material mixture with steam heat - Google Patents

Abstract

The conveyer device comprises a unit (102) for an injection or flow through of a material mixture with steam heat. Another unit is provided for accumulating a fraction, which is lowered in its viscosity of crude oil. Third unit is provided for processing the fraction of the crude oil. A structure is provided with individual components or modules, which are prefabricated.

Description

• • Mittel zu einer Injektion oder Durchflutung des Materialgemisches mit einem erhitzten Dampf,
• • Mittel zu einer Sammlung des so in seiner Viskosität herabgesetzten Anteils
• • und Mittel zu einer Weiterverarbeitung des Anteils enthält.

The invention relates to a conveyor for in-situ recovery of crude oil from a particular sand-containing material mixture with rohölartigem or rohölhaltigem proportion, wherein the device

• Means for injecting or flooding the material mixture with a heated vapor,
• • means for collecting the fraction thus reduced in viscosity
• • and includes funds for further processing of the share.

In known production facilities for the production of crude oil, in particular from oil sands, the so-called "steam-assisted gravity drainage" (SAGD) is preferably used as an in-situ process (cf., for example, a lecture on the complex of the Oberseminar "Unconventional Hydrocarbons" with the topic "Heavy Oils and Ultrasonic Oils" by J. Seim, Freiberg (DE), January 2001 ). Such methods are currently in the pilot stage. Initial plants are currently being built to produce higher quality, so-called synthetic crude, with improved viscosity. The synthetic crude oil is transported from the reservoir site to the refinery site via a pipeline, with the refinery site up to about 500 km away. To operate the SAGD method, the generation of steam is necessary. Natural gas can be used to generate steam.

Currently, about 28 m ^{3 of} natural gas are needed to extract one barrel of bitumen or crude oil. This resulted in a consumption in 2006 of 17 × 10 ⁶ m ³ gas / day. Consumption is estimated to be up to about 40 to 45 × 10 ⁶ m ³ / day in 2015. In order to transport the natural gas to the place where it is needed to generate steam, correspondingly long pipelines are necessary. This leads to high investment costs for the pipelines. Since the price of natural gas depends on the price of oil, running costs are difficult to predict due to the factor of gas costs.

Farther are currently producing up to four barrels of bitumen Barrel of water consumed. The limit of four barrels of water to Production of one barrel of bitumen is currently considered the limit of Economy considered. In areas where oil sands or sand-containing material mixtures with rohölartigem or are exploited crude content, but are the natural resources limited to water. Continue to demand many times the local authorities that used Water to 100% to recycle. The steam generation process requires continued high quality of the process added Water, resulting in a corresponding effort in the water treatment leads.

Usually In the SAGD process, the oil fields to be exploited become surface area sequentially developed. For this purpose, drainage pipes are driven into the ground, typically a first drainage tube or injection tube, and another second drainage pipe located a few meters below, the so-called production pipe. A pair of such pipes will too referred to as a well-pair. The life of such a well-pair is depending on the nature of the exploited reservoir between 3 months and 3 years. A well-pair is usually preheated up to three months before production can begin. During the preheating time both tubes are supplied with steam, what about twice the steam output compared to the production phase is needed. After approx. 3-month heat-up, the production pipe becomes or drainage pipe, which also previously applied with steam was no longer supplied with steam; instead will be through the production pipe bitumen pumped out of the ground. While the production time only half the steam power is needed, as it is needed during the heating time.

The The lifetime of a well-peer is essentially determined by that Ratio of water used for production and oil extracted with this water. This ratio also known as "Steam to Oil Ratio (SOR)" further, affecting the profitability of the operation of a Well Pairs Factors, is discussed below: This is the central hot steam generation to call in a central supply building. It revealed due to the central steam generation great distances between the actual steam generation and the Well Pairs. On the transport the steam is therefore lost heat and also vapor pressure. Furthermore Natural gas is used to generate water vapor. The natural gas must through a pipeline to the appropriate gas production facility be encouraged. The bitumen-water emulsion is attached to a collected central point, this leads to transport problems.

• – zentrale Dampferzeugung,
• – zentrales oder dezentrales Separieren,
• – zentrales Upgrading,
• – Leitungsverlegung in das Feld aus.

Current promotion facilities are characterized mainly by the fact that the large industrial components are centrally located to minimize the investment costs. This means that essential system components must be set up and commissioned on site. The plants are no longer insensitive, so that all connections to the "production wells" have to be changed or extended, when the funding field changes. This leads to relatively high line infrastructure costs and large losses z. B. due to long steam lines, which must be additionally isolated. The operating costs are also relatively high, especially due to conversion and downtime or costs. Previous systems are characterized mainly by

• - central steam generation,
• Centralized or decentralized separation,
• - central upgrading,
• - Cable laying in the field.

task The present invention is the conveying device to improve with the features mentioned in the introduction, that they are cheaper to install and operate is.

• • Mittel zu einer Injektion oder Durchflutung des Materialgemisches mit einem erhitzten Dampf,
• • Mittel zu einer Sammlung des so in seiner Viskosität herabgesetzten Anteils
• • und Mittel zu einer Weiterverarbeitung des Anteils enthalten und dabei einen Aufbau mit oder aus vorzufertigenden Einzelkomponenten oder Moduln aufweisen.

This object is achieved with the measures listed in claim 1. Accordingly, the conveyor to an in-situ recovery of crude oil from a particular sand-containing material mixture with rohölartigem or rohölhaltigem proportion

• Means for injecting or flooding the material mixture with a heated vapor,
• • means for collecting the fraction thus reduced in viscosity
• • and means for further processing of the share and thereby have a structure with or from prefabricated individual components or modules.

at Such a design of the production system revealed the following advantages: steam generation can be decentralized. Each one steam generator can for a certain Number of Well Pairs provide the necessary steam. Such decentralized Steam generators are flexible due to their modular design handle. There is still a short way to the injection points, what compared to the conventional solutions negligible losses and more precise parameters to be determined entails. In this way, the SOR can be optimized. to Steam production can continue to produce synthesis gas that is produced locally will be used. As a result, no pipelines have to be built and no additional natural gas is consumed. The construction of natural gas pipelines carries namely significantly to the investment cost, the omitted in the case of an embodiment according to the invention. Such a modular unit must namely only with a power supply cable and with a pipeline for removal of the crude oil or the collected crude oil-like or be associated with crude oil content.

The improved modular system is characterized by having modules prefabricated and tested as "plug and play" solutions easy to transport and install. The modules can operated independently of each other. Continue to leave Different modules simply according to customer requirements with each other combine. The individual modules can be a reliable one simple design. The modules can be simple and be standardized. That allows compatibility the modules with each other.

The modular plant can also work in difficult geographical conditions (Impassibility of transport routes, poor infrastructure) built become. A modular system still allows fast and easy operation gradual commissioning and thus a very early Production of the entire modular plant, this improves their "return an investment "(ROI). At the same time, to build a modular Plant a smaller number of foundations and less severe Foundations needed. This reduces the costs of dismantling when dismantling the plant.

Farther there is the possibility in winter or in areas of the Permafrost the modules with little effort and low risk build and install. To build a modular system a low road infrastructure is needed for example, because the modules to be transported have standard dimensions can and so by means of commercial trucks are transportable. Transport with a special vehicle can Ideally omitted.

By reduce the modular structure of a plant, the investment As well as the operating costs, the total cost can continue be lowered such a plant. Due to the modularization arises higher availability and reliability the plant due to its redundant structure. In case of a failure For example, a steam generator produces no total loss of production, because the other steam generators can continue running.

• – Erzeugermodul/Fördermodul
• – Dampfinjektormodul
• – Dampferzeugermodul
• – Wasseraufbereitungsmodul
• – Elektrische Versorgung und Automatisierung
• – Separatormodul
• – Destillationsmodul
• – De-Asphaltermodul
• – Vergaser
• – Luftzerlegung (Sauerstoffversorgung für den Vergaser)
• – Abfallsammlung/Behandlung
• – Medienversorgung (beispielsweise Chemikalienvorräte etc.).

A modular system can be made of transportable standardized units z. B. from containers, with weighing less than or equal to 40 tonnes. The modular system can have the following modules:

• - Generator module / conveyor module
• - Steam injector module
• - Steam generator module
• - Water treatment module
• - Electrical supply and automation
• - Separator module
• - distillation module
• - Dehumidifier module
• - Carburetor
• - Air separation (oxygen supply for the carburettor)
• - Waste collection / treatment
• - Media supply (eg chemical supplies, etc.).

A Extension of the system can be done in several stages. Already in an expansion stage in which only a few modules combined The system can already be operated autonomously. So, for example a plant that already produces bitumen, in a further expansion stage for example, a module for the production of synthetic oil be extended. The individual modules can be used for be prepared for the operation and in this prepared condition be brought to the place of use. This procedure allows, for example Staff costs on site to save costs.

All Modules can have a unified design concept, Operating, monitoring and control concept. The single ones Modules can continue to use uniform interfaces With their help they have a kind of "plug and play concept "are interconnectable.

Embodiments of a modular system will be apparent from the drawing described below, the 1 and 2 each show an exemplary modular structure of a system.

1 schematically shows a modular construction of an oil production facility, as it can be used for example for the promotion of bitumen from oil sands. The plant consists of a SAGD plant 101 , with an injection unit 102 and a production unit 103 , Starting from the injection unit 102 hot water vapor enters one or more injection tubes / injection wells 104 pumped. With the hot water vapor bitumen is thermally dissolved out of the oil sands, which now becomes liquid / viscous bitumen via the production pipe, the production well 105 extracted from the ground. To operate the SAGD unit 101 this will be with a steam generator unit 110 connected. This steam generator unit 110 can, as well as all others in 1 represented units, for example, consist of a transportable standardized unit. The steam generator unit 110 is via the water treatment unit 120 Supplied water for steam generation. That from the SAGD unit 101 Promoted bitumen first enters a separator 130 , From this separator 130 out becomes water, which in turn is the water treatment unit 120 can be fed, separated from the mixture of the earthy extracted bitumen-water mixture. A bitumen-containing substance continues in the distiller 140 given. In the distiller 140 will be synthetic crude, in 1 with SCO, won. The residues of the distiller 140 become the de-Asphalter 150 fed. The arrears of the de-asphalter 150 become a waste unit 160 fed. Residues of the de-asphalter 150 can continue a carburetor 170 be supplied. Starting from the carburetor 170 Can over a gas collector and conditioner 180 Gases for steam production in the steam generator unit 110 to be used. Residues of the gas processor 180 can also be the waste unit 160 be supplied. The entire modular production facility can be powered by an electrical supply and drive unit 190 feature.

In a first expansion stage, the in 1 shown modular device only from the steam generator unit 110 , the water purifier 120 , the separator 130 as well as the SAGD unit 101 consist. In further steps is the modular plant around the distiller 140 as well as the de-asphalter 150 , the carburetor 170 as well as the gas collector and conditioner 180 expandable.

2 shows a schematic sketch of a modular system, which compared to the in 1 shown plant is slightly changed. 2 further shows various steps in the production of synthetic crude oil (SCO). Starting from the in the SAGD plant 101 Promoted bitumen represents the production of synthetic crude oil (SCO).

Yourself in the 1 and 2 approximately corresponding modular units are provided in the two figures with the same reference numerals. The SAGD unit 101 points to the opposite 1 known components additionally a device for injecting a solvent 201 on. With the help of this solvent, which the injection tube 104 supplied, the bitumen present in the oil sands could be solved not only exclusively by means of heat from the sand or rock, but also with the aid of a suitable solvent. The solvent injection device 201 can be part of the SAGD unit 101 be. The steam generator unit 110 consists essentially of a steam generator 210 , which as exhaust 211 only contains pure CO ₂ emissions. The steam generator 210 Therefore almost pure CO ₂ comes as exhaust gas 211 because that's the steam generator 210 supplied gas already in the gas collector and conditioner 180 , in particular sulfur, was freed. The exhaust 211 of the steam generator 210 may be used in addition to heating the deposit. That's how the exhaust can be 211 the hot steam entering the injection well 104 is pumped, mixed the who. The CO ₂ off-gas 211 The steam generator can also be fed to the well-pair of another modular system.

In the distiller 140 Synthetic crude oil (SCO) with a viscosity of typically API 20 ° is produced. For further processing, the synthetic crude oil (SCO) can be fed to a Hydrocracker 2000. The product of the Hydrocracker 2000 is a high quality synthetic crude oil 2001. The residues of the Distiller 140 become the de-Asphalter 150 fed. A product of the de-asphalter 150 Asphaltene is the carburetor 140 fed. The carburetor 140 is with pure oxygen 271 fed. In this way arises in the carburetor 170 on the one hand hydrogen 272 as well as synthetic gas 273 , The hydrogen 272 can be fed to the Hydrocracker 2000. Furthermore, in the carburetor 170 resulting hydrogen 272 , how not in 2 shown for generating superheated steam to the steam generator 210 be supplied. That in the evaporator 270 resulting synthetic gas 273 becomes the gas collector and conditioner 180 fed. In the gas collector and conditioner 180 becomes the synthetic gas 273 the sulfur 281 withdrawn. The gas purified in this way, as already mentioned, the steam generator 210 fed. The carburetor 170 typically has cooling. That for the carburetor 170 necessary cooling water can be used to preheat the water for the steam generator 210 be used. In this way, the efficiency of the modular plant, as in 2 sketched out, will be further improved.

With a plant, as exemplified in 2 is sketched, a production of 50,000 bluebarrels / day can be achieved. A bluebarrel is a barrel of synthetic crude oil. For the production of 50,000 Bluebarrels / day are operated in about 50 to 60 Well-Pairs. For steam generation then about 840 mW are needed. The steam / water cycle is closed. The energy balance is also closed when a carburetor 170 whose synthesis gas is used for power generation (steam generator or power plant for combined power generation). During operation, no natural gas is needed. The process is designed to minimize industrial residues / waste.

For logistical reasons, it is conceivable to reduce the size of a modular unit to a production capacity of 5,000 to 10,000 Bluebarrels / day. In this way, the transportability could be significantly improved, especially in a country without solid roads. The steam generator unit 110 can be modular. For example, for a desired power of 100 MW, four 25 MW units can be used. The use of several smaller units has the advantage that they can be used depending on the reservoir quality. In addition, it is more economical to drive individual smaller steam generators under full load instead of driving a large steam generator at part load. This would not achieve good efficiency. As already mentioned, the exhaust gas can 211 of the steam generator 210 be injected into the soil. In this case, the production process would be considered carbon neutral.

Below are some production parameters of individual modular units. The stated values and values are to be understood as exemplary values. A modular unit can be operated without restriction with other technically meaningful parameters. So can the steam generator unit 110 in about 335 kg / s of steam at 280 ° C and 65 bar deliver. For this purpose, the steam generator unit 110 supplied with 58 kg / s of gas. The steam generator unit 110 will continue to receive 335 kg / s of fresh water from the water treatment unit 120 fed. The water treatment plant or the water treatment unit 120 17 kg / s of fresh water are supplied; 318 kg / s come from the separator 130 and are thus recycled in a closed cycle. The separator 130 contained by the SAGD unit 101 106 kg / s bitumen / water mixture. These 106 kg / s are the separator to the distiller 140 further. 8 kg / s gives the separator 130 as gas to gas collector and conditioner 180 from. The gas collector and conditioner 180 in turn supplies the steam generator unit 110. with 58 kg / s gas.

The distiller produces 83 kg / s of synthetic crude oil or 50,000 barrels / day. The corresponding amount is passed on to the Hydrocracker 2000. The distiller continues to deliver 23 kg / s to the de-asphagus 150 using 1.5 kg / s solvent, 30 kg / s solvent and asphaltene to the gasifier 170 emits. The carburetor 170 is supplied with 29 kg / s of oxygen and consequently produces about 50 kg / s of synthetic gas, 7.5 kg / s of waste and 1.8 kg / s of hydrogen. This hydrogen can be added to the Hydrocracker 2000 or the steam generator unit 110 be supplied.

The following table gives the advantages of a modular construction compared to the prior art: State of the art Modular proposed construction Steam to oil ratio (SOR) 2,5-4 2,5-4 natural gas 28 m ³ / Bl bitumen - no gas consumption up to SOR = 3 - no gas consumption when the waste heat of the carburettor 170 is used (up to SOR = 4) energy 1000 MJ / bl 1000 MJ / bl at SOR = 3 Versorgungslietungen - Power plant / Natural gas - Electrical energy - Bitumen pipeline - no gas or steam supply, as closed-circuit operation - electrical supply - synthetic crude oil pipeline

Of the proposed modular design continues to have the following advantages: It reduces water consumption optionally use of solvents for degradation of the bitumen. The logistics will be greatly simplified, in case a conversion or a relocation of the whole unit, as individual discrete units can be moved more easily. Farther the production process of Production wells can be controlled remotely or with other electronic aids (E-assistance) improved become.

Below are some parameters for the steam generator unit 110 specified. Steam production of 335 kg / s, this corresponds to about 1200 t / h. The generated steam should continue to have a temperature of 280 ° at 65 bar. This corresponds to a power of 840 MW. The steam generator unit 110 continues to make low demands on water quality. Thus, water with a conductivity of> 600 mS / cm can be used. The steam generator unit 110 can have a salt recoverer, work oil-free, thermally degas the water, free of oxygen with trisodium phosphate, increase the pH and / or reduce the residual hardness. The steam generator unit 110 It is easy to install and requires little maintenance, which is easy to perform. It is still fast to start and sufficiently dynamic for varying capacity requirements. Furthermore, the steam generator unit requires 110 Low investment costs and costs at the site. It also has a low space consumption, is robust and simply built and allows environmentally friendly operation.

The entire modular system allows environmentally friendly operation. It has a waste management z. B. for heavy metals and ashes. The modular system has a closed water cycle and can produce CO ₂ neutral.

• – Produktion von 50000 Bluebarrel Rohöl (API 20°)
• – Produktion des Rohöls mit einer SAGD-Einheit 101, welche ca. 1 bl pro Meter Produktionsleitung 105 und Tag liefert, das entspricht bei einer Länge der Produktionsleitung 105 von 1000 m ca. 1000 bl/24 h, also ca. 1,8 kg/s. Es können 106 kg/s Bitumen aus 60 Wells gefördert werden.
• – Der Abstand zwischen den Wells kann ca. 20 m betragen, bei 60 Wells und einer Länge von 1200 m pro Produktionsbohrung 105 entspricht dies einer Fläche von in etwa 144 ha.
• – Ein Steam to oil ratio (SOR) von 2,5 bis 4 wird heutzutage als ökonomisch betrachtet.
• – Die Volumenverhältnisse der produzierbaren Emulsion betragen in Bitumen/Wasser/Sand/Rest in etwa ½, 5–4/< 1/< 1.
• – Die Produktion von einem Barrel Bitumen erfordert heutzutage den Verbrauch von in etwa 28 m³ Erdgas (in etwa 1000 MJ/bl).
• – 95 des Wassers werden zurückgewonnen.
• – Die Wassertemperatur hinter dem Separator beträgt in etwa 50°C.
• – Die Vorlauftemperatur für das Füllwasser beträgt in etwa 10°C.
• – Der De-Asphalter 150 verfügt über ein H/C-Verhältnis von in etwa 1.
• – Der Vergaser 170 setzt ca. 100 des Sauerstoffs in der Reaktion um.

The process of the modular unit can be summarized in the following keywords.

• - Production of 50,000 Bluebarrel crude oil (API 20 °)
• - Production of crude oil with a SAGD unit 101 , which about 1 bl per meter production line 105 and day, which corresponds to a length of the production line 105 1000 m approx. 1000 bl / 24 h, ie approx. 1.8 kg / s. It can be promoted 106 kg / s bitumen from 60 wells.
• - The distance between the wells can be about 20 m, with 60 wells and a length of 1200 m per production well 105 this corresponds to an area of about 144 ha.
• - A steam to oil ratio (SOR) of 2.5 to 4 is considered economic today.
• - The volume ratios of the emulsion produced in bitumen / water / sand / rest in about ½, 5-4 / <1 / <1.
• - The production of one barrel of bitumen today requires the consumption of about 28 m ³ natural gas (about 1000 MJ / bl).
• - 95 of the water are recovered.
• - The water temperature behind the separator is about 50 ° C.
• - The flow temperature for the filling water is approximately 10 ° C.
• - The de-Asphalter 150 has an H / C ratio of about 1.
• - The carburetor 170 converts about 100% of the oxygen in the reaction.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited non-patent literature

• - "Unconventional Hydrocarbons" with the theme "Heavy Oils and Ultrasonic Oils" by J. Seim, Freiberg (DE), January 2001 [0002]

Claims (1)

Conveyor for in situ recovery of crude oil from a particular sand-containing material mixture with rohölartigem or crude oil content, wherein the device at least • means for injection or flooding the material mixture with a heated steam, • Medium to a collection of so reduced in its viscosity share • and means for further processing of the Contains proportion, characterized by a construction with or out of individual components or modules to be prefabricated.