U.S. patent application number 14/178000 was filed with the patent office on 2014-08-14 for steam quality boosting.
The applicant listed for this patent is Dante P. Bonaquist, Lawrence E. Bool, III, Raymond F. Drnevich, Michael St. James, Monica Zanfir. Invention is credited to Dante P. Bonaquist, Lawrence E. Bool, III, Raymond F. Drnevich, Michael St. James, Monica Zanfir.
Application Number | 20140224192 14/178000 |
Document ID | / |
Family ID | 51296553 |
Filed Date | 2014-08-14 |
United States Patent
Application |
20140224192 |
Kind Code |
A1 |
Bool, III; Lawrence E. ; et
al. |
August 14, 2014 |
STEAM QUALITY BOOSTING
Abstract
Disclosed are methods for providing steam suitable for injecting
into a subterranean oil well, wherein fuel is combusted within a
conduit that contains the steam to provide direct heat transfer of
the heat of combustion to the steam.
Inventors: |
Bool, III; Lawrence E.;
(East Aurora, NY) ; Bonaquist; Dante P.;
(Boalsburg, PA) ; St. James; Michael; (Calgary,
CA) ; Drnevich; Raymond F.; (Clarence Center, NY)
; Zanfir; Monica; (Amherst, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bool, III; Lawrence E.
Bonaquist; Dante P.
St. James; Michael
Drnevich; Raymond F.
Zanfir; Monica |
East Aurora
Boalsburg
Calgary
Clarence Center
Amherst |
NY
PA
CA
NY
NY |
US
US
US
US
US |
|
|
Family ID: |
51296553 |
Appl. No.: |
14/178000 |
Filed: |
February 11, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61910714 |
Dec 2, 2013 |
|
|
|
61764213 |
Feb 13, 2013 |
|
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Current U.S.
Class: |
122/31.1 |
Current CPC
Class: |
F22B 1/1853 20130101;
F22B 1/22 20130101 |
Class at
Publication: |
122/31.1 |
International
Class: |
F22B 1/18 20060101
F22B001/18 |
Claims
1. A method of providing steam suitable for injection into a
subterranean oil well, comprising combusting fuel with gaseous
oxidant and subjecting a stream that comprises steam flowing from a
source of said steam to a subterranean oil well to direct heat
transfer to said stream of heat produced by said combustion,
thereby increasing the steam quality of said stream to a value that
is above 80% and that is higher than the steam quality of the
stream produced by said source.
2. A method according to claim 1 wherein the stream which is
subjected to said direct heat transfer contains liquid water, and
the method further comprises separating liquid water from the
stream which has been subjected to said direct heat transfer,
thereby providing a product stream comprising steam.
3. A method according to claim 1 wherein said gaseous oxidant is
air.
4. A method according to claim 1 wherein said gaseous oxidant
comprises at least 25 vol. % oxygen.
5. A method according to claim 1 wherein said gaseous oxidant
comprises at least 90 vol. % oxygen.
6. A method according to claim 2 further comprising further heating
the product stream.
7. A method according to claim 2 further comprising further heating
the product stream by direct heat transfer or indirect heat
transfer with heat of combustion produced by further combustion of
fuel and gaseous oxidant.
8. A method according to claim 7 wherein said gaseous oxidant
combusted in said further combustion is air.
9. A method according to claim 7 wherein said gaseous oxidant
combusted in said further combustion comprises at least 25 vol. %
oxygen.
10. A method according to claim 7 wherein said gaseous oxidant
combusted in said further combustion comprises at least 90 vol. %
oxygen.
11. A method according to claim 6 wherein said stream of steam
flowing from said source to said oil well loses heat to the
environment, and wherein said further heating of said product
stream imparts enough energy to said product stream such that the
temperature of said product stream at said oil well is at least
equal to the temperature of the stream produced by said source or
the steam quality of said product stream at said oil well is at
least equal to the steam quality of the stream produced by said
source.
12. A method according to claim 11 wherein said further heating of
said product stream imparts enough energy to said product stream
that the temperature of said product stream at said oil well is
higher than the temperature of the stream produced by said source
or the steam quality of said product stream at said oil well is
higher than the steam quality of the stream produced by said
source.
13. A method according to claim 6 wherein said stream of steam
flowing from said source to said oil well loses heat to the
environment, and wherein said further heating of said product
stream imparts enough energy to said product stream such that the
steam quality of said product stream at said oil well is at least
99%.
14. A method according to claim 6 wherein said stream of steam
flowing from said source to said oil well loses heat to the
environment, and wherein said further heating of said product
stream imparts enough energy to said product stream such that said
product stream at said oil well is saturated steam.
15. A method according to claim 6 wherein said stream of steam
flowing from said source to said oil well loses heat to the
environment, and wherein said further heating of said product
stream imparts enough energy to said product stream such that said
product stream at said oil well is superheated.
16. A method according to claim 1 wherein said direct heat transfer
causes the steam quality of the product stream at said oil well to
be at least 98%.
17. A method of providing steam suitable for injection into a
subterranean oil well, comprising feeding fuel and gaseous oxidant
into a stream that comprises steam flowing in a conduit from a
source of said steam to a subterranean oil well, wherein said fuel
and said oxidant are fed into said stream from one or more outlets
located in said stream within said conduit, and combusting said
fuel with said oxidant at one or more of said outlets in direct
contact with said steam, and heating said steam by direct contact
of said steam with hot combustion products produced by said
combustion.
18. A method according to claim 17 wherein said stream of steam
into which said fuel and oxidant are fed contains liquid water, and
wherein said heating of said steam evaporates at least a portion of
said liquid water.
19. A method according to claim 17 wherein said stream of steam
flowing in said conduit loses heat to the environment outside said
conduit, and wherein said direct contact of said steam with said
hot combustion products imparts enough energy to said steam such
that the temperature or quality of said steam at said oil well is
at least equal to its temperature or quality at the source of said
steam.
20. A method according to claim 17 wherein said stream of steam
from said source contains liquid water, the method further
comprising physically reducing the amount of liquid water in said
stream that contacts the base of the flame that is formed by
combusting said fuel and said oxidant.
21. A method according to claim 20 wherein said reducing the amount
of liquid water comprises passing said stream toward a deflector
disposed between the path of said stream and said base of said
flame, the deflector only partially surrounding said base, wherein
liquid water contacts said deflector instead of contacting said
base of said flame.
22. A method according to claim 20 wherein said reducing the amount
of liquid water comprises, before said stream contacts said base of
said flame, flowing said stream through a path that causes liquid
water in said stream to move toward an inner surface of said
conduit and in a path that differs from the path of said
stream.
23. A method of providing steam suitable for injection into a
subterranean oil well, comprising feeding fuel and gaseous oxidant
into a stream that comprises steam flowing in a conduit from a
source of said steam in a subterranean oil well, wherein said fuel
and said oxidant are fed into said stream from one or more outlets
located in said stream within said conduit, and combusting said
fuel with said oxidant at one or more of said outlets in direct
contact with said steam, and heating said steam by direct contact
of said steam with hot combustion products produced by said
combustion.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to improvements in the
production of streams containing steam, especially steam-containing
streams useful in enhancing the production of oil from an oil
producing well.
BACKGROUND OF THE INVENTION
[0002] Steam can be used to enhance the recovery and production of
oil from subterranean formations containing the oil. Steam is
injected into a well to heat the oil in the formation, thereby
reducing the viscosity of the oil and making recovery of the oil
possible from the same well or more often from another well. In
some situations the injection of steam makes it possible to recover
oil that could not otherwise be recovered at all, and in other
situations the injection of steam makes it possible to recover more
oil than would otherwise be possible.
[0003] The steam used for this purpose is generated in a suitable
apparatus, such as a "once through steam generator" (OTSG) which
produces steam at less than 100% quality. 80% quality steam is
typical. Water is then separated from the steam. The saturated
steam is then sent through insulated piping to a wellhead for
injection into a well. In some cases the wellhead may be many miles
away. As the steam travels through the piping, the steam loses some
heat in spite of the insulation, which leads to some of the steam
condensing and therefore reducing the thermal energy available for
delivery to the formation.
[0004] Steam quality generated in conventional SAGD boilers is
limited to 80% due to water quality constraints. Conventional
practice to increase the energy delivered to the reservoir, with
the ultimate goal to increase the oil production, requires
additional boilers to increase the steam throughput. However, this
solution is unattractive as it is highly capital intensive.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention provides methods to protect or boost
the temperature and/or quality of the steam that is used for
downhole injection in an oil well.
[0006] One such method is a method of providing steam suitable for
injection into a subterranean oil well, comprising
[0007] combusting fuel with gaseous oxidant and subjecting a stream
that comprises steam flowing from a source of said steam to a
subterranean oil well to direct heat transfer to said stream of
heat produced by said combustion. Preferably, the steam quality of
said stream is thereby increased to a value that is above 80% and
that is higher than the steam quality of the stream.
[0008] In a preferred embodiment of the methods, liquid water is
separated from the stream (i.e. physically) before or after the
direct heat transfer.
[0009] In another preferred embodiment of the invention, the stream
that is produced can be further heated to superheat the steam
and/or to increase the steam quality of the stream.
[0010] Another aspect of the present invention is a method of
providing steam suitable for injection into a subterranean oil
well, comprising
[0011] feeding fuel and gaseous oxidant into a stream that
comprises steam flowing in a conduit from a source of said steam in
a subterranean oil well, wherein said fuel and said oxidant are fed
into said stream from one or more outlets located in said stream
within said conduit, and
[0012] combusting said fuel with said oxidant at one or more of
said outlets in direct contact with said steam, and heating said
steam by direct contact of said steam with hot combustion products
produced by said combustion.
[0013] As used herein, the "steam quality" of a stream means the
amount of steam present in the stream as a percentage of all water
present in the stream regardless of what phase the water is in.
[0014] As used herein, "superheated steam" means steam which is at
a temperature that is higher than its vaporization (boiling) point
at the absolute pressure where the temperature measurement is
taken. Superheated steam does not contain liquid water.
[0015] As used herein, "direct heat exchange" and "direct heat
transfer" mean transfer of heat to a material, which is intended to
be heated, by directly contacting it with another material from
which heat is transferred.
[0016] As used herein, "indirect heat exchange" and "indirect heat
transfer" mean transfer of heat to a material, which is intended to
be heated, from another material from which heat is transferred, in
which the material to be heated does not directly contact the
material from which heat is transferred.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a flowsheet of a system depicting an embodiment of
the present invention for use in the recovery of oil from oil
wells.
[0018] FIG. 2 is a cross-sectional view of a stream depicting an
embodiment of one aspect of the invention.
[0019] FIG. 3 is a cross-sectional view of a stream depicting
another embodiment of one aspect of the invention.
[0020] FIG. 4 is a flowsheet of a system depicting another
embodiment of the present invention for use in the recovery of oil
from oil wells.
[0021] FIG. 5 is a cross-sectional view of a typical embodiment of
apparatus useful in the present invention.
[0022] FIG. 6 is a cross-sectional view of another embodiment of
apparatus useful in the present invention.
[0023] FIG. 7 is a cross-sectional view of an oil well showing an
embodiment of the present invention in which the steam is being
heated within the well.
[0024] FIG. 8 is a top view of one possible embodiment of the
embodiment shown in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring to FIG. 1, one embodiment of a SAGD steam system
is shown. The SAGD steam system comprises a once through steam
generator (OTSG) which includes a conventional boiler 10 which is
fired by combustion of fuel 101 and oxidant 102 streams. The fuel
101 can be any hydrocarbon fuel, such as natural gas. Oxidant 102
is gaseous and can be air, or a stream having an oxygen content
greater than 21 vol. % such as oxygen-enriched air or commercially
provided oxygen having an oxygen content of 90 vol. % or higher.
Boiler 10 may be of a design that includes long sections of
straight tubing bounded by one or more removable end sections.
[0026] The boiler 10 typically produces stream 104 with a steam
quality ranging from 75-85%. The temperature of stream 104 will
typically be 450.degree. F. to 600.degree. F. and the pressure of
stream 104 will typically be 500 psia to 1500 psia. The relatively
low steam quality is imposed by utilization of low quality boiler
feed water 204 as the source of the water 209 that is fed to boiler
10 to be heated to produce the steam in stream 104, and the
necessity of conditioning to prevent contaminants in the water
(such as CaCO.sub.3, silica, MgCO.sub.3 and the like) from
solidifying or precipitating on the boiler's heat transfer area. A
removable end section of the boiler allows insertion of mechanical
devices to scrape the deposits off of the surface of the tubes or
other heat transfer surfaces.
[0027] In the embodiment of FIG. 1, feed stream 104 comprising
steam and liquid water is fed to system 11 for vaporizing liquid
water present in feed stream 104. System 11 combusts hydrocarbon
fuel (such as natural gas) and a gaseous oxidant stream which can
be air but more preferably has an oxygen content higher than 21
vol. % such as pure oxygen or oxygen enriched air. Stream 301
represents one of fuel or oxidant, and stream 302 represents the
other of fuel or oxidant, as described herein with respect to FIG.
2. The system 11 heats the wet steam primarily by direct heat
exchange with the heat of combustion of the fuel and oxidant to
vaporize at least a portion, or all, of the liquid water present in
stream 104, so that the steam quality of stream 106 that enters the
separator 20 has been increased and is higher than 80%, preferably
90% to 98%, and more preferably in the range 92-97% while keeping
the non-condensable (CO.sub.2, N.sub.2) content in the stream 106
below 1-2%. The pressure in the portion of system 11 in which the
combustion and direct heat exchange occur will typically be 500
psia to 1500 psia. The temperature of stream 106 will typically be
450.degree. F. to 600.degree. F. and the pressure of stream 106
will typically be 500 psia to 1500 psia.
[0028] FIG. 2 depicts one embodiment of system 11. Stream 104,
downstream from boiler 10, is flowing in a conduit 100 or
equivalent conveyance. Conduit 100 is made of any material capable
of carrying steam at temperatures and pressures suitable for oil
recovery operations. Such materials are known in this field, and
are currently used in operations that employ steam to enhance oil
recovery.
[0029] The embodiment of system 11 that is shown in FIG. 2 includes
burner 310 which extends into conduit 100. The end 311 of burner
310 inside conduit 100 includes outlets 304 and 306 which are shown
as concentric, with outlet 306 surrounding outlet 304. However,
outlets 304 and 306 may instead be side-by-side as they pass
through conduit 100. Outlet 304 is connected to feed line 301
through which is fed one of either oxidant or fuel, preferably
fuel. Outlet 306 is connected to feed line 302 through which is fed
the other of either oxidant or fuel, preferably oxidant. The axis
of burner 310 can be oblique relative to the flow of the steam, as
shown in FIG. 2, or can be relatively parallel to the stream as
shown in FIG. 6.
[0030] Oxidant and fuel are combusted in flame 311 within conduit
100, in direct heat exchange contact with the stream 104. The
combustion generates heat which is used as described herein.
[0031] It should be noted that in the apparatus depicted in FIG. 2,
there is no enclosure forming a combustion chamber within which the
fuel and the oxidant combust before their combustion products
contact the stream 104 in the conduit. Instead, as noted herein,
the flame directly contacts the steam. The hot combustion products
formed by the combustion also directly contact the stream 104 in
conduit 100. Stream 104 is thus heated by direct heat exchange with
the heat of combustion.
[0032] FIG. 3 depicts another embodiment of system 11. Referring to
FIG. 3, stream 104 is flowing in conduit 100 or equivalent
conveyance, as described above. Gaseous oxidant and fuel are fed
into chamber 308. As in FIG. 2, feed line 301 represents one of the
gaseous oxidant and fuel, and feed line 302 represents the other of
the gaseous oxidant and fuel. The gaseous oxidant and fuel are
combusted within chamber 308 to form flame 311 (including hot
combustion products) in chamber 308 which extend from inside
chamber 308 to outside chamber 308. The flame and hot combustion
products directly contact stream 104 which is thus heated by direct
heat exchange. Preferably, the heat exchange from chamber 308 is
assisted by feeding an auxiliary stream gas such as air, nitrogen,
argon, carbon dioxide, steam, or mixtures of any of these, into
chamber 308 wherein the auxiliary gas is heated by the combustion
in chamber 308 and flows out of chamber 308 into stream 104 to
assist in the direct heat exchange to stream 104. The auxiliary
stream is shown as 323. A stream of steam 324 can be fed as shown
into stream 323 from outside conduit 100, or can be aspirated into
chamber 308 from stream 104 within conduit 100.
[0033] In operation of system 11, fuel and oxidant are fed through
their respective feed lines from conventional sources thereof, such
as storage tanks with suitable valves and controls. Preferred fuels
include gaseous hydrocarbons such as natural gas, propane, methane,
mixtures thereof, and the like. Preferred oxidants include air,
oxygen-enriched air having an oxygen content greater than 21 vol.
%, and oxygen streams containing at least 90 vol. % or at least 95
vol. % or even at least 98 vol. % oxygen. The fuel and oxidant are
fed to burner 310 and combusted at the respective outlets 304 and
306, or fed to chamber 308 and combusted as described above. The
flow rates of the fuel and oxidant to system 11 will depend on the
size of the apparatus, the size of the conduit 100, the flow rate
of the stream 104, and the amount of combustion energy that one
desires to create. The stoichiometric ratio between the fuel and
oxidant that are fed to system 11 should be such that there is no
more than 5% excess oxygen. Preferably the stoichiometric ratio
should be 1:1 or with an excess of fuel.
[0034] Steam generated from the combustion of the fuel and oxidant
in system 11 can increase the amount of steam delivered to the well
(compared to what was produced in boiler 10). Other components of
the combustion reaction products (particularly CO.sub.2) may be
advantageous for oil recovery or at worst, inert.
[0035] The combustion in system 11 forms steam-boosted stream 106
which exits system 11 and is fed to separator section 20 which
comprises one or more vessels, such as flash drum separators, in
which the steam (vapor) and liquid components of stream 106 are
separated from each other. The steam component leaves separator
section 20 as saturated steam stream 105 having a steam quality of
at least 99%. The liquid component of stream 106 leaves separator
section 20 as liquid, also known as "blowdown", stream 207. The
temperature of stream 105 will typically be 450.degree. F. to
600.degree. F. and the pressure of stream 105 will typically be 500
psia to 1500 psia.
[0036] Stream 105 can optionally but preferably be fed to one or
more optional steam superheating systems wherein the temperature of
the saturated steam leaving the separator 20 is heated to a higher
temperature that is not so high that it will damage the steam
pipeline and well bore materials, but is still above the saturation
temperature of the steam in stream 105. This treatment helps
overcome heat losses on the steam's path from separator section 20
to the oil well or wells designated as 40. This heat transfer can
be by direct or indirect heat transfer.
[0037] One embodiment of an optional steam superheating system is
shown in FIG. 1 as system 12 which includes a heater 13 that is
fired by combustion of a fuel 401, such as natural gas, and gaseous
oxidant 402 which may be air or a stream having an oxygen content
higher than 21 vol. %. The oxidant 402 can be fed at low pressures
which will typically be 14.8 psia to 15.5 psia. Preheater 14 is
also preferably employed to preheat the combustion oxidant 402 by
indirect heat transfer from stream 403 of the hot gaseous products
of combustion (flue gases) produced in heater 13. In system 12,
stream 105 is heated by indirect heat exchange. With indirect heat
transfer, the stream 105 can be flowed through tubes in heater 13
whose exteriors are exposed to hot products of combustion of fuel
401 and oxidant 402, and heat flows from the hot combustion
products through the tubes into stream 105. Alternatively, the
products of combustion of fuel 401 and oxidant 402 can be flowed
through tubes in heater 13 whose exteriors are exposed to stream
105, and heat flows from the combustion products through the tubes
into stream 105 by indirect heat exchange. Where stream 105
contains little or no liquid water (no more than 2 wt. % liquid),
stream 107 leaves heater 13 as superheated steam.
[0038] FIG. 4 depicts an alternative embodiment of the invention,
in which stream 105 which leaves separator 20 is fed to a system
15, which can be constructed and operated as described above with
respect to system 11, and which heats the steam in stream 105 by
direct heat exchange. Where stream 105 contains little or no liquid
water (no more than 2 wt. % liquid), stream 107 leaves system 15 as
superheated steam.
[0039] In those embodiments of FIG. 1 and FIG. 4 in which stream
105 contains liquid water, stream 107 will have a steam quality
higher than that of stream 105, and enough energy may be imparted
to stream 107 so that stream 107 contains no liquid water and
constitutes superheated steam.
[0040] Before being sent to the oil reservoir through the pipeline
system 30 to be injected in the oil well or wells 40, stream 107
will preferably have a steam quality of at least 98%, and the steam
in stream 107 will typically be superheated by 10.degree. F. to
200.degree. F. The temperature of stream 107 will typically be
500.degree. F. to 750.degree. F. and the pressure of stream 107
will typically be 500 psia to 1500 psia. The duty performed by
system 13 or system 15 will be defined by its location relative to
separator section 20 and well(s) 40, and by the proportion of steam
in stream 107 that undergoes condensation due to loss of heat from
pipeline system 30.
[0041] As described more below, one or more systems 13 and/or one
or more systems 15, and one or more systems as described herein
relative to FIGS. 5, 6, 7 and 8, can be located at any locations
along the piping 30 to the oil wells and/or on individual pipes
leading individual ones of the oil wells 40.
[0042] The steam injected into the oil formation in the wells
condenses and the heat released to the reservoir upon condensation
reduces the heavy oil viscosity and density, forming an oil/water
emulsion 201, which returns to the surface. The emulsion 201 is
separated in separation train 50. This separation produces oil 202
that can be used or subjected to further processing at the site or
elsewhere. This separation also produces water stream 203 which is
sent to water treatment section 60 for further purification. Makeup
water 210 should be provided into the overall process, to make up
for water losses into the oil well formation and/or to evaporation.
A preferred location to feed makeup water is prior to water
treatment section 60. In FIG. 1, stream 210 denotes a stream of
makeup water.
[0043] Typically, the liquid blowdown 207 from the separator 20 is
cooled to recover its heat content in a heat exchanger 80, and then
sent to a condensate recovery section 70, where part of the
blowdown stream 207 may be partially evaporated, so that the waste
water discharge stream 205 represents only up to 5% of the total
boiler feedwater stream 208. Other condensate recovery/treatment
options are available. The condensate from the partial evaporation
step, the treated portion 206 of the blowdown is mixed with the
treated water 204 from the water treatment section 60, to form
stream 208 which is preheated in the heat exchanger 80 by indirect
heat exchange from the blowdown stream 207. The resulting preheated
stream 208 is further preheated in economizer 90 by indirect heat
exchange with the flue gases 103 leaving the OTSG boiler 10, to
produce feed stream 209 which is fed to boiler 10.
[0044] In additional description of the invention, referring now to
FIGS. 5-8, burner 310 is situated inside conduit 100. In one
embodiment, burner 310 is located at a bend or elbow in conduit
100, so that burner 310 extends through a wall of conduit 100. This
embodiment is shown in FIG. 5. In other embodiments, burner 310 is
located in a straight section of conduit 100, as shown in FIGS. 6
and 7. In the embodiment of FIG. 6, typical of an above-ground
installation, burner 310 can be secured to the inner surface of
conduit 100 by suitable brackets 321 (whether conduit 100 is
oriented vertically, horizontally, or otherwise), and feed lines
301 and 302 pass through the wall of conduit 100.
[0045] In the embodiment of FIG. 7, typical of a subterranean
installation in which oil well 731 extends from the surface 730 of
the earth to formation 732 which contains oil 733 that is recovered
at the surface, conduit 100 extends within oil well 731 to the
formation 732. Burner 310 can be suspended within conduit 100 from
feed lines 301 and 302 that extend from the surface 730, or by
auxiliary support cables (not shown). Steam 108 (which may have
been treated in the manner described herein with respect to FIGS.
1-4) is fed down conduit 100 toward burner 310, at which fuel and
oxidant which are fed from the surface combust and impart energy to
steam 108 which then enters the formation 732. In this embodiment,
burner 310 can be located in the oil formation or anywhere below
the surface 730.
[0046] In FIGS. 5-7, the end of burner 310 inside conduit 100
includes outlets 304 and 306 which are shown as concentric, with
outlet 306 surrounding outlet 304. However, outlets 304 and 306 may
instead be side-by-side. Outlet 304 is connected to feed line 301
through which is fed one of either oxidant or fuel, preferably
fuel. Outlet 306 is connected to feed line 302 through which is fed
the other of either oxidant or fuel, preferably oxidant. The fuel
and oxidant are fed through their respective feed lines from
conventional sources thereof, such as storage tanks with suitable
valves and controls. Preferred fuels include gaseous hydrocarbons
such as natural gas, propane, methane, mixtures thereof, and the
like. Preferred oxidants include air, oxygen-enriched air having an
oxygen content greater than 21 vol. %, and oxygen streams
containing at least 90 vol. % or even at least 98 vol. %
oxygen.
[0047] Oxidant and fuel are combusted in flame 311 within conduit
100, in direct contact with the stream 602 that is flowing within
conduit 100. The effects of the flame are described below. One
burner 310 or more than one burner 310 can be located at any point
or points between boiler 10 and oil wells 40. Thus, in FIGS. 5, 6
and 8, the steam-containing stream that stream 602 can be includes
any of streams 104, 106, 105, 107, 30 or 108.
[0048] It should be noted that in the apparatus depicted in FIGS.
5, 6 and 7, there is no enclosure forming a combustion chamber
within which the fuel and the oxidant combust before their
combustion products contact the steam in the conduit. Instead, as
noted herein, the flame directly contacts the steam. The hot
combustion products formed by the combustion also directly contact
the steam in conduit 100.
[0049] It should also be noted that as shown in FIGS. 5, 6 and 7,
the fuel and oxidant are fed into the stream of steam in a
direction that is the same direction as the flow of steam. The
respective flows can be parallel or within an angle of less than
45.degree. to each other. Arranging the flows in this way helps to
maintain flame stability. It also lets the steam flow protect the
walls of conduit 100 from overheating due to the heat of the flame
311. Instead, the flowing steam is entrained in the hot combustion
products which imparts energy to the steam, evaporates droplets of
liquid water present in the steam, and permits the temperature of
the steam to be increased. Condensed water (condensate) on the
inner walls of conduit 100 can be evaporated by radiative and
convective heat transfer from the flame. Steam generated from the
combustion of the fuel and oxidant increases the amount of steam
delivered to the well (compared to what was produced in the steam
generator). Other components of the combustion reaction products
(particularly CO.sub.2) may be advantageous for oil recovery or at
worst, inert.
[0050] In operation, the fuel and oxidant are fed to burner 310 and
combusted as described above with respect to FIGS. 1-4 or at the
respective outlets 304 and 306 as shown in FIG. 5. The flow rates
of the fuel and oxidant will depend on the size of the apparatus,
the size of the conduit 100, the flow rate of the steam in the
stream being heated, and the amount of combustion energy that is
needed to achieve the energy level targeted for stream 106. The
stoichiometric ratio between the fuel and oxidant should be such
that there is no more than 5% excess oxygen. Preferably the
stoichiometric ratio should be 1:1 or with a slight excess of
fuel.
[0051] There are a number of ways to practice the current
invention. For example, although the burner could be an air-fuel
burner, it is more advantageous to use enriched air or pure oxygen
as the oxidant. An air burner would require specific methods (such
as swirl, bluff bodies, and others known to experts in the art) to
achieve flame stability in the steam environment. In some cases
nitrogen contained in the flue gas, and injected into the well, may
be undesirable. In contrast using oxygen enriched air, or pure
oxygen, would enhance flame stability and reduce the nitrogen
content of the resultant mixture of the combustion products with
the steam. This is shown in Table 1. For this table the total
assumed heat loss is approximately 71% of the latent heat of the
steam leaving an OTSG, representing a well far away from the OTSG.
As can be seen from Table 1, reheating the steam yields almost a 4
fold increase in oil production. However, if air is used instead of
substantially pure oxygen, the injection gas would contain
approximately 20 vol. % of nitrogen which could create issues for
the desired oil recovery from the well. Gas produced with the oil
could contain nitrogen quantities so large that the gas would not
be useable as a fuel with nitrogen rejection.
TABLE-US-00001 TABLE 1 Comparison of Air-fuel and Oxy-fuel burners
for steam reheating at well Reheated Reheated with with Leaving
Baseline air-fuel oxy-fuel OTSG at well burner burner Total water
flow.sup.1 relative to 1 1.06 1.06 leaving OTSG Steam Quality.sup.2
95.0% 27.5% 95.0% 95.0% Gas composition (volume %) CH.sub.4 0.0%
0.0% CO.sub.2 2.5% 2.9% H.sub.2O 100.0% 100.0% 78.7% 97.1% N.sub.2
18.8% 0.0% Oil production.sup.3 relative 1 3.7 3.7 to baseline
.sup.1includes liquid and vapor .sup.2defined as the mass ratio of
steam/(steam + liquid) .sup.3assumes 2 bbl steam/bbl oil
[0052] Another aspect of the current invention is the location of
the burner relative to the well. In some cases, as that shown
previously in Table 1, the burner can be located at the well, or
potentially even in the wellbore itself (as shown in FIG. 7). In
this case an oxidant supply and a fuel supply must be provided for
each well. Another option would be to superheat the steam further
upstream in the steam distribution system to such that a single
burner can reheat/superheat the steam for multiple wells. In this
case it will be important to provide at least enough heat to offset
transportation heat losses while avoiding temperature limitations.
For example, in the extreme case where the burner is located at the
OTSG the steam would need to be superheated more than 400.degree.
F. to offset the heat loss used for Table 1. Placing the burner
downstream, but before the steam is split into the piping for
individual wells, would reduce the superheat temperature.
[0053] Other alternate modes for the current invention include
addition of CO.sub.2 to the steam before heating to promote
recoveries in reservoirs where CO.sub.2 can reduce oil
viscosity.
[0054] Another preferred embodiment is the inclusion of a device to
prevent entrained water droplets from directly impinging on the
flame (as a method to enhance flame stability). For example,
referring again to FIG. 5, one embodiment would be a metal shield
120 (with or without perforations) in the path of stream 602 and
extending beyond the outlets 304 and 306 and only partially around
the base 317 of flame 311. This embodiment protects the base 317 of
flame 311 from impingement by droplets of water, without creating a
combustion chamber that would keep the flame from directly
contacting the steam.
[0055] An alternative embodiment would be a structure such as a
cyclone 314, an example of which is shown in FIG. 8 which is a top
view of one embodiment of FIG. 5. In the arrangement shown in FIG.
8, the path in which stream 602 flows curves to follow the shape of
the inner surface of conduit 100, around the axis of burner 310.
However, droplets of liquid water in stream 602 continue in a
different path toward the inner surface of conduit 100. This helps
to separate condensate and force it toward the conduit walls to
keep it away from the burner but still allow the water to be
evaporated by the heat of combustion from flame 311. In some cases
this practice would impinge water droplets on the conduit wall.
[0056] In a preferred mode of operation of the invention, the
invention is employed in situations in which the stream of steam
flowing from its source toward the oil well(s) loses heat to the
surrounding environment before reaching the oil well(s) 40, such as
through conduit walls even though they may be insulated. Similarly,
stream 105 may lose heat between separator 20 and the oil well(s)
40. Such heat loss reduces the temperature and/or the steam quality
of the stream 108 that reaches the oil well(s) 40.
[0057] In such situations, the present invention is practiced to
alleviate these heat losses, by operating one or more than one
system 13 and/or 15 between separator 20 and oil well(s) 40 in a
manner, and at a location or locations, so that the heat transfer
to the steam as described herein imparts enough energy to the steam
such that the temperature or quality of said steam at said oil
well(s) is at least equal to its temperature or quality at the
source of said steam. In another more preferred mode of operation
of the invention, enough energy is imparted to the steam that the
temperature or quality of said steam at said oil well(s) is higher
than its temperature or quality at the source of said steam. More
preferably, the one or more systems 13 and/or 15 are located and
are operated such that the steam quality in the stream at the oil
well(s) 40 is at least 99%. Even more preferably, the steam in
stream 108 at the oil well(s) 40 is saturated or superheated, by
the manner in which the system systems 13 and/or 15 are operated
and the location where it or they are located. It will be
recognized that the location of any such systems 13 and 15, and the
manner in which they are operated, are related in that increased
distance between the oil well(s) 40 and the closest system 13 or 15
increases the steam quality and the temperature or degree of
superheating that are provided in stream 107 from such closest
system, in order to provide a given desired steam quality, degree
of superheating, and /or temperature at the oil well(s) 40.
[0058] The present invention provides numerous advantages.
[0059] One advantage is that unit 11 before the separator 20
significantly reduces the relative volume and flowrate of the
blowdown stream 207, to values in the range of 2-5% of the total
boiler feed water stream, as compared to 20% of the total boiler
feed water stream operation without unit 11. In this manner the
size and operating cost for the condensate recovery section 70 are
significantly reduced.
[0060] The present invention compensates for heat losses in the
SAGD process, and consequently maintains higher oil production
rates, while minimizing at the same time additional incurred costs.
There are significant heat losses on the steam path from the
facility where the SAGD operation is carried out to the oil
reservoir, due to heat losses from the steam pipeline
infrastructure or in the injection well. Thus, even if the steam
quality of stream 105 leaving the separator 20 is 100%, the steam
quality of the stream of steam that reaches the well head, stream
108, may drop to 94-98% or lower, e.g. even to 90% or less.
Furthermore, the heat losses in the well bore are significant, so
that when the steam actually reaches the reservoir underground it
may have a steam quality in the range of 80-90%. Basically, the
heat losses encountered from the pipelines and in the well bore
result in lower energy transferred to the reservoir, and therefore
a decrease in oil production.
[0061] The present invention, by making up for heat losses from the
pipeline, can result in an increase in oil production of up to 20%,
using steam generation from the existing boiler, compared to
production using steam generation from the existing boiler without
the heat transfer described herein.
[0062] The current invention can also be used to superheat the
steam to allow more thermal energy to be carried to the well. In a
conventional OTSG steam quality (which is defined in Table 1) is
intentionally kept below 1 (not full evaporation) due to poor
boiler feedwater quality. If all the water is evaporated in the
OTSG the water contaminants will condense/plate out on the inside
of the conduits--reducing the heat transfer efficiency of the
conduits and potentially leading to conduit failures. However in
the current invention the heat transfer to the steam/liquid is by
direct contact with the flame and combustion products, therefore
any precipitation of feedwater contaminants on the wall will not
impact the boiling/superheating efficiency. As long as the conduit
100 is sized to avoid flow disruptions caused by the reduction of
the conduit's internal diameter by deposition of feedwater
contaminants over the anticipated life of the conduit, superheating
with the current invention is feasible and in some cases
attractive. Another consideration is the maximum working
temperature of the steam piping, which limits the amount of
superheating that can be provided.
* * * * *