U.S. patent application number 13/666108 was filed with the patent office on 2013-05-02 for systems and methods for integrating bitumen extraction with bitumen upg....
This patent application is currently assigned to MARATHON OIL CANADA CORPORATION. The applicant listed for this patent is Mahendra Joshi, Jose Armando Salazar. Invention is credited to Mahendra Joshi, Jose Armando Salazar.
Application Number | 20130105362 13/666108 |
Document ID | / |
Family ID | 48171294 |
Filed Date | 2013-05-02 |
United States Patent
Application |
20130105362 |
Kind Code |
A1 |
Salazar; Jose Armando ; et
al. |
May 2, 2013 |
SYSTEMS AND METHODS FOR INTEGRATING BITUMEN EXTRACTION WITH BITUMEN
UPG...
Abstract
Methods and systems for integrating bitumen extraction processes
with bitumen upgrading processes are disclosed. The methods and
systems can include recovering an emulsion of hydrocarbon and water
from a Steam Assisted Gravity Drainage extraction process, breaking
the emulsion, using the water from the emulsion to make steam,
upgrading the hydrocarbon from the emulsion using the steam,
separating diluent from the upgraded hydrocarbon, and using the
diluent to break SAGD-produced emulsion.
Inventors: |
Salazar; Jose Armando;
(Ashland, KY) ; Joshi; Mahendra; (Katy,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Salazar; Jose Armando
Joshi; Mahendra |
Ashland
Katy |
KY
TX |
US
US |
|
|
Assignee: |
MARATHON OIL CANADA
CORPORATION
Calgary
CA
|
Family ID: |
48171294 |
Appl. No.: |
13/666108 |
Filed: |
November 1, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61554818 |
Nov 2, 2011 |
|
|
|
Current U.S.
Class: |
208/88 ;
166/52 |
Current CPC
Class: |
C10G 57/00 20130101;
C10G 1/047 20130101; C10G 1/02 20130101; E21B 43/2408 20130101;
C10G 33/00 20130101 |
Class at
Publication: |
208/88 ;
166/52 |
International
Class: |
C10G 57/00 20060101
C10G057/00; E21B 43/24 20060101 E21B043/24 |
Claims
1. A method comprising: recovering a first quantity of an emulsion
of hydrocarbon material and water from a Steam Assisted Gravity
Drainage system; adding an emulsion breaker to the first quantity
of emulsion and providing a water stream and a dilbit stream;
converting the water stream to steam; upgrading the dilbit stream
using the steam and providing an upgraded hydrocarbon stream;
separating a diluent stream from the upgraded hydrocarbon stream;
and adding the diulent stream to a second quantity of the emulsion
recovered from the Steam Assisted Gravity Drainage system.
2. The method of claim 1, wherein the emulsion breaker comprises a
hydrocarbon solvent having a boiling point in the range of from -44
to 800.degree. F.
3. The method of claim 1, wherein the emulsion breaker comprises
paraffinic solvent.
4. The method of claim 1, wherein the emulsion breaker is obtained
from an upgraded stream of SAGD-derived hydrocarbon material.
5. The method of claim 1, wherein the emulsion breaker is added to
the emulsion at a ratio of from 5 to 30 on a volume basis.
6. The method of claim 1, wherein adding an emulsion breaker to the
emulsion and providing a water stream and a dilbit stream comprises
separating the water stream from the dilbit stream by settling or
hydrocycloning the dilbit stream.
7. The method of claim 1, wherein the water stream is subjected to
water treatment prior to being converted to steam.
8. The method of claim 1, wherein the steam is converted to
superheated steam.
9. The method of claim 1, wherein upgrading the dilbit stream using
the steam and providing an upgraded hydrocarbon stream comprises:
injecting the steam through a converging then diverging passage of
a cracking material injector into a reaction chamber, wherein
passing the steam through the converging then diverging passage
accelerates the steam to supersonic speed; and injecting the dilbit
into the reaction chamber adjacent to the steam entering the
reaction chamber from the cracking material injector and cracking
the dilbit at least proximate the intersection of the steam and the
dilbit.
10. The method of claim 1, wherein the diluent comprises a
hydrocarbon solvent having a boiling point in the range of from -44
to 800.degree. F.
11. The method of claim 1, wherein hydrocarbon residue is separated
from the upgraded hydrocarbon stream prior to separating a diluent
stream from the upgraded hydrocarbon stream.
12. A system comprising: a Steam Assisted Gravity Drainage system
comprising an injection well and a production well; an emulsion
breaking unit comprising a production well inlet, an emulsion
breaker inlet, a water stream outlet, and a dilbit stream outlet,
wherein the production well of the SAGD system is in fluid
communication with the production well inlet of emulsion breaking
unit; a steam generation unit comprising a water stream inlet and a
steam outlet, wherein the water stream outlet of the emulsion
breaking unit is in fluid communication with the water stream inlet
of the steam generation unit; a nozzle reactor comprising a steam
inlet, a dilbit inlet, and an upgraded hydrocarbon outlet, wherein
the steam outlet of the steam generation unit is in fluid
communication with the steam inlet of the nozzle reactor and the
dilbit stream outlet of the emulsion breaking unit is in fluid
communication with the dilbit inlet of the nozzle reactor; and a
separation unit comprising an upgraded hydrocarbon inlet and a
diluent outlet, wherein the upgraded hydrocarbon outlet of the
nozzle reactor is in fluid communication with the upgraded
hydrocarbon inlet of the separation unit, and wherein diluents
outlet of the separation unit is in fluid communication with the
diluent inlet of the emulsion breaking unit.
Description
[0001] This application claims priority to U.S. Provisional Patent
Application No. 61/554,818, filed Nov. 2, 2011, the entirety of
which is hereby incorporated by reference.
BACKGROUND
[0002] Steam Assisted Gravity Drainage (SAGD) is a known process
for extracting bitumen from oil sands deposits. In the typical SAGD
process, two parallel horizontal oil wells are drilled in the oil
sand formation, one about 4 to 6 metres above the other. The upper
well injects steam and the lower one collects the heated bitumen
that flows out of the formation. The basis of the process is that
the injected steam forms a "steam chamber" that grows vertically
and horizontally in the formation. The heat from the steam reduces
the viscosity of the bitumen, which allows it to flow down into the
lower wellbore. The bitumen is recovered to the surface by pumps
such as progressive cavity pumps that work well for moving
high-viscosity fluids with suspended solids.
[0003] In some SAGD processes, the bitumen that flows down to the
lower wellbore is accompanied by water formed from the condensation
of the injected steam. As a result, the bitumen recovered to the
surface by the production well can be in the form of a
bitumen-water emulsion. Accordingly, additional steps may need to
be carried out to break the emulsion prior to being able to conduct
further processing steps on the bitumen, such as bitumen upgrading.
These additional steps can increase the overall cost of the
process. For example, emulsion breaking materials may need to be
purchased and supplied to the SAGD site.
[0004] The SAGD process can also be costly due to the need for
steam to drive the process. As in all thermal recovery processes,
cost of steam generation is a major part of the cost of oil
production. A water source is also generally required for creating
steam and driving the SAGD process, which can further increase the
cost and complexity of the process.
SUMMARY
[0005] This Summary is provided to introduce a selection of
concepts in a simplified form that are further described below in
the Detailed Description. This Summary, and the foregoing
Background, is not intended to identify key aspects or essential
aspects of the claimed subject matter. Moreover, this Summary is
not intended for use as an aid in determining the scope of the
claimed subject matter.
[0006] In some embodiments, a method of integrating SAGD bitumen
extraction techniques and nozzle reactor upgrading techniques is
disclosed. The method can include a step of recovering a first
quantity of an emulsion of hydrocarbon material and water from a
Steam Assisted Gravity Drainage system; a step of adding an
emulsion breaker to the first quantity of emulsion and providing a
water stream and a dilbit stream; a step of converting the water
stream to steam; a step of upgrading the dilbit stream using the
steam and providing an upgraded hydrocarbon stream; a step of
separating a diluent stream from the upgraded hydrocarbon stream;
and a s step of adding the diulent stream to a second quantity of
the emulsion recovered from the Steam Assisted Gravity Drainage
system.
[0007] In some embodiments, a system for extracting and upgrading
bitumen is disclosed. The system can include a Steam Assisted
Gravity Separation system comprising an injection well and a
production well; an emulsion breaking unit comprising a production
well inlet, an emulsion breaker inlet, a water stream outlet, and a
dilbit stream outlet, wherein the production well of the SAGD
system is in fluid communication with the production well inlet of
emulsion breaking unit; a steam generation unit comprising a water
stream inlet and a steam outlet, wherein the water stream outlet of
the emulsion breaking unit is in fluid communication with the water
stream inlet of the steam generation unit; a nozzle reactor
comprising a steam inlet, a dilbit inlet, and an upgraded
hydrocarbon outlet, wherein the steam outlet of the steam
generation unit is in fluid communication with the steam inlet of
the nozzle reactor and the dilbit stream outlet of the emulsion
breaking unit is in fluid communication with the dilbit inlet of
the nozzle reactor; and a separation unit comprising an upgraded
hydrocarbon inlet and a diluent outlet, wherein the upgraded
hydrocarbon outlet of the nozzle reactor is in fluid communication
with the upgraded hydrocarbon inlet of the separation unit, and
wherein diluents outlet of the separation unit is in fluid
communication with the diluent inlet of the emulsion breaking
unit.
[0008] Various advantages can be achieved from the methods and
systems described herein. The methods and systems are integrated
such that at least partial self sufficiency is obtained. Various
product streams produced throughout the method and system can be
reused in the method and system to continue operation of the
methods and system. For example, diluent produced by the upgrading
of hydrocarbon material can be mixed with the emulsion obtained
from the SAGD process to thereby break the emulsion and separate a
water stream from the extracted hydrocarbon material. The separated
water can then be used to drive either or both of the SAGD and
nozzle reactor upgrading processes.
[0009] These and other aspects of the present system will be
apparent after consideration of the Detailed Description and
Figures herein. It is to be understood, however, that the scope of
the invention shall be determined by the claims as issued and not
by whether given subject matter addresses any or all issues noted
in the Background or includes any features or aspects recited in
this Summary.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The preferred and other embodiments are disclosed in
association with the accompanying drawings in which:
[0011] FIG. 1 is a flow chart illustrating a method of integrating
bitumen recovery and bitumen upgrading according to various
embodiments described herein;
[0012] FIG. 2 shows a cross-sectional view of one embodiment of a
nozzle reactor suitable for use in various embodiments of the
systems and methods described herein;
[0013] FIG. 3 shows a cross-sectional view of the top portion of
the nozzle reactor shown in FIG. 2;
[0014] FIG. 4 shows a cross-sectional perspective view of the
mixing chamber in the nozzle reactor shown in FIG. 2;
[0015] FIG. 5 shows a cross-sectional perspective view of the
distributor from the nozzle reactor shown in FIG. 2;
[0016] FIG. 6 shows a cross-sectional view of another embodiment of
a nozzle reactor suitable for use in various embodiments of the
systems and methods described herein;
[0017] FIG. 7 shows a cross-sectional view of the top portion of
the nozzle reactor shown in FIG. 6; and
[0018] FIG. 8 is a block diagram illustrating various embodiments
of the system disclosed herein.
DETAILED DESCRIPTION
[0019] With reference to FIG. 1, a method of recovering and
upgrading bitumen material includes a step 1000 of recovering a
first quantity of emulsion material from a SAGD system, a step 1100
of adding an emulsion breaker to the first quantity of emulsion to
produce a water stream and a dilbit stream, a step 1200 of
converting the water stream to steam, a step 1300 of upgrading the
dilbit stream using the steam produced in step 1200, a step 1400 of
separating a diluents from the upgraded hydrocarbon stream produced
in step 1300, and a step 1500 of adding the diluent obtained in
step 1400 to a second quantity of emulsion material recovered from
the SAGD system. The method and associated system provide a manner
for the method and system to be at least partially self sustaining
by using steam and diluent produced by the method to continue
operating the method. In so doing, the method is made less
expensive and becomes less dependent on outside sources for
materials required to drive the process.
[0020] In step 1000, emulsion material is recovered using a SAGD
system. The SAGD system can include any SAGD system or variation on
a SAGD system known to those of ordinary skill in the art, and will
generally include at least one horizontal injection well and one
horizontal production well formed in a deposit of bituminous
material. The injection well is typically positioned above the
production well, such that bituminous material heated by the steam
injected into the deposit via the injection well will flow down to
the production well, where it can then be recovered to the surface
through the use of pumps. The bitumen deposit in which the SAGD
system is established is not limited, and can include, for example
oil sands or tar sands deposits, such as those found in the
Athabasca region of Alberta, Canada.
[0021] Because a portion of the steam injected into the deposit of
bituminous material is likely to condense, the bituminous material
that flows down to the production well can include water. Water can
also be present due to the natural presence of water in the
formation that will flow down to the production well with the
warmed bituminous material. As a result of this water, the material
that is pumped to the surface via the production well can be in the
form of an emulsion of water and bituminous material. In some
embodiments, the emulsion will include from 25 to 50 wt % bitumen
and from 50 to 85 wt % water. Other components can also be present
in the emulsion, such as non-bituminous solid particles (e.g.,
sand, clay, etc) and materials added to the injected steam, such as
solvents used for aiding in the extraction of bitumen from the
formation.
[0022] Upon collection of the emulsion obtained from the SAGD
system, steps can be carried out to break the emulsion. In some
embodiments, step 1100 includes adding an emulsion breaker to the
emulsion to break the emulsion and create two separate phases--a
water phase and dilbit phase. Any material suitable for use in
breaking an emulsion of bitumen and water can be used. In some
embodiments, the emulsion breaker is a hydrocarbon solvent. The
hydrocarbon solvent can be a hydrocarbon solvent having a boiling
point in the range of from -44 to 800.degree. F. In some
embodiments, the hydrocarbon solvent is a paraffinic solvent, such
as pentane or hexane. In some embodiments, the emulsion breaker is
a hydrocarbon fraction obtained from downstream upgrading of
bitumen material derived from the SAGD system, as described in
greater detail below.
[0023] The emulsion breaker may be added in any amount necessary to
break the emulsion and create to separate phases. In some
embodiments, the emulsion breaker is added at a ratio of from 5 to
30 (on a volume basis). The emulsion breaker can be added to the
emulsion in any suitable manner, such as through the use of a
mixing vessel where the emulsion can be stored and emulsion breaker
can be introduced into the mixing vessel. Upon introduction, the
emulsion and emulsion breaker can be mixed, such as through the use
of mixing blades, to promote breaking of the emulsion and
separating the material into two distinct phases. When a sufficient
amount of emulsion breaker has been added to the emulsion (and, in
some cases, suitably mixed with the emulsion), the dilbit phase
will rest on top of the water phase. The dilbit phase generally
will include the bitumen material and the emulsion breaker. In
instances where the emulsion breaker is a hydrocarbon solvent, the
dilbit phase can include bitumen diluted in the hydrocarbon
solvent.
[0024] Once the emulsion has been broken and two distinct phases
have been formed, the two phases can then be separated by any
suitable technique known to those of ordinary skill in the art. For
example, a decanting process can be used to remove the bitumen
material phase off the top of the water phase. In some embodiments,
mixing of the emulsion and the emulsion breaker and separation of
dilbit phase from the water phase can be carried out in the same
vessel.
[0025] In step 1200, the water phase obtained from breaking the
emulsion and separating the dilbit phase can be converted to steam.
Any manner of converting the water phase to steam can be used, and
will generally include heating the water phase. In some
embodiments, the water phase is converted to steam by passing the
water through a heat exchanger. Additional water, such as make-up
water, can be added to the water phase before converting the water
phase to steam.
[0026] In some embodiments, the water phase is subjected to water
treatment prior to being convened to steam. Water treatment can
include any water treatment steps that place the water phase in
better condition for being converted to steam. Exemplary water
treatment steps include lime treatment, blow down recirculation,
de-oiling, and pH optimization.
[0027] The steam produced in step 1200 can generally be used in two
different applications. In a first application, a portion of the
steam produced in step 1200 is used to further drive the SAGD
process. Generally speaking, this will include injecting the steam
into the injection wells so that the steam can warm deposits of
bitumen material and cause the bitumen material to flow into
productions wells. In a second application, a portion of the steam
produced in step 120 is used to upgrade the dilbit phase obtained
in step 110. As described in greater detail below, such upgrading
can be carried out in a nozzle reactor. The nozzle reactor allows
for the steam and the dilbit to be injected into the nozzle
reactor, wherein the interaction of the two streams results in the
cracking and upgrading of the hydrocarbon component of the
dilbit.
[0028] In some embodiments, the steam is converted to superheated
steam prior to be used to upgrade the dilbit stream. Any manner of
converting the steam to superheated steam can be used. In some
embodiments, conversion of steam to superheated steam is
accomplished by sending a portion of the steam to a fire heater in
order to raise the temperature of the steam to about 1,250.degree.
F.
[0029] In step 1300, the dilbit stream is upgraded using the steam
produced in step 1200. Any manner of upgrading hydrocarbons in a
dilbit stream using steam known to those of ordinary skill in the
art can be used in the methods described herein. In some
embodiments, the steam from step 1200 is used to upgrade the dilbit
stream by using a nozzle reactor wherein the dilbit stream and the
steam are both introduced into the nozzle reactor and interact in a
manner that results in the steam cracking and upgrading of
hydrocarbons in the dilbit to lighter, more commercially valuable
hydrocarbon products. Any suitable nozzle reactor can be used to
promote the interaction between injected dilbit stream and injected
steam. In some embodiments, the nozzle reactor can be similar or
identical to the nozzle reactor described in U.S. Pat. No.
7,618,597; U.S. Pat. No. 7,927,565, U.S. Pat. No. 7,988,847; U.S.
patent application Ser. No. 12/579,193; U.S. patent application
Ser. No. 12/749,068; U.S. patent application Ser. No. 12/816,844;
U.S. patent application Ser. No. 12/911,409; U.S. patent
application Ser. No. 13/227,470, U.S. patent application Ser. No.
13/292,747; U.S. patent application Ser. No. 13/532,453; U.S.
patent application Ser. No. 13/589,927; and/or U.S. patent
application Ser. No. 13/593,045, each of which is hereby
incorporated by reference in its entirety.
[0030] FIGS. 2 and 3 show cross-sectional views of one 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.
[0031] 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.
[0032] 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.
[0033] 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. The reacting fluid can be a variety of
materials, including steam or natural gas.
[0034] 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. 2 and 3, 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.
[0035] 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".
[0036] 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.
[0037] 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.
[0038] 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.
[0039] 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).
[0040] 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.
[0041] 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.
[0042] 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.
[0043] 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.
[0044] As shown in FIG. 3, 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.
[0045] 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.
[0046] 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.
[0047] 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.
[0048] 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.
[0049] 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.
[0050] As shown in FIG. 5, 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.
[0051] 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.
[0052] 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.
[0053] 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.
[0054] As shown in FIG. 5, 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. 4, 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.
[0055] 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.
[0056] As shown in FIGS. 2 and 3, 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.
[0057] 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.
[0058] 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.
[0059] The dimensions of the nozzle reactor 100 can vary based on
the amount of material that is fed through it. For example, at a
flow rate of approximately 590 kg/hr, the distributor 140 can
include sixteen holes 144 that are 3 mm in diameter. The dimensions
of the various components of the nozzle reactor shown in FIGS. 2
and 3 are not limited, and may generally be adjusted based on the
amount of feed flow rate if desired. Table 1 provides exemplary
dimensions for the various components of the nozzle reactor 100
based on a hydrocarbon feed input measured in barrels per day
(BPD).
TABLE-US-00001 TABLE 1 Exemplary nozzle reactor specifications Feed
Input (BPD) Nozzle Reactor Component (mm) 5,000 10,000 20,000 Main
passage, first region, entry opening 254 359 508 diameter Main
passage, first region, throat diameter 75 106 150 Main passage,
first region, exit opening 101 143 202 diameter Main passage, first
region, length 1129 1290 1612 Wear ring internal diameter 414 585
828 Main passage, second region, entry opening 308 436 616 diameter
Main passage, second region, throat diameter 475 672 950 Main
passage, second region, exit opening 949 1336 1898 diameter Nozzle
reactor, body portion, outside diameter 1300 1830 2600 Nozzle
reactor, overall length 7000 8000 10000
[0060] It should be appreciated that the nozzle reactor 100 can be
configured in a variety of ways that are different than the
specific design shown in the Figures. For example, the location of
the openings 110, 112, 114, 116 may be placed in any of a number of
different locations. Also, the nozzle reactor 100 may be made as an
integral unit instead of comprising two or more portions 102, 104.
Numerous other changes may be made to the nozzle reactor 100.
[0061] Turning to FIGS. 6 and 7, another embodiment of a nozzle
reactor 200 is shown. This embodiment is similar in many ways to
the nozzle reactor 100. Similar components are designated using the
same reference number used to illustrate the nozzle reactor 100.
The previous discussion of these components applies equally to the
similar or same components includes as part of the nozzle reactor
200.
[0062] The nozzle reactor 200 differs a few ways from the nozzle
reactor 100. The nozzle reactor 200 includes a distributor 240 that
is formed as an integral part of the body portion 204. However, the
wear ring 150 is still a physically separate component that can be
removed and replaced. Also, the wear ring 150 depicted in FIG. 7 is
coupled to the distributor 240 using bolts instead of by welding.
It should be noted that the bolts are recessed in the top surface
of the wear ring 150 to prevent them from interfering with the flow
of the feed material.
[0063] In FIGS. 6 and 7, the head portion 102 and the body portion
104 are coupled together with a clamp 280. The seal, which can be
metal or plastic, resembles a "T" shaped cross-section. The leg 282
of the "T" forms a rib that is held by the opposing faces of the
head and body portions 102, 104. The two arms or lips 284 form
seals that create an area of sealing surface with the inner
surfaces 276 of the portions 102, 104. Internal pressure works to
reinforce the seal.
[0064] The clamp 280 fits over outer flanges 286 of the head and
body portions 102, 104. As the portions 102, 104 are drawn together
by the clamp, the seal lips deflect against the inner surfaces 276
of the portions 102, 104. This deflection elastically loads the
lips 284 against the inner surfaces 276 forming a self-energized
seal. In one embodiment, the clamp is made by Grayloc Products,
located in Houston, Tex.
[0065] When a nozzle reactor as shown in FIGS. 2 through 7 is used
to upgrade the dilbit stream using steam, the dilbit stream can be
introduced into the nozzle reactor via entry opening 114 of feed
passage 108. The steam can be introduced into the nozzle reactor
via entry opening 110 of main passage 106, at which point the steam
is accelerated to supersonic speed so that it can interact with the
injected dilbit stream and crack the hydrocarbon components of the
dilbit stream.
[0066] An upgraded hydrocarbon stream is provided as a result of
step 1300. The upgraded hydrocarbon stream can include light
hydrocarbon, molecules formed as a result of cracking heavier
hydrocarbon molecules introduced into the nozzle reactor as part of
the dilbit stream. The upgraded hydrocarbon stream can also include
hydrocarbon molecules that passed through the nozzle reactor
without being cracked. Generally speaking, the upgraded hydrocarbon
stream will include hydrocarbon molecules having a wide range of
molecular weights, such as from 16 to 500. Other components can
also be included in the upgraded hydrocarbon stream, including
solvent and steam. In some embodiments, the upgraded hydrocarbon
stream exits the nozzle reactor at, for example, exit opening 112,
where it is collected for further processing.
[0067] In some embodiments, step 1300 can be carried out using
multiple nozzle reactors. For example, two nozzle reactors can be
used in parallel to crack and upgrade components of the dilbit
stream. In such embodiments, the steam produced in step 1200 is
split into multiple streams (i.e., one stream for each nozzle
reactor) and the dilbit stream is separated into multiple streams
(i.e., one stream for each nozzle reactor). The upgraded
hydrocarbon streams leaving each nozzle reactor can be combined and
subjected to further processing. Optionally, one or more of the
upgraded hydrocarbon streams leaving the nozzle reactors can be
subjected to separation processing to separate any pitch from the
upgraded hydrocarbon streams prior to subjecting the upgraded
hydrocarbon streams to further processing.
[0068] In some embodiments, the dilbit stream is subjected to a
separation step prior to being upgraded in the nozzle reactors. The
separation step can separate certain components of the dilbit
stream that do not require treatment in the nozzle reactor. For
example, the dilbit stream can include some hydrocarbon molecules
with a sufficiently low molecular weight. These low molecular
weight hydrocarbon molecules are already in a desirable form and
therefore do not require further cracking and upgrading. A
separation step can remove these hydrocarbons from the dilbit
stream. Any suitable separation unit can be used to carry out this
separation. In some embodiments, the separation unit is a
distillation tower wherein hydrocarbons with a boiling temperature
below a certain selected temperature are removed from the dilbit
stream. The separation unit can also be a hydrocyclone capable of
separating the lighter molecules from the heavier molecules via
centrifugal forces. The separation unit can be designed to separate
the dilbit stream based on a predetermined cut off temperature,
molecular weight, or the like. In some embodiments, it is desirable
that predominantly pitch materials be sent to the nozzle reactors,
in which case a boiling point temperature cut off of 1,500.degree.
F. can be selected (in the case of a distillation tower) or a
molecular weight cut off of 500 can be selected (in the case of a
hydrocyclone).
[0069] In step 1400, the upgraded hydrocarbon stream is processed
to separate a diluent stream from the upgraded hydrocarbon stream.
The diluent stream separated from the upgraded hydrocarbon stream
will generally include hydrocarbon molecules within a certain range
of boiling point temperatures or molecular weights. For example, in
some embodiments, the diluent stream includes most or all of the
hydrocarbon molecules in the upgraded hydrocarbon stream that have
a boiling point temperature in the range of from -40 to 800.degree.
F. In another example, the diluent stream includes most or all of
the hydrocarbon molecules in the upgraded hydrocarbon stream that
have a molecular weight in the range of from 58 to 500.
[0070] Any manner of separating the diluent stream from the
upgraded hydrocarbon stream can be used. In some embodiments, one
or more separation units are used to isolate the diluent stream.
Any type of separation unit can be used, and in some embodiments,
the separation unit is a distillation tower, such as an atmospheric
distillation tower or a vacuum distillation tower. In a specific
example, the upgraded hydrocarbon stream is first separated in a
mid-distillate separation unit which separates mid-distillate from
the upgraded hydrocarbon stream. The separated mid-distillate is
treated as product, while the light distillate vapor leaving the
top of the separation unit is condensed and transferred to a three
phase separator. The three phase separator separates the light
distillate into three streams: a liquid water stream, a liquid
diluent stream, and a gas stream. The water stream and diluent
stream generally leave the bottom of the three phase separator,
while the gas stream leaves the top of the three phase separator.
The water stream can be recycled back in the process for use in the
generation of steam. The gas stream can be generally C1 through C5
hydrocarbon (e.g., methane and ethane), hydrogen, and hydrogen
sulfide. In order to remove the hydrogen sulfide and provide fuel
gas, the gas stream leaving the three phase separator can be
treated in an acid gas treating unit.
[0071] In step 1500, the diluent stream separated from the upgraded
hydrocarbon stream is recycled back in the process to be used in
the emulsion breaking step 1100 described in greater detail above.
The diluent stream is combined with the product of the SAGD system
to break the water/oil emulsion and create a dilbit stream that can
be subjected to upgrading. In some embodiments, the diluent stream
is combined with make up diluent stream to provide a sufficient
amount of the emulsion breaker for step 1100.
[0072] In a variation on the separation of the upgraded hydrocarbon
material described above, the upgraded hydrocarbon stream is
separated with the aim of providing a steam stream that can be
recycled back in the process for use in the SAGD system, the nozzle
reactors, or both. In such embodiments, the upgraded hydrocarbon
stream is separated in a series of separation units. A first
separation unit can include a distillation tower that removes
mid-distillates from the upgraded hydrocarbon stream. The vapor
leaving the top of the first separation unit can be condensed and
then introduced into a light distillate separator. The light
distillate separator can include a distillation tower configured
for separating light distillate from a feed stream. In some
embodiments, the light distillate separator separates the liquid
light distillate from water, and the water leaves the separator in
the form of steam. The liquid light distillate can be combined with
the mid-distillate and the combined stream can be treated as
product. The steam can be recycled back in the method for use in
the injection wells of the SAGD system, for use in the nozzle
reactors, or both.
[0073] In some embodiments, the separated steam can be superheated
as it is recycled back in the method for use in, e.g., the
injection wells of the SAGD system. In some embodiments,
superheating the steam can be accomplished using hot pitch produced
in the method described herein. For example, as described above in
greater detail, the upgraded hydrocarbon material leaving the
nozzle reactors can be subjected to separation processing in order
to remove pitch from the upgraded hydrocarbon steam. This hot pitch
can be used to superheat the steam recovered from the separation
steps so that superheated steam is provided for the SAGD
system.
[0074] The above variation can be useful because separation steps
that are used to beneficially separate mid and light distillate
also separates water from these products in the form of steam. As a
result, less steam production is required at other portions of the
method, which ultimately provides an overall cost savings due to
decreased energy needs. In other methods, the separation steps used
to recover the mid and light distillates produce a liquid water
stream, which requires heating in order for the water to be reused
in the process as steam. In other methods, the separation steps can
produce steam, but the steam is typically condensed back to water
after separation.
[0075] With reference to FIG. 8, a system for carrying out the
method described above is shown. The system includes a Steam
Assisted Gravity Drainage system 800, an emulsion breaking unit
810, a steam generation unit 820, a nozzle reactor 830, and a
separation system 850. An aim of the system is to recover and
upgrade bituminous material, while integrating the various
components of the system such that the system is at least partially
self-sufficient with respect to various materials streams need to
drive the system.
[0076] The SAGD system 800 can include any SAGD system known to
those of ordinary skill in the art, and will generally include at
least one injection well and at least one production well. The SAGD
system 800 is established at a bituminous material deposit, where
the injection well is provided to inject steam into the bituminous
material deposit. The production well is positioned below the
injection well such that bituminous material heated by the injected
steam will flow down to the production well, where it can then be
pumped to the surface for further processing. In some embodiments,
the material pumped to the surface via the production well includes
water in addition to the bituminous material. The water can be
present due to the injected steam condensing within the deposit
and/or due to water that is naturally present in the deposit. When
water is present with the bituminous material, the material brought
to the surface via the production well can be in the form of an
emulsion.
[0077] The emulsion produced by the production well of the SAGD
system 810 can be transported to an emulsion breaking unit 810. The
emulsion breaking unit 810 generally includes a vessel wherein an
emulsion breaker can be added to and optionally mixed with the
emulsion produced by the SAGD system 800. When mixing can be used
to help promote breaking of the emulsion, the emulsion breaking
unit 810 can include any mechanism known to those in the art for
mixing an emulsion and an emulsion breaker. In some embodiments,
this will include mixing blades or baffles.
[0078] In some embodiments, the emulsion breaking unit 810 will
include an emulsion inlet that is in fluid communication with the
production well of the SAGD system 800 such that emulsion from the
SAGD system 800 can be introduced into the emulsion breaking unit
810. The emulsion breaking unit can also include an emulsion
breaker inlet for introducing emulsion breaker into the emulsion
breaker unit 810.
[0079] The emulsion breaking unit 810 can also include a water
stream outlet and a dilbit stream outlet. These outlet streams are
provided for moving the two phases that are created when the
emulsion breaks out of the emulsion breaking unit 810. In some
embodiments, the emulsion breaking unit can include mechanisms for
separating the two phases and directing them towards their
respective outlet. For example, the emulsion breaking unit can
include mechanisms for decanting the dilbit phase from off the top
of the water phase.
[0080] The water stream leaving the water stream outlet of the
emulsion breaking unit 810 can be transported to a steam generation
unit 820. The steam generation unit 820 can be any type of
equipment suitable for converting water steam, including equipment
that heats the water and/or uses changes in pressure to help
convert water to steam. The steam generation unit 820 can include a
water stream inlet that is in fluid communication with the water
stream outlet of the emulsion breaking unit 810, and a steam outlet
which allows for steam to leave the steam generation unit 820 and
be transported to other equipment, such as to the SAGD system 800
described previously and/or the nozzle reactor described in greater
detail below. When the steam generated in the steam generation unit
820 is transported to equipment located at different parts of the
system, the steam generation unit 820 can include two or more steam
outlets. Alternatively, the steam generation unit 820 can include a
single steam outlet and a mechanism external to the steam
generation unit 820 for dividing the steam stream into two or more
streams that are then transported to equipment located at different
parts of the system.
[0081] While not shown in FIG. 8, the system can include equipment
for converting the steam from steam generation unit 820 into
superheated steam. In some embodiments, the some or all of steam
generated in the steam generation unit 820 can be transported to
the unit capable of converting the steam into superheated steam.
Any suitable method and equipment can be used for converting the
steam to superheated steam.
[0082] Also not shown in FIG. 8 is a water treatment unit that can
be included in the system. The water treatment unit can be located
between the emulsion breaking unit 810 and the steam generation
unit 820, and can be used to treat the water obtained from the
emulsion breaking unit 810 prior to converting into steam in the
steam generation unit 820. Any of a variety of water treatment
units can be used. In some embodiments, the water treatment unit is
a hot lime with cation exchanger (WAC) and is used to reduce silica
content and remove hardness from the water.
[0083] In embodiments where the emulsion breaking unit 810 does not
provide a sufficient amount of water to satisfy the needs of
subsequent processing steps, the system can also include a source
of make up water. In some embodiments, the make up water is added
to the water obtained from the emulsion breaking unit 810 in the
water treatment unit described above, although make up water can be
added at other locations prior to the steam generation unit
820.
[0084] In some embodiments, a portion of the steam produced in the
steam generation unit 820 can be transported to the injection well
of the SAGD system 800. The steam can be injected into the
bituminous deposit to help drive the SAGD process and the recovery
of bituminous material. In some embodiments, the steam diverted to
the SAGD system 800 provides all of the steam needed to operate the
SAGD system 800. In other embodiments, the steam diverted to the
SAGD system 800 is supplemented by another source of steam to
provide sufficient steam for carrying out the SAGD process.
[0085] Steam generated in steam generation unit 820 (and optionally
converted to superheated steam) can be transported to a nozzle
reactor 830. The dilbit stream obtained in the emulsion breaking
unit 810 can also be transported to the nozzle reactor 830 so that
the steam and dilbit stream can each be injected into the nozzle
reactor 830 and caused to interact so that the hydrocarbon material
in the dilbit stream cracks and upgrades. Any nozzle reactor
suitable for upgrading hydrocarbon material using steam can be
used. In some embodiments, the nozzle reactor 830 is similar or
identical to the nozzle reactors described in greater detail
above.
[0086] The nozzle reactor 830 will generally include a steam inlet
and a dilbit inlet. The steam inlet can be in fluid communication
with the steam outlet of the steam generation unit 820. The dilbit
inlet can be in fluid communication with a dilbit outlet of the
emulsion breaking unit 810. The nozzle reactor 830 can also include
an upgraded hydrocarbon stream outlet for transporting upgraded
hydrocarbon material out of the nozzle reactor 830.
[0087] As shown in FIG. 8, the system can include a dilbit
separation unit 835 that is used to separate a portion of the
hydrocarbon material from the dilbit stream prior to the dilbit
stream being injected into the nozzle reactor 830. In some
embodiments, the dilbit separation unit 835 is used to remove light
hydrocarbon material from the dilbit stream, such as hydrocarbon
material having a molecular weight less than 500 or a boiling point
temperature lower than 1,050.degree. F. Hydrocarbon material of
this type is considered to already be commercially useful, and
therefore does not need to be cracked and upgraded in a nozzle
reactor. The dilbit separation unit 835 can be any suitable type of
separation unit, including a distillation tower or one or more
hydrocyclones. After the light hydrocarbon material has been
removed from the dilbit stream, the remainder of the dilbit stream
is transported to the nozzle reactor 830 for upgrading.
[0088] In some embodiments, the system includes two or more nozzle
reactors 830. As shown in FIG. 8, two nozzle reactors 830 are
included in the system. When two or more nozzle reactors 830 are
included, the dilbit stream and the steam are split into multiple
stream (i.e., one stream for each nozzle reactor) so that a dilbit
stream and steam stream are provided for each nozzle reactor. As
also shown in FIG. 8, an upgraded hydrocarbon separator 840 can be
provided for separating certain material from the upgraded
hydrocarbon stream. The upgraded hydrocarbon stream produced by one
or more of the nozzle reactors can be transported to the upgraded
hydrocarbon separator 840 so that pitch material present in the
upgraded hydrocarbon stream can be removed. As shown in FIG. 8, the
upgraded hydrocarbon stream from only one of the two nozzle
reactors is sent to the upgraded hydrocarbon separator 840. The
upgraded hydrocarbon separator 840 can be any type of separator
capable of separating pitch material from the upgraded hydrocarbon
stream, including a distillation tower. After pitch material has
been removed from the upgraded hydrocarbon stream, the remainder of
the upgraded hydrocarbon stream can be transported downstream for
further processing.
[0089] As shown in FIG. 8, the upgraded hydrocarbon stream from
each of the nozzle reactors 830 is transported into the dilbit
separation unit 835. This allows for some of the hydrocarbon
material that has passed through the nozzle reactors 830 uncracked
or insufficiently cracked to be passed through the nozzle reactor
again for another attempt at upgrading the hydrocarbon material.
The hydrocarbon material that has been sufficiently cracked in the
nozzle reactors 830 is separated from the material to be passed to
the nozzle reactors and is routed to further downstream
processing.
[0090] The upgraded hydrocarbon stream (or, in some embodiments,
the light hydrocarbon material separated from the upgraded
hydrocarbon stream) can be transported to a separation unit 850 for
separation of the upgraded hydrocarbon stream. Generally speaking,
the separation unit 850 will include a upgraded hydrocarbon stream
inlet that is in fluid communication with the upgraded hydrocarbon
stream outlet of the nozzle reactor 840. The upgraded hydrocarbon
stream can be separated in a variety of different ways, including
separating the hydrocarbon material included in the stream based on
molecular weight or boiling point temperature. An aim of the
separation unit 850 can be to provide various commercially useful
products. Any suitable separation unit can be used for separating
the upgraded hydrocarbon stream, and in some embodiments, the
separation unit 850 includes two or more separation units.
[0091] As shown in FIG. 8, the separation unit 850 includes two
separation units. The first separation unit is used to separate the
upgraded hydrocarbon stream into a mid distillates stream and a
light distillates stream. In some embodiments, the mid distillates
include the hydrocarbon compounds having a boiling point
temperature in the range of from 383 to 1,110.degree. F., and the
light distillates stream includes hydrocarbon compounds having a
boiling point temperature less than 1,050.degree. F. The separation
unit used for this separation can include, for example, a
distillation tower.
[0092] The mid distillate stream can be treated as a product
stream, while the light distillate stream can be transported to a
second separation unit. The second separation unit can be used to
separate the remaining components of the light distillate stream.
In some embodiments, the light distillates includes a water
content, and so one aim of the second separation unit can be to
separate the water from the hydrocarbon material. The second
separator can be any suitable type of separation unit, and in some
embodiments, the second separation unit is a 3-phase separator
capable of producing two liquid streams and a gas stream. The light
distillate stream can be separated in a 3-phase separator to
produce a liquid water stream, a liquid diluent stream, and a gas
stream. The liquid diluent stream can include hydrocarbon materials
within a given range of molecular weights or boiling point
temperatures, such as between. The gas can include C1 through C5
hydrocarbons, hydrogen, and hydrogen sulfide.
[0093] In some embodiments, the diluent stream produced by the
separation unit 850 is transported back in the system for use as
the emulsion breaker in the emulsion breaking unit 810.
Accordingly, the separation unit can include a diluent outlet and
the diluent outlet can be in fluid communication with the diluents
inlet of the emulsion breaking unit 810 (which can also be the
emulsion breaker inlet of the emulsion breaking unit 810.
[0094] The water obtained from the separation unit 850 can also be
reused in the system, such as by transporting the water to the
steam generation unit 820. The water can then be converted to steam
and used in either the SAGD system 800 or the nozzle reactor 830.
The separation unit 850 can therefore include a water outlet that
is in fluid communication with the water inlet of the steam
generation unit 820.
[0095] In some embodiments, the separation unit 850 can includes a
second separation unit designed to remove water in the form of
steam from the hydrocarbon material in the light distillate stream
leaving the first separator. In other words, the 3-phase separator
described above is replaced with a separation unit that separates
the light distillate stream into a steam stream and a light
hydrocarbon stream. Any suitable separation unit can be used to
separate the water from the light distillate stream. The steam
obtained from such a separation process can be transported back in
the system for use in either the SAGD system or the nozzle reactor.
The light hydrocarbon stream can be combined with the previously
obtained mid distillate stream and the combined stream and be
treated as product.
[0096] The terms recited in the claims should be given their
ordinary and customary meaning as determined by reference to
relevant entries in widely used general dictionaries and/or
relevant technical dictionaries, commonly understood meanings by
those in the art, etc., with the understanding that the broadest
meaning imparted by any one or combination of these sources should
be given to the claim terms (e.g., two or more relevant dictionary
entries should be combined to provide the broadest meaning of the
combination of entries, etc.) subject only to the following
exceptions: (a) if a term is used in a manner that is more
expansive than its ordinary and customary meaning, the term should
be given its ordinary and customary meaning plus the additional
expansive meaning, or (b) if a term has been explicitly defined to
have a different meaning by reciting the term followed by the
phrase "as used herein shall mean" or similar language (e.g.,
"herein this term means," "as defined herein," "for the purposes of
this disclosure the term shall mean," etc.).
[0097] References to specific examples, use of "i.e.," use of the
word "invention," etc., are not meant to invoke exception (b) or
otherwise restrict the scope of the recited claim terms. Other than
situations where exception (b) applies, nothing contained herein
should be considered a disclaimer or disavowal of claim scope. The
subject matter recited in the claims is not coextensive with and
should not be interpreted to be coextensive with any particular
embodiment, feature, or combination of features shown herein. This
is true even if only a single embodiment of the particular feature
or combination of features is illustrated and described herein.
Thus, the appended claims should be given their broadest
interpretation in view of the prior art and the meaning of the
claim terms.
[0098] As used herein, spatial or directional terms, such as
"left," "right," "front," "back," and the like, relate to the
subject matter as it is shown in the drawings. However, it is to be
understood that the described subject matter may assume various
alternative orientations and, accordingly, such terms are not to be
considered as limiting. Furthermore, articles such as "the," "a,"
and "an" can connote the singular or plural. Also, the word "or"
when used without a preceding "either" (or other similar language
indicating that "or" is unequivocally meant to be exclusive . . .
e.g., only one of x or y, etc.) shall be interpreted to be
inclusive (e.g., "x or y" means one or both x or y). Likewise, as
used herein, the term "and/or" shall also be interpreted to be
inclusive (e.g., "x and/or y" means one or both x or y). In
situations where "and/or" or "or" are used as a conjunction for a
group of three or more items, the group should be interpreted to
include one item alone, all of the items together, or any
combination or number of the items. Moreover, terms used in the
specification and claims such as have, having, include, and
including should be construed to be synonymous with the terms
comprise and comprising.
[0099] Unless otherwise indicated, all numbers or expressions, such
as those expressing dimensions, physical characteristics, etc. used
in the specification (other than the claims) are understood as
modified in all instances by the term "approximately." At the very
least, and not as an attempt to limit the application of the
doctrine of equivalents to the claims, each numerical parameter
recited in the specification or claims which is modified by the
term "approximately" should at least be construed in light of the
number of recited significant digits and by applying ordinary
rounding techniques. Moreover, all ranges disclosed herein are to
be understood to encompass and provide support for claims that
recite any and all subranges or any and all individual values
subsumed therein. For example, a stated range of 1 to 10 should be
considered to include and provide support for claims that recite
any and all subranges or individual values that are between and/or
inclusive of the minimum value of 1 and the maximum value of 10;
that is, all subranges beginning with a minimum value of 1 or more
and ending with a maximum value of 10 or less (e.g., 5.5 to 10,
2.34 to 3.56, and so forth) or any values from 1 to 10 (e.g., 3,
5.8, 9.9994, and so forth).
[0100] In view of the many possible embodiments to which the
principles of the disclosed invention may be applied, it should be
recognized that the illustrated embodiments are only preferred
examples of the invention and should not be taken as limiting the
scope of the invention. Rather, the scope of the invention is
defined by the following claims. We therefore claim as our
invention all that comes within the scope and spirit of these
claims.
* * * * *