U.S. patent application number 12/724665 was filed with the patent office on 2010-09-23 for method for the integrated production and utilization of synthesis gas for production of mixed alcohols, for hydrocarbon recovery, and for gasoline/diesel refinery.
Invention is credited to Leslie Wayne Kreis.
Application Number | 20100236987 12/724665 |
Document ID | / |
Family ID | 42736572 |
Filed Date | 2010-09-23 |
United States Patent
Application |
20100236987 |
Kind Code |
A1 |
Kreis; Leslie Wayne |
September 23, 2010 |
METHOD FOR THE INTEGRATED PRODUCTION AND UTILIZATION OF SYNTHESIS
GAS FOR PRODUCTION OF MIXED ALCOHOLS, FOR HYDROCARBON RECOVERY, AND
FOR GASOLINE/DIESEL REFINERY
Abstract
A method for the integrated production and utilization of
synthesis gas for production of mixed alcohols, for hydrocarbon
recovery, and for gasoline/diesel refinery, has the following
steps: forming a hydrocarbon fuel including coal and/or gas oil;
gasifying the hydrocarbon fuel to form synthesis gas that includes
hydrogen and carbon monoxide; directing the carbon monoxide and a
stoichiometric amount of the hydrogen to an alcohol synthesis unit
for the synthesis of mixed alcohols; combusting the remaining
hydrogen with oxygen via a downhole gas combustion unit; and adding
the water to the combustion to produce high-pressure steam for the
recovery of crude oil from the hydrocarbon bearing formation.
Inventors: |
Kreis; Leslie Wayne;
(Midland, TX) |
Correspondence
Address: |
LAW OFFICES OF ERIC KARICH
2807 ST. MARK DR.
MANSFIELD
TX
76063
US
|
Family ID: |
42736572 |
Appl. No.: |
12/724665 |
Filed: |
March 16, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61161503 |
Mar 19, 2009 |
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Current U.S.
Class: |
208/177 ;
166/272.4 |
Current CPC
Class: |
C10J 2300/0959 20130101;
C10J 2300/093 20130101; C01B 3/36 20130101; C01B 2203/0415
20130101; C10J 2300/1665 20130101; C01B 2203/0475 20130101; C01B
2203/0485 20130101; C01B 2203/80 20130101; C01B 2203/86 20130101;
C01B 2203/025 20130101; C10L 1/023 20130101; C01B 2203/061
20130101; C10K 3/04 20130101; E21B 43/24 20130101; C10J 2300/0913
20130101; Y02P 30/30 20151101; C01B 3/52 20130101; C10J 2300/1659
20130101; C01B 3/48 20130101; C10K 1/005 20130101; Y02P 30/00
20151101; C01B 2203/0283 20130101; C10J 2300/0903 20130101; C10G
2/30 20130101; C10J 2300/1612 20130101 |
Class at
Publication: |
208/177 ;
166/272.4 |
International
Class: |
C10G 31/00 20060101
C10G031/00; E21B 43/22 20060101 E21B043/22 |
Claims
1. A method for the integrated production and utilization of
synthesis gas for production of mixed alcohols, for hydrocarbon
recovery, and for gasoline/diesel refinery, the method comprising
the steps of: forming a hydrocarbon fuel including coal and/or gas
oil; gasifying the hydrocarbon fuel to form synthesis gas that
includes hydrogen and carbon monoxide; synthesizing mixed alcohols
from the carbon monoxide and a stoichiometric amount of the
hydrogen; directing remaining hydrogen to a downhole gas combustion
unit positioned underground within a hydrocarbon bearing formation;
directing sufficient oxygen to the downhole gas combustion unit for
combustion with the hydrogen; combusting the remaining hydrogen
with the oxygen via the downhole gas combustion unit; and adding
water to the combustion to produce high-pressure steam for the
recovery of crude oil from the hydrocarbon bearing formation.
2. The method of claim 1, wherein the a hydrocarbon fuel includes
lignite coal and gas oil.
3. The method of claim 1, wherein the alcohol synthesis unit
includes a fixed bed copper catalyst to produce the mixed alcohols,
the catalyst including as an oxide precursor, copper oxide and zinc
oxide, which is transformed into a catalytically active state by
reduction with the hydrogen.
4. The method of claim 1, wherein the mixed alcohols produced
include C1-C8 alcohols.
5. The method of claim 1, wherein the mixed alcohols produced
include C1-C8 alcohols, and wherein there is a greater amount of
methanol than ethanol.
6. The method of claim 1, further comprising the steps of:
separating carbon dioxide from the synthesis gas; and sequestering
the carbon dioxide.
7. The method of claim 1, further comprising the steps of:
separating sulfur from the synthesis gas; and converting the sulfur
to sulfuric acid.
8. The method of claim 1, further comprising the step of increasing
the relative amount of hydrogen in the synthesis gas using a
water-gas shift.
9. A method for the integrated production and utilization of
synthesis gas for production of mixed alcohols, for hydrocarbon
recovery, and for gasoline/diesel refinery, the method comprising
the steps of: forming a hydrocarbon fuel including coal and gas
oil; gasifying the hydrocarbon fuel to form synthesis gas that
includes hydrogen and carbon monoxide; synthesizing mixed alcohols
from the carbon monoxide and a stoichiometric amount of the
hydrogen; positioning a downhole gas combustion unit underground
within a hydrocarbon bearing formation; directing remaining
hydrogen to the downhole gas combustion unit; directing sufficient
oxygen to the downhole gas combustion unit for combustion with the
hydrogen; combusting the remaining hydrogen with the oxygen via the
downhole gas combustion unit; adding water to the combustion to
produce high-pressure steam for the recovery of crude oil from the
hydrocarbon bearing formation; recovering the crude oil from the
hydrocarbon bearing formation; separating the crude oil into
gasoline and gas oil; adding the gas oil to the hydrocarbon fuel
being gasified; and mixing the gasoline with the mixed alcohols to
form high octane gasoline.
10. The method of claim 9, wherein the alcohol synthesis unit
includes a fixed bed copper catalyst to produce the mixed alcohols,
the catalyst including as an oxide precursor, copper oxide and zinc
oxide, which is transformed into a catalytically active state by
reduction with the hydrogen.
11. The method of claim 9, wherein the crude oil is separated into
gasoline and gas oil using steam distillation.
12. The method of claim 9, further comprising the step of
increasing the relative amount of hydrogen in the synthesis gas
using a water-gas shift.
13. The method of claim 9, further comprising the steps of:
removing unreacted hydrogen and carbon monoxide from the mixed
alcohols; and returning the unreacted hydrogen and carbon monoxide
to the alcohol synthesis unit.
14. A method for the integrated production and utilization of
synthesis gas for production of mixed alcohols, for hydrocarbon
recovery, and for gasoline/diesel refinery, the method comprising
the steps of: forming a hydrocarbon fuel including lignite coal and
gas oil; gasifying the hydrocarbon fuel to form synthesis gas that
includes hydrogen and carbon monoxide; increasing the relative
amount of hydrogen in the synthesis gas using a water-gas shift;
separating the hydrogen and the carbon monoxide from the synthesis
gas; directing the carbon monoxide and a stoichiometric amount of
the hydrogen to an alcohol synthesis unit; synthesizing mixed
alcohols within the alcohol synthesis unit from the carbon monoxide
and the hydrogen; removing unreacted hydrogen and carbon monoxide
from the mixed alcohols; returning the unreacted hydrogen and
carbon monoxide to the alcohol synthesis unit; positioning a
downhole gas combustion unit underground within a hydrocarbon
bearing formation; directing remaining hydrogen to the downhole gas
combustion unit; directing oxygen to the downhole gas combustion
unit; directing water to the downhole gas combustion unit;
combusting the remaining hydrogen with the oxygen via the downhole
gas combustion unit; adding the water to the combustion to produce
high-pressure steam for the recovery of crude oil from the
hydrocarbon bearing formation; recovering the crude oil from the
hydrocarbon bearing formation; separating the crude oil into
gasoline and gas oil; adding the gas oil to the hydrocarbon fuel
being gasified; and mixing the gasoline with the mixed alcohols to
form high octane gasoline.
Description
CROSS-REFERENCE TO RELATE APPLICATIONS
[0001] This application for a utility patent claims the benefit of
U.S. Provisional Application No. 61/161,503, filed Mar. 19,
2009.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates generally to methods of producing
gasoline and related fuels, and more particularly to a method for
the integrated production and utilization of synthesis gas for
production of mixed alcohols, for hydrocarbon recovery, and for
gasoline/diesel refinery.
[0005] 2. Description of Related Art
[0006] Vinegar et al., U.S. Pat. No. 7,461,691 (Shell Oil), teaches
an in situ hydrocarbon recovery system that utilizes a wide variety
of heating systems to heat hydrocarbons for enhanced recovery. The
reference discusses in great length the gasification of
hydrocarbons (including lignite coal) for the production of
synthesis gases. This reference teaches the use of the hydrogen for
hydrogenation of the oil formation for enhanced recovery. It also
discusses the use of hydrogen as a fuel for combustion and for
making steam, but particularly for electricity generation. Also, it
teaches the use of the hydrogen for use as a feedstock for a
Fischer-Tropsch process.
[0007] The production of hydrogen from a reformer process, from
hydrocarbons such as oil and coal, is also taught in various other
references, such as Stine, U.S. Pat. No. 4,448,251. Stine
specifically discusses producing hydrogen from the hydrocarbon
formation for use in extracting oil from that formation; however,
the hydrogen is used for hydrogenation, not fuel in an in situ
combustion system.
[0008] Gregoli et al., U.S. Pat. No. 6,016,867 (and other related
patents to World Energy Systems, Inc.), teaches a downhole
combustion unit that burns hydrogen and oxygen with steam for in
situ hydrovisbreaking This reference specifically discusses the
production of the necessary hydrogen from hydrocarbons recovered
from the site. Related references include Hamrick, U.S. Pat. Nos.
4,078,613, and 3,982,591.
[0009] DeFrancesco, U.S. 2008/0257543 (application published Oct.
23, 2008), teaches an enhanced hydrocarbon recovery process that
includes burning a hydrocarbon rich fuel with O2 to form a hot CO2
and steam mixture that is then injected into a reservoir of heavy
oil/bitumen. The produced hydrogen may be used to fuel a turbine,
or for hydrogenation of bitumen.
[0010] Clark, U.S. Pat. No. 4,458,756, teaches the wet oxidation of
coal slurry, in situ, for producing steam and carbon dioxide for
force heavy oil from a formation.
[0011] Rose et al., U.S. Pat. No. 4,159,743, teaches a process for
recovering hydrocarbons that includes burning methane in a
combustion unit in situ. The methane produces CO2 and H2, and water
may be added to produce steam. In one embodiment, O2 is added to
also combust the H2 for increased temperature.
[0012] Other references of interest include Gondouin, U.S. Pat. No.
4,706,751, Steinberg, U.S. 2006/0219403 (application), and Shirley,
U.S. Pat. No. 5,332,036. All of the above-described references are
hereby incorporated by reference in full.
SUMMARY OF THE INVENTION
[0013] The present invention teaches certain benefits in
construction and use which give rise to the objectives described
below.
[0014] The present invention provides a method for the integrated
production and utilization of synthesis gas for production of mixed
alcohols, for hydrocarbon recovery, and for gasoline/diesel
refinery. The method comprises the steps of forming a hydrocarbon
fuel including coal and/or gas oil; gasifying the hydrocarbon fuel
to form synthesis gas that includes hydrogen and carbon monoxide;
directing the carbon monoxide and a stoichiometric amount of the
hydrogen to an alcohol synthesis unit for the synthesis of mixed
alcohols; directing remaining hydrogen to the downhole gas
combustion unit positioned underground within a hydrocarbon bearing
formation; directing oxygen to the downhole gas combustion unit;
combusting the remaining hydrogen with the oxygen via the downhole
gas combustion unit; and adding water to the combustion to produce
high-pressure steam for the recovery of crude oil from the
hydrocarbon bearing formation.
[0015] A primary objective of the present invention is to provide a
method for the integrated production and utilization of synthesis
gas for production of mixed alcohols, for hydrocarbon recovery, and
for gasoline/diesel refinery, the method having advantages not
taught by the prior art.
[0016] Another objective is to provide a method for using lignite
coal and/or gas oil and/or other undesirable carbon sources as
feedstocks for syngas production.
[0017] A further objective is to provide a method for utilizing
syngas for the production of both low octane gasoline and mixed
alcohols which can then be blended together to form an optimal high
octane gasoline that is ready for sale and utilization.
[0018] A further objective is to provide an integrated process for
the production of high octane gasoline that provides optimal
efficiency and limited waste and/or environmental impact.
[0019] Other features and advantages of the present invention will
become apparent from the following more detailed description, taken
in conjunction with the accompanying drawings, which illustrate, by
way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The accompanying drawings illustrate the present invention.
In such drawings:
[0021] FIG. 1 is a flow diagram of one embodiment of a synthesis
gas generation process to produce mixed alcohols;
[0022] FIG. 2 is a flow diagram of one embodiment of a synthesis
gas utilization process wherein synthesis gas generated in the
generation process of FIG. 1 is utilized to recover hydrocarbons
from a hydrocarbon bearing formation via a recovery well; and
[0023] FIG. 3 is a flow diagram illustrating one method of
processing crude oil recovered from the recovery well of FIG.
2.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The above-described drawing figures illustrate the
invention, a method for the integrated production and utilization
of synthesis gas for production of mixed alcohols, for hydrocarbon
recovery, and for gas/diesel refinery.
[0025] FIG. 1 is a flow diagram of one embodiment of a synthesis
gas generation process 10 utilized for generating a synthesis gas
30 for use in the production of mixed alcohols, and for hydrocarbon
recovery (as described in greater detail below, and illustrated in
FIG. 2).
[0026] As illustrated in FIG. 1, the synthesis gas generation
process 10 includes a lignite preparation unit 20 in which lignite
coal is prepared for gasification. The lignite preparation unit 20
processes the coal to form the hydrocarbon fuel 22 that is sent to
a lignite gasifier 24. The hydrocarbon fuel 22 may include crushed
coal, and may further include gas oil 23 generated in later stages
of the process. The hydrocarbon fuel 22 may be processed to a dry
and powdered form; however, in alternative embodiments it may be
mixed with water to form a lignite slurry. In addition to lignite
coal, other syngas feedstocks may also be used (e.g., hydrocarbons,
biomass, or other carbohydrates synthesized to
hydrogen/carbon).
[0027] The hydrocarbon fuel 22 is transported to the lignite
gasifier 24, so that it may be converted to synthesis gasses (e.g.,
hydrogen, carbon dioxide, carbon monoxide). An air separation plant
26, or suitable process, separates oxygen 28 from ambient air, and
the oxygen 28 is transported for use in the lignite gasifier 24.
Since the construction of the air separation plant 26 is well known
in the art, it is not discussed in greater detail herein.
[0028] The lignite gasifier 24 produces synthesis gas 30 using
techniques known in the art. For example, the lignite gasifier 24
meters high temperature combustion to produce the synthesis gas 30.
The synthesis gas 30 includes hydrogen (H2), carbon monoxide (CO),
and carbon dioxide (CO2). Typical lignite coal, although considered
low-quality coal, produces a large amount of hydrogen. Furthermore,
a water gas shift reactor 29 may be utilized to increase the
proportion of hydrogen produced.
[0029] In the preferred embodiment, the lignite gasifier 24 is a
small, skid-mounted, modular, and portable construction. While
prior art devices are adapted for generating electricity, and are
therefore very large and expensive, the current plant is many times
smaller and easily portable.
[0030] The synthesis gas 30 is then transported to a synthesis gas
separation unit 32 for separation of the various components of the
synthesis gas 30. Some components and/or contaminants, such as
sulfur 33 and carbon dioxide 40 are removed. Some of these
components and/or contaminants may be utilized in a productive
manner (e.g., the sulfur 33 may be used in the production of
sulfuric acid 34). The carbon dioxide 40 may be removed by an amine
tower, pressure reduction, or any other technique known to those
skilled in the art. The carbon dioxide 40 may be directed to a CO2
storage 41 such as may be devised by those skilled in the art.
Different techniques of CO2 sequestration known in the art may be
utilized, and/or the carbon dioxide 40 may be used in hydrocarbon
recovery efforts using techniques known in the art. The carbon
dioxide 40 may also simply be stored and sold to those requiring
carbon dioxide.
[0031] The carbon monoxide 36 and the hydrogen 38 are then
transported for further use. The carbon monoxide 36 and a
stoichiometrically correct portion of the hydrogen 38 may be
transported to an alcohol synthesis unit 42 for use in the
synthesis of an alcohol mixture 44, as described in greater detail
below. The remainder of the hydrogen 38 is transported to the
hydrocarbon recovery process 50, illustrated in FIG. 2, for use in
enhancing recovery of crude oil. The portion of the hydrogen 38
used in the hydrocarbon recovery process 50 may be separated from
the rest using pressure swing absorption, ceramic filtering, or any
other process or method known in the art.
[0032] The carbon monoxide 36 and the hydrogen 38 transported to
the alcohol synthesis unit 42 are used for the production of the
alcohol mixture 44. In one embodiment, the alcohol synthesis unit
42 utilizes a copper catalyst to produce methanol and higher
aliphatic alcohols. In one embodiment, the mixed alcohols include
C1-C8 alcohols. The C1-C8 alcohols may include a greater amount of
methanol than ethanol, and in one embodiment the majority of the
mixed alcohols is methanol.
[0033] In one embodiment, a fixed bed copper catalyst is used to
produce the alcohols, using a process disclosed in Schneider et
al., U.S. Pat. No. 4,598,061, which is hereby incorporated by
reference in full. In this embodiment, the catalyst includes, as an
oxide precursor, copper oxide and zinc oxide, which is transformed
into a catalytically active state by reduction with hydrogen.
Aluminum oxide may be used as a thermostabilizing substance, and it
further includes at least one alkali carbonate or alkali oxide. In
other embodiments, a copper catalyst in a liquid bed is used in a
process developed by Eastman Kodak, Inc. Other alternative methods
may also be used to produce other fuels (e.g., Fischer-Tropsch, and
other alternative processes), and such alternatives should be
considered within the scope of the present invention.
[0034] In one embodiment, the synthesis gas generation process 10
further includes a stabilization unit 46 that captures un-reacted
synthesis gas components back to the alcohol synthesis unit 42. The
stabilization unit 46 may perform this process using techniques
that are known in the art, to increase the efficiency of the
process and increase the yield of the alcohol synthesis unit
42.
[0035] In one embodiment, the lignite gasifier 24 and related
components are all located at an oilfield and the coal utilized is
transported to the oilfield for use. This arrangement is useful
because gas oil may be added to the coal to increase production of
the synthesis gas 30, as described in greater detail below. In
another embodiment, the lignite gasifier 24 may be located adjacent
a source of coal (e.g., a coal mine), and the hydrogen 38 may be
piped or otherwise transported to the oilfield for use in the oil
recovery processes.
[0036] FIG. 2 is a flow diagram of one embodiment of the
hydrocarbon recovery process 50, wherein the synthesis gas 30
generated in the synthesis gas generation process 10 of FIG. 1 is
utilized to recover hydrocarbons from a hydrocarbon bearing
formation 58. As illustrated in FIG. 2, the hydrogen 38 is used to
fuel a gas combustion unit 52 which is located downhole 54 adjacent
the hydrocarbon bearing formation 58 (beneath an overburden 56).
The gas combustion unit 52, described in greater detail below, is
used to generate sufficient heat and pressure to drive hydrocarbons
from the hydrocarbon bearing formation 58 to a recovery well
60.
[0037] The gas combustion unit 52 also utilizes the hydrogen 38,
along with oxygen 64 and water, to generate super-heated steam to
drive oil recovery. An air separation plant 62 removes the oxygen
64 from ambient air, and the oxygen 62 along with water from a
water source 66 are transported to the gas combustion unit 52,
along with the hydrogen 38. The gas combustion unit 52 may be
similar to the gas combustion unit disclosed in Hamrick et al.,
U.S. Pat. No. 3,982,591, which is hereby incorporated by reference
in full. The gas combustion unit 52 burns the hydrogen 38 and the
oxygen 64 at an extremely high temperature, and the water is used
to cool the combustion zone, thereby creating large quantities of
high-pressure steam.
[0038] In one embodiment that is not illustrated, the carbon
dioxide 40 may also be pumped into the hydrocarbon bearing
formation 58. Not only does this sequester the carbon dioxide 40
and remove it from the atmosphere, the carbon dioxide 40 also
increases the production of the hydrocarbons. Since the carbon
dioxide 40, which is the only waste, may be sequestered in the
hydrocarbon bearing formation 58, the present process produces
little to no pollution to the surrounding ecosystem. The negligible
environmental impact, and its carbon neutrality, makes this process
particularly attractive.
[0039] The high-pressure steam, which is relatively pure and free
of contamination, is a preferred method of light-oil steam-flooding
to recover residual oil from water flooded light oil reservoirs.
The high pressure and heat (typically around 650 degrees F., 3,000
psi, although the specifics will depend upon the depth, and other
characteristics of the formation) of the steam produced using the
current method are particularly effective at driving the
hydrocarbons to the recovery well 60, utilizing both distillation
and re-pressurization. This process is notably more effective than
processes used in the current state-of-the-art, wherein steam is
produced by burning hydrocarbons, and which operate at much lower
temperatures and pressures.
[0040] It is also worth noting that the gas combustion unit 52 may
be readily modified to lower or higher temperatures, and/or
pressures, depending upon the characteristics of a given
reservoir.
[0041] While the above-described hydrocarbon recovery process 50 is
particularly well-suited for the recovery of oil from water flooded
light oil reservoirs, it may also be utilized in the recovery of
heavy oils, and other hydrocarbon sources. The gas combustion unit
52 produces extremely high heat and pressure, which may be used to
recover heavy oils using techniques well-known in the art. It is
also possible to add additional hydrogen for the hydrogenation of
the hydrocarbon bearing formation 58, using techniques well-known
in the art. The gas combustion unit 52, or "downhole rocket," can
be utilized in many ways for the recovery of hydrocarbon sources
because of its extremely high heat, high pressure, and massive
production of extremely high quality steam. The downhole rocket 52
may include a restricted orifice, such as is disclosed in
Hamrick.
[0042] FIG. 3 is a flow diagram illustrating one method of
processing crude oil recovered from the recovery well of FIG. 2. As
illustrated in FIG. 3, the crude oil 70 recovered via the recovery
well 60 (of FIG. 2) is refined via steam distillation 73 to provide
heavier gas oil 74 as well as lighter gasoline, typically a low
octane gasoline 76 having an octane of approximately 80-85. For
purposes of this application, the term "steam distillation" is
hereby defined to include other suitable forms of distillation that
are suitable for the present process. For purposes of this
application, the term "gasoline" is defined to include similar
and/or equivalent fuels, such as diesel, which may also be used to
fuel engines, and which may be blended with varying amounts of the
mixed alcohols 44.
[0043] The gas oil 74 is then used as a feedstock to the lignite
preparation unit 20, as described above. The low octane gasoline 76
may be blended with the mixed alcohols 44, whose production is
described above, to form high octane gasoline 78. Likewise, diesel
may be blended in a similar manner.
[0044] In this manner, lignite coal and similar undesirable carbon
sources, and also including gas oil 74 that is readily available at
the site of production, are utilized as valuable feedstocks for
syngas production, which is then utilized for the production of
both low octane gasoline 76 and mixed alcohols 44 which can then be
blended together to form an optimal high octane gasoline 78 that is
ready for sale and utilization. The integrated nature of the
production provides optimal efficiency and limited waste and/or
environmental impact.
[0045] As used in this application, the words "a," "an," and "one"
are defined to include one or more of the referenced item unless
specifically stated otherwise. Also, the terms "have," "include,"
"contain," and similar terms are defined to mean "comprising"
unless specifically stated otherwise. Furthermore, the terminology
used in the specification provided above is hereby defined to
include similar and/or equivalent terms, and/or alternative
embodiments that would be considered obvious to one skilled in the
art given the teachings of the present patent application.
* * * * *