US20140144626A1 - Superheated steam water treatment process - Google Patents
Superheated steam water treatment process Download PDFInfo
- Publication number
- US20140144626A1 US20140144626A1 US14/078,634 US201314078634A US2014144626A1 US 20140144626 A1 US20140144626 A1 US 20140144626A1 US 201314078634 A US201314078634 A US 201314078634A US 2014144626 A1 US2014144626 A1 US 2014144626A1
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- steam
- contaminants
- superheated steam
- solids
- separators
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title claims abstract description 89
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- 238000010796 Steam-assisted gravity drainage Methods 0.000 claims abstract description 23
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Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/16—Enhanced recovery methods for obtaining hydrocarbons
- E21B43/24—Enhanced recovery methods for obtaining hydrocarbons using heat, e.g. steam injection
-
- 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
- F22B1/08—Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being steam
- F22B1/14—Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being steam coming in direct contact with water in bulk or in sprays
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/16—Enhanced recovery methods for obtaining hydrocarbons
- E21B43/24—Enhanced recovery methods for obtaining hydrocarbons using heat, e.g. steam injection
- E21B43/2406—Steam assisted gravity drainage [SAGD]
Definitions
- the invention relates generally to a method and apparatus of producing steam and, more particularly, to a method utilizing untreated feedwater as a source for steam used in enhanced oil recovery.
- Superheated steam from treated water is contacted with untreated feedwater in multiple sequential stages to allow for a higher fraction of untreated water to be vaporized.
- EOR enhanced oil recovery
- EOR During EOR, compounds not naturally found in the reservoir are injected into the reservoir to assist in oil recovery. Simply stated, EOR techniques overcome the physical forces holding the oil hydrocarbons underground. There are many types of EOR techniques that are categorized by the injection: gas injection, chemical injection, microbial injection or thermal recovery. While there are many types of EOR techniques, reservoirs containing heavier crude oils tend to be more amenable to thermal EOR methods, which heat the crude oil to reduce its viscosity and thus decrease the mobility ratio. The increased heat reduces the surface tension of the oil and increases the mobility of the oil.
- THAI Toe to Heel Air Injection is an ISC method that combines a vertical air injection well with a horizontal production well.
- COGD Combustion Overhead Gravity Drainage is another ISC method that employs a number of vertical air injection wells above a horizontal production well located at the base of the bitumen pay zone.
- An initial Steam Cycle similar to CSS is used to prepare the bitumen for ignition and mobility. Following that cycle, air is injected into the vertical wells, igniting the upper bitumen and mobilizing (through heating) the lower bitumen to flow into the production well. It is expected that COGD will result in water savings of 80% compared to SAGD.
- EM A variety of electromagnetic methods of heating oil in situ are also being developed.
- GAS A variety of gas injection methods are also used or being developed, including INJECTION the use of cryogenic gases. COMBO Any of the above methods can be used in combination.
- SAGD While many EOR techniques involve injecting steam into underground formations, SAGD is the most favored form of EOR involving steam. It is especially useful for the recovery of semi-solid crude oil known as bitumen.
- steam is injected into an upper horizontal injection well, which creates a steam chamber, and mobilizes the oil at the edges of the chamber. The live oil then gravity drains to a lower horizontal production well, where the oil and water mixture is then collected. Large amounts of steam are needed for this operation, and in SAGD the steam to oil ratio (SOR) is typically about 3, and can easily go higher.
- OTSG Once Through Steam Generator
- Produced water and brackish well water are the main boiler feedwater sources used for SAGD. But, both sources of water contain contaminants, particularly dissolved solids, which cause scaling or fouling of boiler systems. Fouling or scale from the contaminants can result in failure of boiler tubes, down time to blow-down of the boiler and/or loss of boiler efficiency.
- an OTSG can produce about 75-80% quality steam from feedwater with total dissolved solid (TDS) levels of 3,000 to 8,000 ppm. This relatively low steam quality is necessary to maintain wet conditions in the OTSG tubes in order to reduce fouling and scaling, but results in high blow-down levels of 20-25%.
- TDS total dissolved solid
- OTSG feedwater has relatively high TDS levels, it still requires some treatment to reduce silica and hardness levels. This is typically accomplished by warm lime softening followed by ion exchange. This water treatment process represents a significant portion of surface facility capital costs, and has a significant economic impact on a SAGD operation.
- What is needed in the art is a method of recycling untreated water for steam generation without pretreatment, yet without fouling the boiler systems.
- U.S. Pat. No. 4,398,603 describes a method of using low quality feedwater to produce steam.
- feedwater is recycled and contacted with superheated steam to produce saturated steam and precipitated minerals.
- the precipitated minerals are removed by withdrawing a stream of waste water containing the minerals from the contacting vessel.
- this method requires a steam compressor that is not commercially available.
- Betzer-Zilevitch et al. (2010) disclose another “Direct Contact Steam Generation” system in which untreated water is heated by direct contact with combustion gases, as opposed to the non-direct heating seen in OTSGs. However, the resulting steam is again mixed with a high percentage of CO 2 , which is then co-injected into the well.
- US20110061610 discloses a method of using water from waste streams.
- the untreated water is preheated in a heat exchanger before entering a dryer, wherein input steam is used to indirectly dry (evaporate) the heated untreated water.
- This method reduces the amount of energy need to dry the untreated water while still producing high-quality water.
- the resulting steam is recycled in the dryer.
- the contaminants form a solid cake that, upon further processing, can be used to backfill the reservoir.
- Embodiments of the invention describe a method of utilizing superheated steam to vaporize untreated water for use in enhanced oil recovery techniques, preferably SAGD.
- the vaporization occurs in stages, thus allowing for a greater fraction of untreated water to be utilized. In doing so, the water treatment cost of SAGD surface facilities are decreased.
- Some embodiments meet one or more of the following objectives.
- a general objective is the design of an apparatus and method for generating steam that is simple in design, economic to build, maintain and operate, and is sufficiently rugged for wellpad use.
- Another objective is the design of an apparatus and method for generating steam from untreated water to reduce water treatment cost.
- Another objective is the ability to reduce boiler fouling and any resulting boiler blow-down time.
- Another objective is the adaptability of the present invention to steam generating systems currently in use with little modification.
- superheated steam generated by a boiler or a furnace
- untreated water is directly contacted with untreated water to vaporize some or all of the untreated water.
- the contaminants in the untreated water are removed as solids if all of the water is vaporized. Otherwise, the contaminants can be removed as a concentrated brine if only partial vaporization occurs. Both can be removed simultaneously in a suitable steam/water separator (such as a cyclonic separator) or solid and liquid separators can be used sequentially.
- the initial superheated steam is heated to about 900-1000° F. before mixing with the initial untreated feedwater.
- the boiler or furnace used to generate superheated steam can be any commercial available unit capable of superheating steam.
- the superheated steam can either by produced in superheater coils placed in the radiant section of a boiler (common practice in power generation boilers), or in a stand-alone fired steam superheater.
- the mixing of steam and untreated water results in a wet steam plus liquid.
- Contaminants are then removed as a concentrated brine.
- This concentrated brine, removed at each step, is vaporized in a single mixer and solids are removed in a single filter.
- the use of a single mixer and solid filtration device can lower overall costs.
- the contaminants are removed using well-known methods.
- cyclones and/or filters can be used for solids removal devices.
- liquid/gas separation devices such as gravity separators, centrifugal separators, and filter vane separators can be used for a concentrated brine.
- untreated water with high levels of total dissolved solids can be used without any pretreatment step.
- boiler denotes any means of indirectly producing superheated steam from feedwater before the initial contact of superheated steam and untreated water, wherein the heat source is water.
- furnace as used herein implies indirect heating of steam to increase its level of superheat; wherein the heat source is a hydrocarbon such as gas or oil.
- untreated water encompasses all water used for SAGD that has not undergone significant pretreatment to e.g., remove dissolved solids before being heated and includes sources such as feedwater, brackish water and water recovered from a production fluid.
- separatators mean any type of separation device used to separate components in different phases, i.e. solids/liquids, or liquids/gases.
- filter refers to a device that separates solids from liquids (or solids) on the basis of particle retention and thus is size based.
- mixer and “contacting vessel” are used interchangeable and refer to the vessel wherein the untreated water and superheated steam are contacted.
- the term “superheated steam” means a water vapor that is 100% vaporized and at a temperature higher than its boiling point or at least 482° C.
- steam refers generally to water vapor although there may be some amounts of liquid water, water mist and solids therein.
- saturated steam is steam at the temperature of the boiling point which corresponds to its pressure; the term is sometimes also applied to wet steam, and the terms are used interchangeably herein.
- lightly saturated steam is steam at a temperature 2.5-16° C. higher than its boiling point.
- FIG. 1 Block flow diagram of process that uses superheated steam for the staged vaporization of untreated water wherein solids are removed after each vaporization step.
- FIG. 2 Block flow diagram of process that uses superheated steam for the staged vaporization of untreated water wherein concentrated brine is removed after each vaporization step.
- Embodiments of the invention provide a novel method of producing steam to be used in enhanced oil recovery techniques.
- steam produced from a treated water source is superheated, and the superheated steam then used in one or more stages to directly vaporize untreated water.
- the resulting steam is easily separated from any solid contaminants using well-known solid filtration devices.
- the method thus uses multiple stages for superheated steam/untreated water contact. Essentially, the initial vaporized untreated water and steam are superheated after the solids are removed and then directed to a second stage to mix with more untreated water. Again, the resulting vaporized untreated water is superheated and contacted with more untreated water in a third stage. In some embodiments, this process repeats multiple times, for a minimum of 3 stages, preferably a minimum of 5 stages. By using a staged vaporization, a higher fraction of untreated water can be converted to steam, thereby reducing water treatment cost associated with SAGD surface facilities.
- a treated water source is superheated to about 482-538° C. using a boiler or fired steam superheater.
- This initial superheated steam is then mixed with an untreated feedwater stream in a 2.5 to 4.5 ratio in a contactor vessel.
- This mixing results in a less heated steam and solid minerals or concentrated brine.
- the brine and solid minerals are removed from the less heated steam using a solid/liquid separating device or a liquid/gas separating device.
- the less heated steam is then re-superheated to about 482-538° C. using a furnace.
- This larger volume of steam is then mixed with a new amount of untreated feedwater in another contacting vessel.
- the process repeats at least two times, resulting in larger quantities of untreated feedwater being converted into less heated steam.
- the less heated steam is injected in a well for mobilizing heavy oil.
- FIGS. 1 and 2 The present invention is exemplified with respect to FIGS. 1 and 2 .
- FIGS. 1 and 2 are exemplary only, and the invention can be broadly applied to any steam generating system and any source of untreated water.
- the following examples are intended to be illustrative only, and not unduly limit the scope of the appended claims.
- Exemplary results, generated by process modeling, of the basic steam generation system depicted in FIG. 1 for reducing the amount of treated feedwater is given in Table 2.
- superheated steam is mixed with untreated water in five separate contacting vessels. Different contacting vessels have to be used at each stage because progressively lower operating pressures are necessary.
- superheated steam is mixed with untreated water in a 3.3 mass ratio.
- the water is converted into a less heated steam, resulting in a final composition of steam and solid contaminants.
- the solids are filtered out using a solids separation device such as a cyclone separator and/or filter, and the steam flows into a furnace to reheat.
- the re-superheated steam is directed into a second contacting vessel with a new batch of untreated water and the mixing/separation process is repeated.
- Table 2 displays the fraction of treated and untreated water as a function of mixing stages. As shown, increasing the number of stages decreases the amount of treated feedwater needed. As such, more untreated water is utilized, thus reducing traditional water treatment cost of the facility.
- FIG. 2 depicts a steam generating system wherein a concentrated brine is filtered out, as opposed to actual solids.
- the superheated steam is mixed with untreated water in a contacting vessel in five separate stages. During mixing, the untreated water is transformed into a less heated steam, resulting in a final composition of steam and concentrated brine contaminants.
- the concentrated brine is separated out using a gas/liquid separator (‘Sep’).
- the brine can then be vaporized in a single mixer with the solids being removed via a single filter afterwards. Note, this differs from FIG. 1 , in that only one solid removal device is needed for all five stages.
- a single filter reduces cost and system complexity.
- the remaining steam is directed into a furnace to be reheated.
- a second stream of superheated steam is added to the wet steam before it enters the furnace. This second stream is added to vaporize any droplets carried over from the mixers, which prevents the droplets from drying and fouling the furnace tubes.
- the superheated steam is streamed into a second contacting vessel with a new batch of untreated water and the mixing/separation process is repeated.
- Some embodiments allow for the removal of both solids and concentrated brine.
- This design is similar to FIG. 2 except a solid/gas filter is located in-line after the gas-liquid separator in the ‘Sep’.
- the solid/gas filter could also be located in-line with the gas-liquid separator, but after the makeup steam line. This configuration would allow one system to separate out either solids or concentrated brine, depending on the needs of the technique.
- Betzer-Zilvitch M. “Integrated Steam Generation Process and System for Enhanced Oil Recovery,” Conference Paper, Society of Petroleum Engineers, GSUG/SPE 137633, 2010.
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- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Geology (AREA)
- Mining & Mineral Resources (AREA)
- Physics & Mathematics (AREA)
- Geochemistry & Mineralogy (AREA)
- Fluid Mechanics (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Environmental & Geological Engineering (AREA)
- Sustainable Development (AREA)
- Sustainable Energy (AREA)
- Thermal Sciences (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
- Heat Treatment Of Water, Waste Water Or Sewage (AREA)
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US14/078,634 US20140144626A1 (en) | 2012-11-29 | 2013-11-13 | Superheated steam water treatment process |
| PCT/US2013/069986 WO2014085096A1 (fr) | 2012-11-29 | 2013-11-14 | Procédé de traitement d'eau par vapeur surchauffée |
| CA2892960A CA2892960A1 (fr) | 2012-11-29 | 2013-11-14 | Procede de traitement d'eau par vapeur surchauffee |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US201261731242P | 2012-11-29 | 2012-11-29 | |
| US14/078,634 US20140144626A1 (en) | 2012-11-29 | 2013-11-13 | Superheated steam water treatment process |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US20140144626A1 true US20140144626A1 (en) | 2014-05-29 |
Family
ID=50772248
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US14/078,634 Abandoned US20140144626A1 (en) | 2012-11-29 | 2013-11-13 | Superheated steam water treatment process |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US20140144626A1 (fr) |
| CA (1) | CA2892960A1 (fr) |
| WO (1) | WO2014085096A1 (fr) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20140026823A1 (en) * | 2012-01-18 | 2014-01-30 | Steorn Limited | Water heater device with heat and water recovery |
| CN106837292A (zh) * | 2017-03-24 | 2017-06-13 | 西安长庆科技工程有限责任公司 | 一种多层系站场不同处理规模的地面工艺处理系统及方法 |
| WO2017208023A1 (fr) * | 2016-06-03 | 2017-12-07 | Sowers Hank James | Système et procédé de traitement de l'eau |
| US12036492B2 (en) | 2021-05-11 | 2024-07-16 | Saudi Arabian Oil Company | Dynamic heating media conditioning for heat transfer optimization and fouling control |
Citations (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US1827244A (en) * | 1926-06-16 | 1931-10-13 | La Mont Corp | Generation of steam and other vapors |
| GB669928A (en) * | 1949-07-22 | 1952-04-09 | English Electric Co Ltd | Improvements in and relating to compression distillation plant |
| US3147598A (en) * | 1961-11-24 | 1964-09-08 | Westinghouse Electric Corp | Apparatus for evaporating impure water |
| US4398603A (en) * | 1981-01-07 | 1983-08-16 | Hudson's Bay Oil And Gas Company Limited | Steam generation from low quality feedwater |
| US20070051513A1 (en) * | 1999-05-07 | 2007-03-08 | Ge Ionics, Inc. | Treatment of Brines for Deep Well Injection |
| US20100200231A1 (en) * | 2009-02-06 | 2010-08-12 | Hpd, Llc | Method and System for Recovering Oil and Generating Steam from Produced Water |
| US20110005751A1 (en) * | 2009-07-07 | 2011-01-13 | Total S.A. | Production of steam and its application to enhanced oil recovery |
| US20110061867A1 (en) * | 2009-08-07 | 2011-03-17 | Bjorklund Daniel P | Method for production of high purity distillate from produced water for generation of high pressure steam |
| US20120000642A1 (en) * | 2009-12-10 | 2012-01-05 | Ex-Tar Technologies | Steam driven direct contact steam generation |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB262396A (en) * | 1925-12-04 | 1927-07-21 | Bbc Brown Boveri & Cie | An improved method of generating steam |
| US7694736B2 (en) * | 2007-05-23 | 2010-04-13 | Betzer Tsilevich Maoz | Integrated system and method for steam-assisted gravity drainage (SAGD)-heavy oil production to produce super-heated steam without liquid waste discharge |
-
2013
- 2013-11-13 US US14/078,634 patent/US20140144626A1/en not_active Abandoned
- 2013-11-14 CA CA2892960A patent/CA2892960A1/fr not_active Abandoned
- 2013-11-14 WO PCT/US2013/069986 patent/WO2014085096A1/fr not_active Ceased
Patent Citations (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US1827244A (en) * | 1926-06-16 | 1931-10-13 | La Mont Corp | Generation of steam and other vapors |
| GB669928A (en) * | 1949-07-22 | 1952-04-09 | English Electric Co Ltd | Improvements in and relating to compression distillation plant |
| US3147598A (en) * | 1961-11-24 | 1964-09-08 | Westinghouse Electric Corp | Apparatus for evaporating impure water |
| US4398603A (en) * | 1981-01-07 | 1983-08-16 | Hudson's Bay Oil And Gas Company Limited | Steam generation from low quality feedwater |
| US20070051513A1 (en) * | 1999-05-07 | 2007-03-08 | Ge Ionics, Inc. | Treatment of Brines for Deep Well Injection |
| US20100200231A1 (en) * | 2009-02-06 | 2010-08-12 | Hpd, Llc | Method and System for Recovering Oil and Generating Steam from Produced Water |
| US20110005751A1 (en) * | 2009-07-07 | 2011-01-13 | Total S.A. | Production of steam and its application to enhanced oil recovery |
| US20110061867A1 (en) * | 2009-08-07 | 2011-03-17 | Bjorklund Daniel P | Method for production of high purity distillate from produced water for generation of high pressure steam |
| US20120000642A1 (en) * | 2009-12-10 | 2012-01-05 | Ex-Tar Technologies | Steam driven direct contact steam generation |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20140026823A1 (en) * | 2012-01-18 | 2014-01-30 | Steorn Limited | Water heater device with heat and water recovery |
| WO2017208023A1 (fr) * | 2016-06-03 | 2017-12-07 | Sowers Hank James | Système et procédé de traitement de l'eau |
| US11414960B2 (en) | 2016-06-03 | 2022-08-16 | Hank James Sowers | Water processing system and method |
| CN106837292A (zh) * | 2017-03-24 | 2017-06-13 | 西安长庆科技工程有限责任公司 | 一种多层系站场不同处理规模的地面工艺处理系统及方法 |
| US12036492B2 (en) | 2021-05-11 | 2024-07-16 | Saudi Arabian Oil Company | Dynamic heating media conditioning for heat transfer optimization and fouling control |
Also Published As
| Publication number | Publication date |
|---|---|
| CA2892960A1 (fr) | 2014-06-05 |
| WO2014085096A1 (fr) | 2014-06-05 |
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