U.S. patent application number 13/593045 was filed with the patent office on 2013-02-28 for methods and systems for upgrading hydrocarbon.
This patent application is currently assigned to MARATHON OIL CANADA CORPORATION. The applicant listed for this patent is Thomas Edward Carter, Mahendra Joshi, Jose Armando Salazar. Invention is credited to Thomas Edward Carter, Mahendra Joshi, Jose Armando Salazar.
Application Number | 20130048539 13/593045 |
Document ID | / |
Family ID | 50150859 |
Filed Date | 2013-02-28 |
United States Patent
Application |
20130048539 |
Kind Code |
A1 |
Salazar; Jose Armando ; et
al. |
February 28, 2013 |
Methods and Systems for Upgrading Hydrocarbon
Abstract
Methods and systems for upgrading hydrocarbon are described. The
system can include a combustor and a nozzle reactor. The combustor
can be used to produce a motive fluid suitable for use in the
nozzle reactor. The motive fluid produced by the combustor and a
hydrocarbon stream can be injected into the nozzle reactor to
upgrade the hydrocarbon material. The systems and methods can also
be integrated with a steam assisted gravity drainage system.
Inventors: |
Salazar; Jose Armando;
(Reno, NV) ; Joshi; Mahendra; (Katy, TX) ;
Carter; Thomas Edward; (Magnolia, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Salazar; Jose Armando
Joshi; Mahendra
Carter; Thomas Edward |
Reno
Katy
Magnolia |
NV
TX
TX |
US
US
US |
|
|
Assignee: |
MARATHON OIL CANADA
CORPORATION
Calgary
CA
|
Family ID: |
50150859 |
Appl. No.: |
13/593045 |
Filed: |
August 23, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61526434 |
Aug 23, 2011 |
|
|
|
Current U.S.
Class: |
208/106 ;
196/127; 196/46; 431/4 |
Current CPC
Class: |
B01J 2219/00006
20130101; F23C 3/002 20130101; C10G 9/34 20130101; C10G 1/02
20130101; B01J 19/26 20130101 |
Class at
Publication: |
208/106 ; 431/4;
196/127; 196/46 |
International
Class: |
C10G 27/00 20060101
C10G027/00; F23J 7/00 20060101 F23J007/00 |
Claims
1. A hydrocarbon upgrading system comprising: a combustor, the
combustor comprising: an oxidant inlet; a fuel inlet; a combustion
chamber; and an atomizer nozzle in fluid communication with the
combustion chamber; and a nozzle reactor, the nozzle reactor
comprising: a reactor body having a reactor body passage with an
injection end and an ejection end; a first material injector having
a first material injection passage and being mounted in the nozzle
reactor in material injecting communication with the injection end
of the reactor body passage, the first material injection passage
having (a) an enlarged volume injection section, an enlarged volume
ejection section, and a reduced volume mid-section intermediate the
enlarged volume injection section and enlarged volume ejection
section, (b) a material injection end in material injecting
communication with the combustion chamber, and (c) a material
ejection end in material injecting communication with the reactor
body passage; and a second material feed port penetrating the
reactor body and being (a) adjacent to the material ejection end of
the first material injection passage and (b) transverse to a first
material injection passage axis extending from the material
injection end to the material ejection end in the first material
injection passage in the first material injector.
2. The hydrocarbon upgrading system recited in claim 1, further
comprising a turbine, the turbine comprising: an exhaust outlet in
fluid communication with the combustor inlet.
3. The hydrocarbon upgrading system recited in claim 1, further
comprising a water source, the water source in fluid communication
with the atomizer nozzle.
4. A hydrocarbon recovery and upgrading system comprising: a
combustor, the combustor comprising: an oxidant inlet; a fuel
inlet; a combustion chamber; and an atomizer nozzle in fluid
communication with the combustion chamber; and a nozzle reactor,
the nozzle reactor comprising: a reactor body having a reactor body
passage with an injection end and an ejection end; a first material
injector having a first material injection passage and being
mounted in the nozzle reactor in material injecting communication
with the injection end of the reactor body passage, the first
material injection passage having (a) an enlarged volume injection
section, an enlarged volume ejection section, and a reduced volume
mid-section intermediate the enlarged volume injection section and
enlarged volume ejection section, (b) a material injection end in
material injecting communication with the combustion chamber, and
(c) a material ejection end in material injecting communication
with the reactor body passage; and a second material feed port
penetrating the reactor body and being (a) adjacent to the material
ejection end of the first material injection passage and (b)
transverse to a first material injection passage axis extending
from the material injection end to the material ejection end in the
first material injection passage in the first material injector; a
steam assisted gravity drainage system, the steam assisted gravity
drainage system comprising: a steam assisted gravity drainage
injection well in material injecting communication with the
combustion chamber; and a steam assisted gravity drainage
production well; and a separation unit, the separation unit
comprising: an inlet in fluid communication with the steam assisted
gravity drainage production well; a fuel outlet in fluid
communication with the fuel inlet; and a hydrocarbon outlet in
fluid communication with the second material feed port.
5. The hydrocarbon recovery and upgrading system recited in claim
4, further comprising a turbine, the turbine comprising: an exhaust
outlet in fluid communication with the oxidant inlet.
6. The hydrocarbon recovery and upgrading system recited in claim
4, further comprising: a nozzle reactor product separator in fluid
communication with the ejection end of the reactor body passage and
comprising a non-upgraded material outlet in fluid communication
with the inlet of the separation unit.
7. A method of upgrading hydrocarbon material comprising: injecting
an oxidant stream and a fuel stream into a combustor and producing
a combustion flame in a combustion chamber; injecting atomized
pre-motive fluid into the combustion chamber and forming motive
fluid; injecting the motive fluid into a nozzle reactor; and
injecting a hydrocarbon material into the nozzle reactor.
8. The method of upgrading hydrocarbon material as recited in claim
7, wherein the motive fluid is injected into the nozzle reactor at
a direction transverse to the direction the hydrocarbon material is
injected into the nozzle reactor.
9. The method of upgrading hydrocarbon material as recited in claim
7, wherein the oxidant stream is exhaust from a turbine.
10. The method of upgrading hydrocarbon material as recited in
claim 9, wherein the exhaust from the turbine has a temperature of
from about 1250 to 1500.degree. F. and a pressure of from about 100
to 550 psig.
11. The method of upgrading hydrocarbon material as recited in
claim 7, wherein the fuel stream comprises natural gas.
12. The method of upgrading hydrocarbon material as recited in
claim 7, wherein the hydrocarbon material is bitumen.
13. The method of upgrading hydrocarbon material as recited in
claim 7, wherein the fuel stream, the atomized pre-motive stream,
and the hydrocarbon material are all derived from the same source
material.
14. The method of upgrading hydrocarbon material as recited in
claim 7, wherein the stoichiometric ratio of fuel injected into the
combustor to oxidant injected into the combustor is greater than
1.
15. A method of recovering and upgrading hydrocarbon material
comprising: withdrawing a steam assisted gravity drainage product
from a steam assisted gravity drainage production well; separating
a fuel stream and a hydrocarbon stream from the gravity assisted
drainage product; injecting an oxidant stream and the fuel stream
into a combustor and producing a combustion flame in a combustion
chamber; atomizing a water stream, injecting the atomized water
into the combustion chamber, and forming steam; injecting a first
portion of the steam into a nozzle reactor; injecting the
hydrocarbon stream into the nozzle reactor; and injecting a second
portion of the steam into a steam assisted gravity drainage
injection well.
16. The method of recovering and upgrading hydrocarbon material as
recited in claim 15, wherein the first portion of the steam is
injected into the nozzle reactor at a direction transverse to the
direction the hydrocarbon stream is injected into the nozzle
reactor.
17. The method of recovering and upgrading hydrocarbon material as
recited in claim 15, wherein the oxidant stream is exhaust from a
turbine.
18. The method of recovering and upgrading hydrocarbon material as
recited in claim 17, wherein the exhaust from the turbine has a
temperature of from about 1250 to 1500.degree. F. and a pressure of
from about 100 to 500 psig.
19. The method of recovering and upgrading hydrocarbon material as
recited in claim 15, wherein the fuel stream comprises natural
gas.
20. The method of recovering and upgrading hydrocarbon material as
recited in claim 15, wherein the hydrocarbon stream comprises
bitumen.
21. The method of recovering and upgrading hydrocarbon material as
recited in claim 15, wherein the stoichiometric ratio of fuel
injected into the combustor to oxidant injected into the combustor
is greater than 1.
Description
[0001] This application claims priority to U.S. Provisional Patent
Application No. 61/526,434, filed Aug. 23, 2011, the entirety of
which is hereby incorporated by reference.
BACKGROUND
[0002] Recovery of heavy oil from subsurface deposits is often
carried out at remote locations, such as on offshore platforms
located many miles from land and oil sands deposits located in
generally uninhabited areas where extreme weather conditions are
common. As would be expected, many issues arise due to the
remoteness of these locations. One example of such an issue is the
difficulty in transporting the recovered viscous heavy oil to
locations where upgrading equipment is available. Additionally, in
the case of offshore platforms, there is a market penalty for oil
that arrives back to shore in a highly viscous state.
[0003] As discussed in co-pending U.S. application Ser. No.
13/589,927, one possible solution to these problems is to subject
the viscous heavy oil to upgrading at the remote location and prior
to transporting the recovered material to refinery facilities
located either onshore or in more populated areas. However, many
materials needed to carry out upgrading processes can be scarce
and/or expensive to produce at the remote locations where the heavy
oil is initially recovered. For example, steam is used in several
upgrading processes, but the standard boiler equipment typically
available at remote locations and which can be used to generate
steam have several shortcomings.
[0004] To begin with, steam generation by boilers can be very
expensive. In some instances, almost 40% of the capital expenditure
of upgrading equipment on an offshore platform can be attributed to
boiler steam generation. The operating expenditure of boilers is
also very high, due primarily to the need to pre-treat water used
to create steam in a boiler. If the water supplied to the boiler
for steam generation contains impurities (such as in the case of
seawater), it must be pretreated in order to avoid scaling and
sediment deposition on the inside of the boiler. Scaling build-up
in the boiler decreases the boiler efficiency and can ultimately
lead to equipment malfunction. Boilers also produce a flue gas that
must be cleaned in order to ensure compliance with emissions
standards. Additionally, roughly 10% of fuel heating value can be
lost in the form of water vapor in the flue gas produced by
boilers.
[0005] Process integration that can allow scarce resources to be
reused is also difficult to accomplish with standard boiler
equipment available at most remote facilities. For example, as
noted above, only water free of certain impurities can be used in
boilers to generate steam. However, most produced water streams are
not free of such impurities, meaning that produced water can not be
directly supplied to a boiler as part of a process integration
scheme.
SUMMARY
[0006] The foregoing and other features, utilities and advantages
of the invention will be apparent from the following more
particular description of a preferred embodiment of the invention
as illustrated in the accompanying drawings.
[0007] In some embodiments, a hydrocarbon upgrading system is
disclosed. The system includes a combustor and a nozzle reactor.
The combustor includes an oxidant inlet, a fuel inlet, a combustion
chamber, and an atomizer nozzle in fluid communication with the
combustion chamber. The nozzle reactor includes a reactor body
having a reactor body passage with an injection end and an ejection
end, a first material injector having a first material injection
passage and being mounted in the nozzle reactor in material
injecting communication with the injection end of the reactor body
passage, and a second material feed port penetrating the reactor
body. The first material injection passage has (a) an enlarged
volume injection section, an enlarged volume ejection section, and
a reduced volume mid-section intermediate the enlarged volume
injection section and enlarged volume ejection section, (b) a
material injection end in material injecting communication with the
combustion chamber, and (c) a material ejection end in material
injecting communication with the reactor body passage. The second
material feed port is (a) adjacent to the material ejection end of
the first material injection passage and (b) transverse to a first
material injection passage axis extending from the material
injection end to the material ejection end in the first material
injection passage in the first material injector.
[0008] In some embodiments, a hydrocarbon recovery and upgrading
system is disclosed. The system includes a combuster, a nozzle
reactor, a steam assisted gravity drainage system, and a separation
unit. The combustor includes an oxidant inlet, a fuel inlet, a
combustion chamber, and an atomizer nozzle in fluid communication
with the combustion chamber. The nozzle reactor includes a reactor
body having a reactor body passage with an injection end and an
ejection end, a first material injector having a first material
injection passage and being mounted in the nozzle reactor in
material injecting communication with the injection end of the
reactor body passage, and a second material feed port penetrating
the reactor body. The first material injection passage has (a) an
enlarged volume injection section, an enlarged volume ejection
section, and a reduced volume mid-section intermediate the enlarged
volume injection section and enlarged volume ejection section, (b)
a material injection end in material injecting communication with
the combustion chamber, and (c) a material ejection end in material
injecting communication with the reactor body passage. The second
material feed port is (a) adjacent to the material ejection end of
the first material injection passage and (b) transverse to a first
material injection passage axis extending from the material
injection end to the material ejection end in the first material
injection passage in the first material injector. The steam
assisted gravity drainage system includes a steam assisted gravity
drainage injection well in material injecting communication with
the combustion chamber and a steam assisted gravity drainage
production well. The separation unit includes an inlet in fluid
communication with the steam assisted gravity drainage production
well, a fuel outlet in fluid communication with the fuel inlet and
a hydrocarbon outlet in fluid communication with the second
material feed port.
[0009] In some embodiments, a method of upgrading hydrocarbon
material is disclosed. The method includes: injecting an oxidant
stream and a fuel stream into a combustor and producing a
combustion flame in a combustion chamber; injecting atomized
pre-motive fluid into the combustion chamber and forming motive
fluid; injecting the motive fluid into a nozzle reactor; and
injecting a hydrocarbon material into the nozzle reactor.
[0010] In some embodiments, method of recovering and upgrading
hydrocarbon is disclosed. The method includes: withdrawing a steam
assisted gravity drainage product from a steam assisted gravity
drainage production well; separating a fuel stream and a
hydrocarbon stream from the steam assisted gravity drainage
product; injecting an oxidant stream and the fuel stream into a
combustor and producing a combustion flame in a combustion chamber;
atomizing a pre-motive fluid stream, injecting the atomized
pre-motive fluid into the combustion chamber, and forming motive
fluid; injecting a first portion of the motive fluid into a nozzle
reactor; injecting the hydrocarbon stream into the nozzle reactor;
and injecting a second portion of the motive fluid into a steam
assisted gravity drainage injection well.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The preferred and other embodiments are disclosed in
association with the accompanying drawings in which:
[0012] FIG. 1 is flow chart of embodiments of a hydrocarbon
upgrading method described herein;
[0013] FIG. 2 is a cross-sectional view of a combustor suitable for
use in embodiments described herein;
[0014] FIG. 3 is a cross-sectional view of a nozzle reactor
suitable for use in embodiments described herein;
[0015] FIG. 4 is a cross-sectional view of a nozzle reactor
suitable for use in embodiments described herein;
[0016] FIG. 5 is flow chart of embodiments of a hydrocarbon
recovery and upgrading method described herein;
[0017] FIG. 6 is a block diagram illustrating embodiments of a
hydrocarbon recovery and upgrading system described herein;
[0018] FIG. 7 shows a cross-sectional view of some embodiments of a
nozzle reactor described herein;
[0019] FIG. 8 shows a cross-sectional view of the top portion of
the nozzle reactor shown in FIG. 7;
[0020] FIG. 9 shows a cross-sectional perspective view of the
mixing chamber in the nozzle reactor shown in FIG. 7; and
[0021] FIG. 10 shows a cross-sectional perspective view of the
distributor from the nozzle reactor shown in FIG. 7.
DETAILED DESCRIPTION
[0022] With reference to FIG. 1, some embodiments of a method for
upgrading hydrocarbon material include a step 1000 of injecting an
oxidant stream and a fuel stream into a combustor and producing a
combustion flame in a combustion chamber, a step 1100 of injecting
atomized pre-motive fluid into the combustion chamber and forming
motive fluid, a step 1200 of injecting the motive fluid into a
nozzle reactor, and a step 1300 of injecting hydrocarbon material
into the nozzle reactor. The method beneficially provides an
alternative to boilers for motive fluid (e.g., steam) generation.
In addition to being less cost-intensive than boilers, the method
also allows for the use of untreated water in motive fluid
generation, which further makes the method more cost effective than
motive fluid generated by boilers. Other benefits of the method
over the use of boilers for motive fluid generation include the
elimination of a flue gas by-product and ability to take advantage
of produced streams from other processes for better process
integration.
[0023] In step 1000, an oxidant stream and a fuel stream are
injected into a combustor. The reaction of the fuel stream and the
oxidant stream creates a combustion flame in the combustion chamber
of the combustor. An objective of step 1000 is to provide a heat
from the reaction between the fuel stream and the oxidant stream to
convert pre-motive fluid injected into the combustion chamber into
motive fluid. The reaction between the oxidant stream and the fuel
stream can also produce additional materials that can be used as
motive fluids in upgrading processes such as cracking of
hydrocarbon material in a nozzle reactor.
[0024] Any oxidant stream capable of being reacted with a fuel
stream in a combustor to produce an exothermic reaction can be used
in step 1000. In some embodiments, the oxidant stream is standard
air from the surrounding environment. The oxidant stream will
typically include a content of O.sub.2 and N.sub.2. In some
embodiments, the oxidant stream includes an O.sub.2 content in the
range of from 18 to 21 vol %. Industrial oxygen can also be used
alone or in combination with air as the oxidant stream. Industrial
oxygen can include from 90 to 99 vol % oxygen. The use of
industrial oxygen can advantageously reduce or eliminate nitrogen
in the process and result in the production of a greater proportion
of motive fluid. Additionally, when motive fluid produced using
industrial oxygen is used in a nozzle reactor to produce cracked
hydrocarbon products, the product leaving the nozzle reactor can be
cleaner and more combustible. Other materials suitable for use as
the oxidant stream include exhaust from a turbine (which can have
depleted amounts of oxygen, such as less than 14 vol % O.sub.2) and
enriched air (which can include from 22 to 28 vol % O.sub.2). Any
combination of standard air, industrial oxygen, turbine exhaust,
and enriched air can be used as the oxidant stream.
[0025] The oxidant stream injected into the combustor in step 1000
can be at a raised temperature and pressure to facilitate the
reaction in the combustor. In some embodiments, the oxidant stream
has a temperature in the range of from 1250 to 1500.degree. F. and
the oxidant stream can have a pressure of from 100 to 550 psig.
When the source of the oxidant stream does not provide oxidant at
the desired temperature and/or pressure, steps can be taken to
adjust the temperature and/or pressure to within the desired
ranges. Any suitable techniques for heating and/or pressurizing the
oxidant stream can be used. For example, the oxidant stream can be
run through a compressor to raise the pressure to within a suitable
range.
[0026] In instances where a turbine, such as a gas turbine, is
present at the remote location, the exhaust from the turbine can be
used as the oxidant stream in step 1000. Use of the turbine exhaust
as the oxidant stream can be useful because turbine exhaust
typically has a raised temperature and pressure and has a desirable
O.sub.2 content. Accordingly, use of turbine exhaust can eliminate
or reduce the need to heat and pressurize the oxidant stream prior
to injecting the oxidant stream into the combustor. In one example,
turbine exhaust having an O.sub.2 of 14% is provided at a
temperature of 1,400.degree. F. and a pressure of 450 psig, meaning
that the exhaust from the turbine can be directly injected into the
combustor without the need for any pre-treatment. Such process
integration lowers the overall cost of generating motive fluid.
[0027] The turbine integrated into the process can include the
turbine used to generate power for the entire remote facility, such
as the power needed for all rotating machines, powered electrical
units, and accommodations (lights, air conditioning, etc.). Such
turbines can be natural gas or fuel gas powered turbines. The
motive fluid generation capacity can be calculated based on the
exhaust gas temperature and flow rate from the turbine designed to
power the remote facility, which in turn can be used to calculate
the capacity of the nozzle reactor. An example of a commercially
available gas turbine that can be used at the remote facility and
integrated into the process is the Centaur 50 manufactured by Solar
Turbines of California, USA. The Centaur 50 is a natural gas fired
turbine that generates roughly 5 MW of electrical power.
[0028] In some embodiments, the exhaust from a custom engine can be
used as the oxidant stream. The custom engine can include only an
air compressor and a combustor section. The exhaust from such a
custom engine can be used in the combustor to generate motive fluid
in the same manner as described above when exhaust from a turbine
is used in the combustor.
[0029] Any fuel stream capable of being reacted with an oxidant
stream in a combustor to produce an exothermic reaction can be used
in step 1000. Exemplary fuel streams include natural gas, methane,
or any other low carbon-producing hydrocarbon. The fuel stream can
also include hydrogen. The fuel stream does not require any
pretreatment as long as the concentration of high molecular weight
hydrocarbons is kept below 0.4 vol %.
[0030] The source of the fuel stream is generally not limited, and
can include both fuel provided independently of any other processes
being performed at the remote facility and fuel produced by other
processes being performed at the remote facility. As described in
greater detail below, in some embodiments the fuel stream is
obtained in whole or in part from material recovered via a SAGD
process being carried out at the remote location. Such material is
typically subjected to various separation processes, one of which
provides fuel suitable for use as a fuel stream in step 1000.
[0031] The oxidant stream and the fuel stream are injected into a
combustor to react and provide an exothermic reaction. Any
combustor suitable for reacting the oxidant stream and fuel stream
to provide an exothermic reaction can be used. With reference to
FIG. 2, a typical combustor 200 suitable for use in the methods
described herein will include a fuel injector 210, an oxidant
stream injector 220, an igniter 230, a combustion chamber 240 where
the exothermic reaction takes place and where the combustion flame
is produced, and a casing 250 housing all of the components of the
combustor. The oxidant and fuel streams are injected into the
combustor, where the two materials react, produce heat, and, with
the aid of the igniter, provide a combustion flame. A basic example
of the reaction that can take place inside the combustion zone when
the fuel stream is methane is shown below:
CH.sub.4+0.5O.sub.2.fwdarw.CO+2H.sub.2,h=-36 kJ/mol
[0032] In addition to CO and H.sub.2, other reaction products that
can be formed by the reaction of the fuel stream and the oxidant
stream in the combustor include CO.sub.2, N.sub.2 and H.sub.2O.
[0033] The amount of the fuel stream and oxidant stream injected
into the combustor can include any rates suitable for reacting the
two streams and that can be handled by the combustor used. In some
embodiments, the stoichiometric ratio of fuel to oxidant is greater
than 1 (i.e., fuel rich). Typical combustion products for the
reaction of standard air and natural gas (no additional steam
added) at various stoichiometric ratios of fuel to air (.PHI.) are
provided in Table 1.
TABLE-US-00001 TABLE 1 .PHI. = 1.1 .PHI. = 1.3 .PHI. = 1.5 Wet Wet
Wet (%) (%) (%) N2 69 N2 66 N2 63 CO2 8 CO2 5.5 CO2 3.9 CO 2.5 CO
2.5 CO 9.0 H2 1.0 H2 4.0 H2 7.5 H2O 18.5 H2O 18.0 H2O 17.0 O2 0.0
O2 0.0 O2 0.0
[0034] Combustion of the fuel stream and standard air stream and
sub-stoichiometric ratios lowers the adiabatic temperature of the
combustion flame. Table 2 provides the adiabatic flame temperature
at various .PHI. when the air stream is not pre-heated and when the
air stream is pre-heated to 1,400.degree. F.
TABLE-US-00002 TABLE 2 Without Air With Air .PHI. Preheating
(.degree. F.) Preheating (.degree. F.) 1.0 3500 4100 1.3 3400 4000
1.5 2800 3400 2.0 2400 3000
[0035] Heat energy provided by the combustion flame is generally
sufficient to produce motive fluid at a desired temperature and
quench the products of combustion. For example, some cracking
processes using nozzle reactors (discussed in greater detail below)
operate more efficiently with motive fluid at 1,200.degree. F. At
many of the temperatures provided in Table 2 above, sufficient heat
energy will be available to both produce motive fluid at
1,200.degree. F. and quench the combustion products.
[0036] In step 1100, atomized pre-motive fluid is injected into the
combustion chamber and motive fluid is formed. When the atomized
pre-motive fluid enters the combustion chamber, the heat energy
provided by the combustion reaction between the oxidant stream and
the fuel stream converts the atomized pre-motive fluid into motive
fluid. Thus produced, the motive fluid can be used for various
recovery and upgrading processing being carried out at the remote
facility.
[0037] The pre-motive fluid used in step 1100 can be selected from
a variety of suitable materials. Generally speaking, the pre-motive
fluid is a material that is suitable for use as a motive fluid in
nozzle reactors Exemplary pre-motive fluids include, but are not
limited to, water, natural gas, methanol, ethanol, ethane, propane,
biodiesel, carbon monoxide, nitrogen, and combinations thereof.
[0038] When the pre-motive fluid injected into the combustion
chamber is water, the water can be obtained from any suitable
source available at the remote facility. The water may not require
pretreatment, and therefore the source of the water is greatly
expanded as compared to water sources that can be used when a
boiler is used for steam generation. In some embodiments (e.g.,
where the remote location is an offshore platform), seawater can be
used as the source of water. In some embodiments where seawater is
used, some pretreatment may be carried out, such as filtration to
remove solids or desalination.
[0039] In some embodiments, the water is obtained from material
recovered by a SAGD process being carried out at the remote
facility. Such material is typically subjected to various
separation processes, one of which provides water suitable for use
as the atomized pre-motive fluid in step 1100.
[0040] The pre-motive fluid injected into the combustion chamber is
atomized. Atomized pre-motive fluid refers to small droplets of
pre-motive fluid that are part of fine spray injected into the
combustion chamber. Any technique capable of atomizing pre-motive
fluid can be used. In some embodiments, atomization of the
pre-motive fluid and injection of the atomized pre-motive fluid is
performed by the same equipment.
[0041] In one example where the pre-motive fluid is water, high
pressure atomizer nozzles can be used to both create an atomized
water spray and inject the atomized water spray into the combustion
chamber. Referring back to FIG. 2, the combustor 200 can be
equipped with such a high pressure atomizer nozzle 260. The
atomizer nozzle 260 is in fluid communication with the combustion
chamber 240 such that the atomized water can be injected into the
combustion chamber where heat energy is available to create steam
from the atomized water droplets. As shown in FIG. 2, in some
embodiments the atomizer nozzle 260 is located near the periphery
of the combustion chamber 240. In this manner, the atomized water
can enter the combustion chamber 240 around the entire
circumference of the combustion flame.
[0042] In some embodiments, the amount of atomized pre-motive fluid
injected into the combustion chamber is generally dependent on the
amount of heat energy being produced inside the combustion chamber
and available to convert the atomized pre-motive fluid to motive
fluid. As noted above, some of the produced heat energy will be
used to quench the other combustion products. In some embodiments,
the atomized pre-motive fluid is injected into the combustion
chamber to keep a pre-motive fluid to oil ratio in the range from
0.5 to 2.0.
[0043] Other reactions occur in the combustion chamber as a result
of injecting the atomized pre-motive fluid into the combustion
chamber and creating motive fluid. For example, when the pre-motive
fluid is water, produced steam can react with unreacted fuel (e.g.,
methane) to produce H.sub.2 and CO, which is an endothermic
reaction. An exemplary reaction between steam and methane fuel is
provided below:
CH4+H2O.fwdarw.CO+3H2,h=+206 kJ/mol
[0044] Carbon monoxide produced from this reaction with react with
steam to undergo an exothermic water gas shift reaction. For
example:
CO+H2O.fwdarw.CO+H2,h=-41 kJ/mol
[0045] Taking into consideration all of these possible reactions,
the final products that can be produced in the combustion chamber
as a result of the introduction of the oxidant stream, the fuel
stream, and atomized water into the combustion chamber include
steam, H.sub.2, CO, CO.sub.2, and N.sub.2. Each of these products
can be used as motive fluids in the nozzle reactor cracking
processes described in greater detail below.
[0046] In embodiments where the fuel stream includes hydrogen and
the oxidant stream includes industrial oxygen, it is theorized that
an efficiency higher than 98% can be obtained. This also would
advantageously provide a zero carbon dioxide emission process.
[0047] Natural gas can also serve as a pre-motive fluid that can be
converted into a motive fluid. Use of natural gas as a pre-motive
fluid may require some modification to the processes described
above. For example, use of natural gas as a pre-motive fluid may
eliminate the need to atomize the pre-motive fluid prior to its
introduction into a combustor. In some embodiments, natural gas is
added to the combustor as a pre-motive fluid to heat and pressurize
the pre-motive fluid and thereby put it in a condition for use as a
motive fluid in a nozzle reactor. Accordingly, in some embodiments,
natural gas is introduced into the combustor where it directly
mixes with the fuel stream (and optionally the oxidant stream) to
heat the natural gas. Atomized water can also be provided as a
means of controlling the mixing and preventing unwanted reactions.
For example, atomized water introduced into the combustion chamber
where natural gas is mixing with the fuel stream can moderate the
mixed fluid temperature and prevent the cracking of the natural gas
into soot. The result of this modified process is the creation of
heated and pressurized natural gas suitable for use as a motive
fluid in a nozzle reactor. In some embodiments, the natural gas
leaving the combustor has a temperature in the range of
1,200.degree. F. and a pressure of 450 psig.
[0048] In some embodiments, the use of natural gas as a motive
fluid can have a beneficial impact on upgrading performance in the
nozzle reactor. For example, use of a motive fluid comprising 100%
natural gas provide improved upgrading performance over motive
fluid comprising mixture of natural gas and steam, or steam
alone.
[0049] In alternative embodiments, natural gas is used as a
pre-motive fluid to produce syngas for use as a motive fluid. This
process can differ from the previously described use of natural gas
as a pre-motive fluid in that reactions are allowed to take place
within the combustor to thereby produce syngas. In some
embodiments, natural gas is used as a pre-motive fluid in
conjunction with using gas turbine exhaust as an oxidant. In such
embodiments, reactions between gas turbine exhaust and the natural
gas inside of the combustor creates hot syngas (CH.sub.4, H.sub.2,
CO, H.sub.2O, N.sub.2, etc) suitable for use as a motive fluid. In
carrying out this reaction, it can be important to ensure that all
oxygen content from the gas turbine exhaust is consumed in the
reforming reactions occurring inside the combustor.
[0050] In some embodiments, the direct fired combustor in a gas
turbine can be used to create motive fluids. Gas turbines typically
include direct fired combustors similar or identical to the direct
fired combustor described above and shown in FIG. 2. The direct
fired combustor in a gas turbine can be used to make motive fluid
by utilizing the exhaust generated by the direct fired combustor in
the gas turbine. In some embodiments, the exhaust generated can be
directly mixed with atomized water to make steam that is suitable
for use as a motive fluid. The exhaust (which can be O.sub.2
depleted as described above) can have a temperature in the range of
1,400.degree. F. Exhaust at this temperature can be capable direct
mixing with atomized water to produce steam. Any manner of mixing
the exhaust with atomized water can be used, and the resulting
steam can have a sufficient temperature and pressure to be used as
a motive fluid (including when the steam created is superheated
steam).
[0051] Another manner in which exhaust generated by a direct fired
combustor in a gas turbine can be used to make motive fluid is
through indirect heating of water. For example, the exhaust having
a sufficiently high temperature (e.g., 1,400.degree. F.) can be
used in a shell and tube heat exchanger to transfer heat to water
and thereby produce steam. The steam produced in this manner can be
suitable for use as a motive fluid.
[0052] In steps 1200 and 1300, the motive fluid produced in the
combustion chamber as part of step 1100 is injected into a nozzle
reactor and a hydrocarbon material is injected into the nozzle
reactor. An objective of injecting the two materials into the
nozzle reactor is to crack the hydrocarbon material into lighter
hydrocarbon compounds.
[0053] The nozzle reactor into which the motive fluid is injected
can be any type of nozzle reactor capable of using motive fluid as
a cracking material to upgrade hydrocarbon material. In some
embodiments, the nozzle reactor into which the motive fluid is
injected is the nozzle reactor described in U.S. Pat. No.
7,618,597, the entirety of which is hereby incorporated by
reference. The nozzle reactor described in the '597 patent
generally receives a motive fluid (also referred to as cracking
material and, in this case, the motive fluid derived from the
combustion chamber) and accelerates it to a supersonic speed via a
converging and diverging injection passage. Hydrocarbon material is
injected into the nozzle reactor adjacent the location the cracking
material exits the injection passage and at a direction transverse
to the direction of the cracking material. The interaction between
the cracking material and the hydrocarbon material results in the
cracking of the hydrocarbon material into a lighter hydrocarbon
material.
[0054] With reference to FIG. 3, an exemplary nozzle reactor
suitable for use in the methods and systems described herein is
shown. The nozzle reactor, indicated generally at 10, has an
injection end 12, a tubular reactor body 14 extending from the
injection end 12, and an ejection port 13 in the reactor body 14
opposite its injection end 12. The injection end 12 includes an
injection passage 15 extending into the interior reactor chamber 16
of the reactor body 14. The central axis A of the injection passage
15 is coaxial with the central axis B of the reactor chamber.
[0055] With continuing reference to FIG. 3, the injection passage
15 has a circular diametric cross-section and, as shown in the
axially-extending cross-sectional view of FIG. 3, opposing inwardly
curved side wall portions 17, 19 (i.e., curved inwardly toward the
central axis A of the injection passage 15) extending along the
axial length of the injection passage 15. In certain embodiments,
the axially inwardly curved side wall portions 17, 19 of the
injection passage 15 allow for a higher speed of injection when
passing through the injection passage 15 into the reactor chamber
16.
[0056] In certain embodiments, the side wall of the injection
passage 15 can provide one or more among: (i) uniform axial
acceleration of material passing through the injection nozzle
passage; (ii) minimal radial acceleration of such material; (iii) a
smooth finish; (iv) absence of sharp edges; and (v) absence of
sudden or sharp changes in direction. The side wall configuration
can render the injection passage 15 substantially isentropic. These
latter types of side wall and injection passage 15 features can be,
among other things, particularly useful for pilot plant nozzle
reactors of minimal size.
[0057] A material feed passage or channel 18 extends from the
exterior of the junction of the injection end 12 and the tubular
reactor body 14 toward the reaction chamber 16 transversely to the
axis B of the interior reactor chamber 16. The material feed
passage 18 penetrates an annular material feed port 20 adjacent the
interior reactor chamber wall 22 at the end 24 of the interior
reactor chamber 16 abutting the injection end 12. The material feed
port 20 includes an annular, radially extending chamber feed slot
26 in material-injecting communication with the interior reactor
chamber 16. The material feed port 20 is thus configured to inject
feed material: (i) at about a 90.degree. angle to the axis of
travel of cracking material injected from the injection nozzle
passage 15; (ii) around the entire circumference of a cracking
material injected through the injection passage 15; and (iii) to
impact the entire circumference of the free cracking material
stream virtually immediately upon its emission from the injection
passage 15 into the reactor chamber 16.
[0058] The annular material feed port 20 may have a U-shaped or
C-shaped cross-section among others. In certain embodiments, the
material feed port may be open to the interior reactor chamber 16,
with no arms or barrier in the path of fluid flow from the material
feed passage 18 toward the interior reactor chamber 16. The
junction of the material feed port 20 and material feed passage 18
can have a radiused cross-section.
[0059] In alternative embodiments, the material feed passage 18,
associated feed port 20, and/or injection passage 15 may have
differing orientations and configurations, and there can be more
than one material feed port and associated structure. Similarly, in
certain embodiments the injection passage 15 may be located on or
in the side 23 of the reactor chamber 16 (and if desired may
include an annular cracking material port) rather than at the
injection end 12 of the reactor chamber 16; and the material feed
port 20 may be non-annular and located at the injection end 12 of
the reactor chamber 16.
[0060] In the embodiment of FIG. 3, the interior reactor chamber 16
can be bounded by stepped, telescoping tubular side walls 28, 30,
32 extending along the axial length of the reactor body 14. In
certain embodiments, the stepped side walls 28, 30, 32 are
configured to: (i) allow a free jet of injected cracking material,
such as superheated steam, natural gas, carbon dioxide, or other
material, to travel generally along and within the conical jet path
C generated by the ejection nozzle passage 15 along the axis 13 of
the reactor chamber 16, while (ii) reducing the size or involvement
of back flow areas, e.g., 34, 36, outside the conical or expanding
jet path C, thereby forcing increased contact between the high
speed cracking material stream within the conical path C and feed
material, such as heavy hydrocarbons, injected through the feed
port 20. As indicated by the drawing gaps 38, 40 in the embodiment
of FIG. 3, the tubular reactor body 14 has an axial length (along
axis B) that is much greater than its width. In the FIG. 3
embodiment, exemplary length-to-width ratios are typically in the
range of 2 to 4 or more.
[0061] With reference now to FIG. 4 and the particular embodiment
shown therein, the reactor body 44 includes a generally tubular
central section 46 and a frustoconical ejection end 48 extending
from the central section 46 opposite an insert end 50 of the
central section 46, with the insert end 50 in turn abutting the
injection nozzle 52. The insert end 50 of the central section 46
consists of a generally tubular central body 51. The central body
51 has a tubular material feed passage 54 extending from the
external periphery 56 of the insert end 50 radially inwardly to
injectingly communicate with the annular circumferential feed port
depression or channel 58 in the otherwise planar, radially inwardly
extending portion 59 of the axially stepped face 61 of the insert,
end 50. The inwardly extending portion 59 abuts the planar radially
internally extending portion 53 of a matingly stepped face 55 of
the injection nozzle 52. The feed port channel 58 and axially
opposed radially internally extending portion 53 of the injection
nozzle 52 cooperatively provide an annular feed port 57 disposed
transversely laterally, or radially outwardly, from the axis A of a
preferably non-linear injection passage 60 in the injection nozzle
52.
[0062] The tubular body 51 of the insert end SD is secured within
and adjacent the interior periphery 64 of the reactor body 44. The
mechanism for securing the insert end 50 in this position may
consist of an axially-extending nut-and-bolt arrangement (not
shown) penetrating co-linearly mating passages (not shown) in: (i)
an upper radially extending lip 66 on the reactor body 44; (ii) an
abutting, radially outwardly extending thickened neck section 68 on
the insert end 50; and (iii) in turn, the abutting injector nozzle
52. Other mechanisms for securing the insert end 50 within the
reactor body 44 may include a press fit (not shown) or mating
threads (not shown) on the outer periphery 62 of the tubular body
51 and on the inner periphery 64 of the reactor body 44. Seals,
e.g., 70, may be mounted as desired between, for example, the
radially extending lip 66 and the abutting the neck section 68 and
the neck section 68 and the abutting injector nozzle 52.
[0063] The non-linear injection passage 60 has, from an
axially-extending cross-sectional perspective, mating, radially
inwardly curved opposing side wall sections 72, 74 extending along
the axial length of the non-linear injection passage 60. The entry
end 76 of injection passage 60 provides a rounded circumferential
face abutting an injection feed tube 78, which can be bolted (not
shown) to the mating planar, radially outwardly extending distal
face 80 on the injection nozzle 52.
[0064] In the embodiment of FIG. 3, the nozzle passage 60 is a
DeLaval type of nozzle and has an axially convergent section 82
abutting an intermediate relatively narrower throat section 84,
which in turn abuts an axially divergent section 86. The nozzle
passage 60 also has a circular diametric cross-section (i.e., in
cross-sectional view perpendicular to the axis of the nozzle
passage) all along its axial length. In certain embodiments, the
nozzle passage 60 may also present a somewhat roundly curved thick
82, less curved thicker 84, and relatively even less curved and
more gently sloped relatively thin 86 axially extending
cross-sectional configuration from the entry end 76 to the
injection end 88 of the injection passage 60 in the injection
nozzle 52.
[0065] The nozzle passage 60 can thus be configured to present a
substantially isentropic or frictionless configuration for the
injection nozzle 52. This configuration may vary, however,
depending on the application involved in order to yield a
substantially isentropic configuration for the application.
[0066] The injection passage 60 is formed in a replaceable
injection nozzle insert 90 press-fit or threaded into a mating
injection nozzle mounting passage 92 extending axially through an
injection nozzle body 94 of the injection nozzle 52. The injection
nozzle insert 90 is preferably made of hardened steel alloy, and
the balance of the nozzle reactor 100 components other than seals,
if any, are preferably made of steel or stainless steel.
[0067] In the particular embodiment shown in FIG. 3, the narrowest
diameter D within the injection passage is 140 mm. The diameter E
of the ejection passage opening 96 in the ejection end 48 of the
reactor body 44 is 2.2 meters. The axial length of the reactor body
44, from the injection end 88 of the injector passage 60 to the
ejection passage opening 96, is 10 meters.
[0068] The interior peripheries 89, 91 of the insert end 50 and the
tubular central section 46, respectively, cooperatively provide a
stepped or telescoped structure expanding radially outwardly from
the injection end 88 of the injection or injector passage 60 toward
the frustoconical end 48 of the reactor body 44. The particular
dimensions of the various components, however, will vary based on
the particular application for the nozzle reactor, generally 100.
Factors taken into account in determining the particular dimensions
include the physical properties of the cracking gas (density,
enthalpy, entropy, heat capacity, etc.) and the pressure ratio from
the entry end 76 to the injection end 88 of the injector passage
60.
[0069] In certain embodiments having one or more non-linear
cracking gas injection passages, e.g., 60, such as the
convergent/divergent configuration of FIG. 3, the pressure
differential can yield a steady increase in the kinetic energy of
the cracking material as it moves along the axial length of the
cracking gas injection passage(s) 60. The cracking material may
thereby eject from the ejection end 88 of the injection passage 60
into the interior of the reactor body 44 at supersonic speed with a
commensurately relatively high level of kinetic energy. In these
embodiments, the level of kinetic energy of the supersonic
discharge cracking material is therefore greater than can be
achieved by certain prior art straight-through.
[0070] Feed stock is injected into the material feed passage 54 and
then through the mating annular feed port 57. The feed stock
thereby travels radially inwardly to impact a transversely (i.e.,
axially) traveling high speed cracking mateiral (for example,
steam, natural gas, carbon dioxide or other gas not shown)
virtually immediately upon its ejection from the ejection end 88 of
the injection passage 60. The collision of the radially injected
feed stock with the axially traveling high speed steam jet delivers
kinetic and thermal energy to the feed stock. The applicants
believe that this process may continue, but with diminished
intensity and productivity, through the length of the reactor body
44 as injected feed stock is forced along the axis of the reactor
body 44 and yet constrained from avoiding contact with the jet
stream by the telescoping interior walls, e.g., 89, 91 101, of the
reactor body 44. Depending on the nature of the feed stock and its
pre-feed treatment, differing results can be procured, such as
cracking of heavy hydrocarbons, including bitumen, into lighter
hydrocarbons.
[0071] FIGS. 7 and 8 show cross-sectional views of another
embodiment of a nozzle reactor 100 suitable for use in the methods
described herein. The nozzle reactor 100 includes a head portion
102 coupled to a body portion 104. A main passage 106 extends
through both the head portion 102 and the body portion 104. The
head and body portions 102, 104 are coupled together so that the
central axes of the main passage 106 in each portion 102, 104 are
coaxial so that the main passage 106 extends straight through the
nozzle reactor 100.
[0072] It should be noted that for purposes of this disclosure, the
term "coupled" means the joining of two members directly or
indirectly to one another. Such joining may be stationary in nature
or movable in nature. Such joining may be achieved with the two
members or the two members and any additional intermediate members
being integrally formed as a single unitary body with one another
or with the two members or the two members and any additional
intermediate member being attached to one another. Such joining may
be permanent in nature or alternatively may be removable or
releasable in nature.
[0073] The nozzle reactor 100 includes a feed passage 108 that is
in fluid communication with the main passage 106. The feed passage
108 intersects the main passage 106 at a location between the
portions 102, 104. The main passage 106 includes an entry opening
110 at the top of the head portion 102 and an exit opening 112 at
the bottom of the body portion 104. The feed passage 108 also
includes an entry opening 114 on the side of the body portion 104
and an exit opening 116 that is located where the feed passage 108
meets the main passage 106.
[0074] During operation, the nozzle reactor 100 includes a reacting
fluid that flows through the main passage 106. The reacting fluid
enters through the entry opening 110, travels the length of the
main passage 106, and exits the nozzle reactor 100 out of the exit
opening 112. A feed material flows through the feed passage 108.
The feed material enters through the entry opening 114, travels
through the feed passage 106, and exits into the main passage 108
at exit opening 116.
[0075] The main passage 106 is shaped to accelerate the reacting
fluid. The main passage 106 may have any suitable geometry that is
capable of doing this. As shown in FIGS. 7 and 8, the main passage
106 includes a first region having a convergent section 120 (also
referred to herein as a contraction section), a throat 122, and a
divergent section 124 (also referred to herein as an expansion
section). The first region is in the head portion 102 of the nozzle
reactor 100.
[0076] The convergent section 120 is where the main passage 106
narrows from a wide diameter to a smaller diameter, and the
divergent section 124 is where the main passage 106 expands from a
smaller diameter to a larger diameter. The throat 122 is the
narrowest point of the main passage 106 between the convergent
section 120 and the divergent section 124. When viewed from the
side, the main passage 106 appears to be pinched in the middle,
making a carefully balanced, asymmetric hourglass-like shape. This
configuration is commonly referred to as a convergent-divergent
nozzle or "con-di nozzle".
[0077] The convergent section of the main passage 106 accelerates
subsonic fluids since the mass flow rate is constant and the
material must accelerate to pass through the smaller opening. The
flow will reach sonic velocity or Mach 1 at the throat 122 provided
that the pressure ratio is high enough. In this situation, the main
passage 106 is said to be in a choked flow condition.
[0078] Increasing the pressure ratio further does not increase the
Mach number at the throat 122 beyond unity. However, the flow
downstream from the throat 122 is free to expand and can reach
supersonic velocities. It should be noted that Mach 1 can be a very
high speed for a hot fluid since the speed of sound varies as the
square root of absolute temperature. Thus the speed reached at the
throat 122 can be far higher than the speed of sound at sea
level.
[0079] The divergent section 124 of the main passage 106 slows
subsonic fluids, but accelerates sonic or supersonic fluids. A
convergent-divergent geometry can therefore accelerate fluids in a
choked flow condition to supersonic speeds. The
convergent-divergent geometry can be used to accelerate the hot,
pressurized reacting fluid to supersonic speeds, and upon
expansion, to shape the exhaust flow so that the heat energy
propelling the flow is maximally converted into kinetic energy.
[0080] The flow rate of the reacting fluid through the
convergent-divergent nozzle is isentropic (fluid entropy is nearly
constant). At subsonic flow the fluid is compressible so that
sound, a small pressure wave, can propagate through it. At the
throat 122, where the cross sectional area is a minimum, the fluid
velocity locally becomes sonic (Mach number=1.0). As the cross
sectional area increases the gas begins to expand and the gas flow
increases to supersonic velocities where a sound wave cannot
propagate backwards through the fluid as viewed in the frame of
reference of the nozzle (Mach number>1.0).
[0081] The main passage 106 only reaches a choked flow condition at
the throat 122 if the pressure and mass flow rate is sufficient to
reach sonic speeds, otherwise supersonic flow is not achieved and
the main passage will act as a venturi tube. In order to achieve
supersonic flow, the entry pressure to the nozzle reactor 100
should be significantly above ambient pressure.
[0082] The pressure of the fluid at the exit of the divergent
section 124 of the main passage 106 can be low, but should not be
too low. The exit pressure can be significantly below ambient
pressure since pressure cannot travel upstream through the
supersonic flow. However, if the pressure is too far below ambient,
then the flow will cease to be supersonic or the flow will separate
within the divergent section 124 of the main passage 106 forming an
unstable jet that "flops" around and damages the main passage 106.
In one embodiment, the ambient pressure is no higher than
approximately 2-3 times the pressure in the supersonic gas at the
exit.
[0083] The supersonic reacting fluid collides and mixes with the
feed material in the nozzle reactor 100 to produce the desired
reaction. The high speeds involved and the resulting collision
produces a significant amount of kinetic energy that helps
facilitate the desired reaction. The reacting fluid and/or the feed
material may also be pre-heated to provide additional thermal
energy to react the materials.
[0084] The nozzle reactor 100 may be configured to accelerate the
reacting fluid to at least approximately Mach 1, at least
approximately Mach 1.5, or, desirably, at least approximately Mach
2. The nozzle reactor may also be configured to accelerate the
reacting fluid to approximately Mach 1 to approximately Mach 7,
approximately Mach 1.5 to approximately Mach 6, or, desirably,
approximately Mach 2 to approximately Mach 5.
[0085] As shown in FIG. 8, the main passage 106 has a circular
cross-section and opposing converging side walls 126, 128. The side
walls 126, 128 curve inwardly toward the central axis of the main
passage 106. The side walls 126, 128 form the convergent section
120 of the main passage 106 and accelerate the reacting fluid as
described above.
[0086] The main passage 106 also includes opposing diverging side
walls 130, 132. The side walls 130, 132 curve outwardly (when
viewed in the direction of flow) away from the central axis of the
main passage 106. The side walls 130, 132 form the divergent
section 124 of the main passage 106 that allows the sonic fluid to
expand and reach supersonic velocities.
[0087] The side walls 126, 128, 130, 132 of the main passage 106
provide uniform axial acceleration of the reacting fluid with
minimal radial acceleration. The side walls 126, 128, 130, 132 may
also have a smooth surface or finish with an absence of sharp edges
that may disrupt the flow. The configuration of the side walls 126,
128, 130, 132 renders the main passage 106 substantially
isentropic.
[0088] The feed passage 108 extends from the exterior of the body
portion 104 to an annular chamber 134 formed by head and body
portions 102, 104. The portions 102, 104 each have an opposing
cavity so that when they are coupled together the cavities combine
to form the annular chamber 134. A seal 136 is positioned along the
outer circumference of the annular chamber 134 to prevent the feed
material from leaking through the space between the head and body
portions 102, 104.
[0089] It should be appreciated that the head and body portions
102, 104 may be coupled together in any suitable manner. Regardless
of the method or devices used, the head and body portions 102, 104
should be coupled together in a way that prevents the feed material
from leaking and withstands the forces generated in the interior.
In one embodiment, the portions 102, 104 are coupled together using
bolts that extend through holes in the outer flanges of the
portions 102, 104.
[0090] The nozzle reactor 100 includes a distributor 140 positioned
between the head and body portions 102, 104. The distributor 140
prevents the feed material from flowing directly from the opening
141 of the feed passage 108 to the main passage 106. Instead, the
distributor 140 annularly and uniformly distributes the feed
material into contact with the reacting fluid flowing in the main
passage 106.
[0091] As shown in FIG. 10, the distributor 140 includes an outer
circular wall 148 that extends between the head and body portions
102, 104 and forms the inner boundary of the annular chamber 134. A
seal or gasket may be provided at the interface between the
distributor 140 and the head and body portions 102, 104 to prevent
feed material from leaking around the edges.
[0092] The distributor 140 includes a plurality of holes 144 that
extend through the outer wall 148 and into an interior chamber 146.
The holes 144 are evenly spaced around the outside of the
distributor 140 to provide even flow into the interior chamber 146.
The interior chamber 146 is where the main passage 106 and the feed
passage 108 meet and the feed material comes into contact with the
supersonic reacting fluid.
[0093] The distributor 140 is thus configured to inject the feed
material at about a 90.degree. angle to the axis of travel of the
reacting fluid in the main passage 106 around the entire
circumference of the reacting fluid. The feed material thus forms
an annulus of flow that extends toward the main passage 106. The
number and size of the holes 144 are selected to provide a pressure
drop across the distributor 140 that ensures that the flow through
each hole 144 is approximately the same. In one embodiment, the
pressure drop across the distributor is at least approximately 2000
pascals, at least approximately 3000 pascals, or at least
approximately 5000 pascals.
[0094] Referring to FIG. 9, holes 144 are shown having a circular
cross-section. Circular holes 144 are suitable for effective nozzle
reactor operation when the nozzle reactor is relatively small and
handling production capacities less than, e.g., 1,000 bbl/day. At
such production capacities, the feed material passing through the
circular holes will break up into the smaller droplet size
necessary for efficient mixing or shearing with the reacting
fluid.
[0095] The distributor 140 includes a wear ring 150 positioned
immediately adjacent to and downstream of the location where the
feed passage 108 meets the main passage 106. The collision of the
reacting fluid and the feed material causes a lot of wear in this
area. The wear ring is a physically separate component that is
capable of being periodically removed and replaced.
[0096] As shown in FIG. 10, the distributor 140 includes an annular
recess 152 that is sized to receive and support the wear ring 150.
The wear ring 150 is coupled to the distributor 140 to prevent it
from moving during operation. The wear ring 150 may be coupled to
the distributor in any suitable manner. For example, the wear ring
150 may be welded or bolted to the distributor 140. If the wear
ring 150 is welded to the distributor 140, as shown in FIG. 9, the
wear ring 150 can be removed by grinding the weld off. In some
embodiments, the weld or bolt need not protrude upward into the
interior chamber 146 to a significant degree.
[0097] The wear ring 150 can be removed by separating the head
portion 102 from the body portion 104. With the head portion 102
removed, the distributor 140 and/or the wear ring 150 are readily
accessible. The user can remove and/or replace the wear ring 150 or
the entire distributor 140, if necessary.
[0098] As shown in FIGS. 7 and 8, the main passage 106 expands
after passing through the wear ring 150. This can be referred to as
expansion area 160 (also referred to herein as an expansion
chamber). The expansion area 160 is formed largely by the
distributor 140, but can also be formed by the body portion
104.
[0099] Following the expansion area 160, the main passage 106
includes a second region having a converging-diverging shape. The
second region is in the body portion 104 of the nozzle reactor 100.
In this region, the main passage includes a convergent section 170
(also referred to herein as a contraction section), a throat 172,
and a divergent section 174 (also referred to herein as an
expansion section). The converging-diverging shape of the second
region differs from that of the first region in that it is much
larger. In one embodiment, the throat 172 is at least 2-5 times as
large as the throat 122.
[0100] The second region provides additional mixing and residence
time to react the reacting fluid and the feed material. The main
passage 106 is configured to allow a portion of the reaction
mixture to flow backward from the exit opening 112 along the outer
wall 176 to the expansion area 160. The backflow then mixes with
the stream of material exiting the distributor 140. This mixing
action also helps drive the reaction to completion.
[0101] The combustion chamber of the combustor can be in fluid
communication with the cracking material injection passage of the
nozzle reactor such that the produced motive fluid passes directly
into the nozzle reactor. The motive fluid exiting the combustion
chamber and entering the nozzle reactor is passed through the
cracking material injection passage where, as described above, the
motive fluid is accelerated to a supersonic speed. Any amount of
motive fluid necessary to crack hydrocarbon material injected into
the nozzle reactor can be supplied into the nozzle reactor.
[0102] In some embodiments, supplemental motive fluid can be
provided to the nozzle reactor, such as in the case where the
combustor does not produce sufficient motive fluid for cracking the
amount of hydrocarbon injected into the nozzle reactor. The
supplemental motive fluid can be joined with the motive fluid
produced by the combustor prior to injection into the nozzle
reactor. Any suitable source of supplemental motive fluid can be
used. In embodiments where the motive fluid is steam, traditional
steam generation boilers can be used to produce supplemental motive
fluid. In offshore contexts, steam generation boilers are a good
source of supplemental motive fluid because the offshore platform
already uses steam generation boilers for other processes carried
out on the offshore platform.
[0103] In step 1300, the hydrocarbon material to be upgraded is
injected into the nozzle reactor. When a nozzle reactor as
described above is used, the hydrocarbon material is injected into
the nozzle reactor at a location adjacent to where the motive fluid
exits the cracking material injection passage and a direction
transverse to the direction the motive fluid enters the reactor
body passage.
[0104] Any hydrocarbon material capable of being upgraded in the
nozzle reactor through interaction with motive fluid travelling at
supersonic speeds can be used in step 1300. In some embodiments,
the hydrocarbon material is a heavy hydrocarbon material, such as a
hydrocarbon material having a molecular weight greater than 500.
Such hydrocarbon materials can include bitumen and asphaltenes. In
some embodiments, the hydrocarbon material is hydrocarbon material
that is recovered from SAGD recovery processes being carried out at
the same remote facility as the nozzle reactor upgrading. Such
material when recovered via a SAGD process is typically subjected
to one or more separation units, and one potential output stream of
the separation units may be a heavy hydrocarbon stream.
[0105] In some embodiments, some deposits may appear within the
nozzle reactor as a result of the upgrading process. Such scale
build up should be monitored. In some embodiments, treatment of the
water prior to injection into the nozzle reactor can be provided in
order to reduce or avoid scale build up. Such treatments can
include distillation, desalting, and/or desalination depending on
the source.
[0106] Some embodiments of the method can include further process
integration such that the upgrading processes are assisted by the
recovery processes and vice versa. With reference to FIG. 5, some
embodiments of a method for recovering and upgrading hydrocarbon
material include a step 500 of withdrawing a steam assisted gravity
drainage product from a steam assisted gravity drainage production
well, a step 510 of separating a fuel stream and a hydrocarbon
stream from the steam assisted gravity drainage product, a step 520
of injecting a combustion stream and the fuel stream into a
combustor and producing a combustion flame in a combustion chamber,
a step 530 of atomizing a water stream, injecting the atomized
water into the combustion chamber, and forming steam, a step 540 of
injecting a first portion of the steam into a nozzle reactor, a
step 550 of injecting they hydrocarbon stream into the nozzle
reactor, and a step 560 of injecting a second portion of the steam
into a steam assisted gravity drainage injection well. In such a
method, the SAGD recovery processing assists the upgrading
processing by providing the fuel and hydrocarbon streams, and the
upgrading processing assists the SAGD recovery processing by
providing a portion of the necessary steam.
[0107] In step 500, a SAGD production well is provided through
which SAGD product can be withdrawn. The SAGD production well can
be any type of SAGD production well known to those of ordinary
skill in the art and is part of any type of SAGD system to known to
those of ordinary skill in the art. Generally speaking, the SAGD
production well has a first end that is located within a deposit of
hydrocarbon material. Typically, this end of the production well
will be oriented in a horizontal direction and will be located
under a SAGD injection well that introduces steam into the deposit
of hydrocarbon material. The steam introduced into the deposit of
hydrocarbon material will lower the viscosity of the hydrocarbon
material until it flows downwardly under the influence of gravity
to the SAGD production well located under the SAGD injection well.
The SAGD production well receives this hydrocarbon material and
provides a channel for the material to be pumped upwardly to the
opposite end of the production well. The opposite end of the
production well is located above ground.
[0108] The SAGD product brought to the surface by the SAGD
production well can have a variety of components. In some
embodiments, the SAGD product includes hydrocarbon material, fuel,
and water, as well as other components. The hydrocarbon material
component of the SAGD product can be from 15 to 35% of the product
and can include, e.g., bitumen, asphaltenes and other heavy
hydrocarbon material. The fuel component of the SAGD product can be
from 0 to 0.5% of the product and can include, e.g., natural gas
and methane. The water component of the SAGD product can be from 65
to 85% of the product.
[0109] The withdrawn SAGD product is subjected to separation
processing in step 520. An objective of the separation processing
is to separate a fuel stream and a hydrocarbon stream from the SAGD
product. Once a fuel stream and a hydrocarbon stream are separated
from the SAGD product, the streams can be used in steam generation
and hydrocarbon upgrading to provide for beneficial process
integration. Any equipment capable of separating these streams from
the SAGD product can be used. In some embodiments, the separations
are carried out in multiple separation apparatus. For example, a
first separation can be carried out in an emulsion breaker tank,
followed by a separation in a distillation unit.
[0110] The fuel stream separated in step 510 can be used in step
520, where an air stream and the fuel stream are injected into a
combustor and a combustion flame is produced in the combustion
chamber. Step 520 is similar or identical to step 100 described in
greater detail above, with the condition that at least a portion of
the fuel stream used in step 520 is derived from the SAGD product
withdrawn in step 500 and separated in step 510. Typically, make-up
fuel, such as imported natural gas, will be necessary to provide a
sufficient amount of fuel to produce steam.
[0111] The water needed for 530 is typically provided by a source
of water independent from the SAGD product. Any water source
suitable for use in generating steam in a combustor can be used.
The water is atomized, injected into the combustion chamber, and
steam is formed. Step 530 is similar or identical to step 110
described in greater detail above. In some embodiments, water from
the SAGD product can be used in addition to or in place of the
independent water source, although water from the SAGD produce will
typically require pretreatment prior to being used in the combustor
to generate steam. A typical required pretreatment process for
water derived from SAGD product is a silica removing process.
Without such a silica removing process, scaling of process
equipment such as the nozzle reactor can occur.
[0112] When the upgrading process is integrated with the SAGD
recovery process, the steam produced in step 530 can be used in
both processes. In step 540, a first portion of the steam is
injected into a nozzle reactor to carry out hydrocarbon cracking
and upgrading as described in greater detail above. Step 540 is
similar or identical to step 120 described in greater detail above,
with the condition that only portion of the steam produced in the
combustion chamber is injected into the nozzle reactor. The first
portion of steam injected into the nozzle reactor can be any
suitable amount needed to carry out the upgrading in the nozzle
reactor. Any mechanism known to those of ordinary skill in the art
can be used withdraw only a portion of the steam produced in the
combustion chamber.
[0113] In step 550, the hydrocarbon stream separated from the SAGD
product in step 510 is injected into the nozzle reactor to interact
with the steam injected into the nozzle reactor in step 540 and
crack and upgrade the hydrocarbon material. Step 550 can be similar
or identical to step 130 described in greater detail above, with
the condition that at least a portion of the hydrocarbon material
used in step 550 is derived from the SAGD product withdrawn in step
500 and separated in step 510. To the extent necessary, additional
make-up hydrocarbon material may be used.
[0114] In step 560, a second portion of the steam formed in the
combustion chamber in step 530 is injected into a SAGD injection
well. An objective of injecting steam into the SAGD injection well
is to assist with continued hydrocarbon recovery via the SAGD
operation. The SAGD injection well can be any type of SAGD
production well known to those of ordinary skill in the art for
recovery hydrocarbon material from hydrocarbon deposits. Generally
speaking, the SAGD injection well has a first end located within a
deposit of hydrocarbon material and a second end above ground where
steam is entered into the well. Typically, the end of the injection
well within the deposit will be oriented in a horizontal direction
and will be located above a SAGD production. Steam transported
through the SAGD injection well is injected into the deposit of
hydrocarbon material in order to lower the viscosity of the
hydrocarbon material and cause it to flow downwardly under the
force of gravity. Located beneath the SAGD injection well is the
SAGD production well discussed above, which can receive the flowing
hydrocarbon material and transport it above ground.
[0115] In some embodiments, the amount of steam required for the
SAGD recovery operation is supplied by the second portion of steam
generated in the combustion chamber and allocated for use in the
SAGD process. However, in embodiments where an insufficient amount
of steam is formed in the combustion chamber, make-sup steam can be
provided to the SAGD injection well. Any suitable source of make-up
steam can be used.
[0116] With reference to FIG. 6, a system that can be used to carry
out embodiments of the methods described above includes a combustor
610, a SAGD injector 620, a nozzle reactor 630, a SAGD producer
640, and a separation unit 650. As described in greater detail
above, fuel 611, water 612, and air 613 are injected into the
combustor 610 to produce steam 615. A portion of the produced steam
615a can be transported to the SAGD injector 620 for use in
carrying out the SAGD process. A portion of the produced steam 615b
can be transported to the nozzle reactor 630 for use in upgrading a
stream of heavy hydrocarbon material 631 being injected into the
nozzle reactor 630. The SAGD producer 640 produces a SAGD product
641 that can include hydrocarbon material, fuel, and water. The
SAGD product 641 is therefore sent to a separation unit 650 capable
of separating a fuel stream 652 and a hydrocarbon stream 653 from
the SAGD product 641. Leftover SAGD product, including water, can
leave the separation unit 650 via leftover stream 651. Fuel stream
652 separated from the SAGD product 641 in the separation unit 650
can be sent to the combustor 610, while hydrocarbon stream 653 in
need of upgrading can be sent to the nozzle reactor 630.
[0117] As described in greater detail above, the combustor 610 can
be any type of combustor suitable for converting water into steam,
and in some embodiments, includes an atomizer for receiving water
612 and injecting the water 612 in atomized form into the
combustion chamber of the combustor 610. The source of the water is
not limited, and can include, for example, sea water when the
system is located on an off-shore platform. The air 613 injected
into the combustor can come from any suitable source, and in some
embodiments if provided by a turbine. Gas turbine exhaust can be
useful in the process described herein because it is provided at a
high temperature and pressure. If the air 613 is not gas turbine
exhaust, additional equipment to heat and compress the air prior to
injection into the combustor 610 can be provided. Gas turbine
exhaust can also be used in conjunction with an air make-up stream
where the gas turbine does not provide a sufficient amount of air
for the combustor 610. The fuel 611 provided to the combustor can
be any fuel for operating the combustor. In some embodiments, the
fuel 611 is natural gas. As described in greater detail below, a
portion or all of the fuel 611 and the water 612 can be provided by
a SAGD process integrated with combustor 610. To the extent that
the SAGD process does not provide a sufficient amount of water
and/or fuel, make-up streams can be provided.
[0118] The steam 615 generated by the combustor can be divided into
two streams, with one steam stream 615b being directed to a nozzle
reactor 630 and the other steam stream 615a being directed to a
SAGD injector 620. Any manner of separating the steam 615 into the
two streams 615a, 615b can be provided and the amount of steam 615
diverted to each stream can be determined based on the amount of
steam 615 produced by the combustor 610 and the steam demands of
the SAGD injector 620 and the nozzle reactor 630.
[0119] The steam 615a directed to the SAGD injector 620 is injected
into the ground to soften hydrocarbon material such as bitumen and
cause the bitumen to flow down towards a SAGD producer. The SAGD
injector 620 can include a plurality of SAGD injectors 620 such
that the steam 615a is distributed to each of the SAGD injectors
620 and a larger area of the bituminous deposit is subjected to
steam injection. In instances where the steam 615a is not
sufficient to supply one or more of the SAGD injectors 620, make up
steam can be provided.
[0120] Steam 615b transported to the nozzle reactor 630 is injected
into the nozzle reactor 630 to interact with a hydrocarbon stream
631 also injected into the nozzle reactor 630. The two materials
interact to crack and upgrade the hydrocarbon stream 631. In some
embodiments, the nozzle reactor 630 is the nozzle reactor described
above and illustrated in FIGS. 3 and 4 such that the steam 615b is
injected into the nozzle reactor 630 in a direction perpendicular
to the direction the hydrocarbon stream 631 is injected into the
nozzle reactor. In instances where steam 615b does not provide a
sufficient amount of steam for the nozzle reactor 630, a make-up
steam stream can be provided to supplement steam 615b. The products
leaving the nozzle reactor 630 can be re-used in the process, such
as when the product stream includes fuel gas, water, and/or
non-upgraded (or insufficiently upgraded) hydrocarbon. The fuel gas
and water can be separated from the product stream and re-used in
the combustor 610, while the non-upgraded hydrocarbon can be
re-injected into the nozzle reactor 630.
[0121] As noted above, the SAGD injector 620 provides steam into a
bituminous deposit to cause bitumen to flow down to a SAGD producer
640. The SAGD producer 640, which may actually be a plurality of
SAGD producers, collects the softened bitumen and transports it
above ground. The SAGD product 641 transported above ground by the
SAGD producer can include heavy hydrocarbon material (such as
bitumen), water, and fuel gas (such as natural gas), along with
other components. Accordingly, a portion of the SAGD product 641
can be transported to a separation unit 650, where the components
of the SAGD product 641 are separated to be used in the system.
[0122] Any separation unit 650 capable of separating a fuel stream
652 and a hydrocarbon stream 653 from the SAGD product 641 can be
used, including various settling and distillation apparatus. Once
separated, the fuel stream 652 can be sent to the combustor 610 for
use in steam generation. The hydrocarbon stream 653 can be sent to
the nozzle reactor 630 for upgrading. Fuel stream make-up and/or
hydrocarbon stream make-up can each be provided in instances where
the separation unit 650 does not provide suitable amounts of either
one of these components.
[0123] While the above described systems and methods generally
reference use of a single nozzle reactor, multiple nozzle reactors
can be used in the systems and methods described herein. The
multiple nozzle reactors can be arranged in series, in parallel, or
any combination of the two. Use of multiple nozzle reactors in
series can generally help to increase the conversion of heavy
hydrocarbon material into lighter hydrocarbon material, such as by
separating heavy hydrocarbon exiting a first nozzle reactor and
running it through a second nozzle reactor located downstream and
whose operating conditions are adjusted to improve the conversion
of heavy hydrocarbons. The use of multiple nozzle reactors in
parallel can increase the amount of hydrocarbon material that can
be processed and can mitigate issues relating to scaling up nozzle
reactors to handle larger capacities.
[0124] In some embodiments of the systems and methods described
herein, separation processing is carried out on the products
produced by the nozzle reactor. Such separation processing can be
carried out on an offshore platform in embodiments where the nozzle
reactor and/or combustor are located on an offshore platform. Any
manner of separating the hydrocarbon product can be used. In some
embodiments, cyclone separators are used. Cyclone separators can be
useful due to their relatively small foot print. The hydrocarbon
products can be separated into, for example, a lights, middle
distillate, and residue stream. The residue stream may be recycled
back into the nozzle reactor for further upgrading.
[0125] While the invention has been particularly shown and
described with reference to a preferred embodiment thereof, it will
be understood by those skilled in the art that various other
changes in the form and details may be made without departing from
the spirit and scope of the invention.
[0126] A presently preferred embodiment of the present invention
and many of its improvements have been described with a degree of
particularity. It should be understood that this description has
been made by way of example, and that the invention is defined by
the scope of the following claims.
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