CA2621991A1 - Method and system for generating steam in the oil industry - Google Patents

Method and system for generating steam in the oil industry Download PDF

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Publication number
CA2621991A1
CA2621991A1 CA 2621991 CA2621991A CA2621991A1 CA 2621991 A1 CA2621991 A1 CA 2621991A1 CA 2621991 CA2621991 CA 2621991 CA 2621991 A CA2621991 A CA 2621991A CA 2621991 A1 CA2621991 A1 CA 2621991A1
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Prior art keywords
steam
primary
liquid phase
generators
wet
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Granted
Application number
CA 2621991
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French (fr)
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CA2621991C (en
Inventor
Brian C. Speirs
James A. Dunn
Jody L. Calvert
Brian P. Head
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Imperial Oil Resources Ltd
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Imperial Oil Resources Ltd
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Priority to CA2621991A priority Critical patent/CA2621991C/en
Publication of CA2621991A1 publication Critical patent/CA2621991A1/en
Priority to PCT/US2009/032019 priority patent/WO2009105309A1/en
Application granted granted Critical
Publication of CA2621991C publication Critical patent/CA2621991C/en
Active legal-status Critical Current
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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22STEAM GENERATION
    • F22BMETHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B33/00Steam-generation plants, e.g. comprising steam boilers of different types in mutual association

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
  • Control Of Eletrric Generators (AREA)

Abstract

The present invention provides a novel method and system for generating steam in the oil and gas industry, in particular, in the heavy oil industry. The process comprises feeding boiler feed water (BFW) of sufficient quality through one or more primary wet steam generators to generate primary wet steam therefrom; separating the primary wet steam into primary dry steam and a primary liquid phase; and feeding the primary liquid phase into one or more secondary steam generators to generate secondary steam therefrom. The secondary steam generators may or may not be wet steam generators. This unique serial configuration results in increased steam production per unit of inlet BFW, as well as an overall reduction of liquid waste or boiler blowdown, when compared to the conventional SAGD wet steam generation configuration. A system for carrying out the process is also provided.

Claims (99)

1. A process for generating steam, comprising:
(a) feeding boiler feed water (BFW) of sufficient quality through one or more primary wet steam generators to generate primary wet steam therefrom;
(b) separating the primary wet steam into primary steam and a primary liquid phase;
and (c) feeding the primary liquid phase into one or more secondary steam generators to generate secondary steam therefrom.
2. The process of claim 1, wherein the primary steam is primary dry steam.
3. The process of claim 2, wherein the primary dry steam has a steam quality of 90% or higher.
4. The process of claim 3, wherein the primary dry steam has a steam quality of 95% or higher.
5. The process of claim 4, wherein the primary dry steam has a steam quality of 99% or higher.
6. The process of any on of claims 1 to 5, wherein the one or more secondary steam generators comprise one or more secondary wet steam generators for generating secondary wet steam from the primary liquid phase.
7. The process of claim 6, further comprising:
(d) separating the secondary wet steam into secondary dry steam and a secondary liquid phase.
8. The process of claim 6 or claim 7, wherein the one or more primary wet steam generators and the one or more secondary wet steam generators comprise once-through steam generators (OTSGs), heat recovery steam generators (HRSGs), or a combination thereof.
9. The process of claim 8, wherein the BFW is fed into 2 to 24 said primary wet steam generators configured in parallel.
10. The process of claim 9, wherein the BFW is fed into 2 to 12 said primary wet steam generators configured in parallel.
11. The process of claim 10, wherein the BFW is fed into 2 to 8 said primary wet steam generators configured in parallel.
12. The process of claim 11, wherein the BFW is fed into 3 to 6 said primary wet steam generators configured in parallel.
13. The process of claim 12, wherein the BFW is fed into 4 said primary wet steam generators configured in parallel.
14. The process of any one of claims 8 to 13, wherein the primary wet steam generators are OTSGs.
15. The process of any one of claims 1 to 14, wherein in step (c) the primary liquid phase is fed into one said secondary steam generator configured in series with said one or more primary wet steam generators.
16. The process of claim 15, wherein the secondary steam generator is an OTSG.
17. The process of any one of claims 1 to 15, wherein the one or more primary wet steam generators and the one or more secondary steam generators are each once-through steam generators.
18. The process of claim 17, wherein each said once-through steam generator is substantially identical in design and operation.
19. The process of claim 7, wherein the BFW is fed into one said primary wet steam generator and wherein the primary liquid phase is fed into one said secondary wet steam generator.
20. The process of claim 19, wherein the primary wet steam generator is a HRSG
and the secondary wet steam generator is a OTSG capable of handling the primary liquid phase from the HRSG.
21. The process of any one of claims 1 to 20, wherein the BFW is of sufficient quality that the primary liquid phase is suitable for processing in the one or more secondary steam generators.
22. The process of claim 21, wherein the quality of the BFW, based on total dissolved solids (TDS) as ppm, is selected based on the following formula, wherein [BFW
TDS] =
[Liquid Phase TDS] × (100 - % Steam Quality)/100.
23. The process of any one of claims 6 to 22, wherein the primary wet steam and the secondary wet steam generated is of about 60% to about 85% steam quality.
24. The process of claim 23, wherein the primary and secondary wet steam generated is of about 75% to about 80% steam quality.
25. The process of claim 24, wherein the primary and secondary wet steam generated is of about 80% steam quality and the BFW has a hardness, iron and TDS
concentration about 20% of conventional BFW specifications or lower.
26 26. The process of claim 24, wherein the primary and secondary wet steam generated is of about 75% steam quality and the BFW has a hardness, iron and TDS
concentration about 25% of conventional BFW specifications or lower.
27. The process of any one of claims 1 to 26, wherein the BFW has the following specifications: hardness less than 0.25 ppm as CaCO3; total Fe less than 0.05 ppm; and TDS less than 12,000 ppm.
28. The process of claim 27, wherein the BFW has the following additional specifications:
silica less than 25 ppm; pH in the range of 7.0 to 12.0; 02 content less than 2 ppb; and oil and grease content less than 0.1 ppm.
29. The process of any one of claims 1 to 28, wherein the primary liquid phase meets conventional BFW specifications prior to being fed into the one or more secondary steam generators.
30. The process of any one of claims 1 to 29, wherein the BFW and the primary liquid phase are moved through the primary and secondary steam generators without an additional pressure boost therebetween.
31. The process of any one of claims 1 to 30, further comprising the step of cooling the primary liquid phase prior to entry into the one or more secondary steam generators such that the BFW and the primary liquid phase are of substantially the same temperature upon entering the primary and secondary steam generators, respectively.
32. The process of claim 31, wherein the primary liquid phase is cooled by transferring a portion of heat from the primary liquid phase to the BFW.
33. The process of any one of claims 2 to 29, further comprising the step of adjusting the pressure of the primary dry steam or the secondary dry steam, or both, such that the respective pressures are compatible; and combining the two streams into a common stream.
34. The process of claim 33, wherein the pressure of the primary dry steam is reduced to produce a reduced pressure steam prior to combining the reduced pressure steam with the secondary dry steam.
35. The process of claim 34, wherein a portion of heat from the primary liquid phase is transferred to the reduced pressure steam to improve the quality thereof prior to being combined with the secondary dry steam, and to thereby cool the primary liquid phase prior to being fed into the secondary steam generator.
36. The process claim 33, wherein the pressure of the secondary dry steam is increased to produce an increased pressure steam prior to combining the increased pressure steam with the primary dry steam.
37. The process of any one of claims 1 to 29, further comprising a flash step to reduce the pressure of the primary liquid phase to thereby generate low pressure utility steam and a concentrated primary liquid phase for discharge to the one or more secondary steam generators.
38. The process of claim 37, wherein a portion of heat from the concentrated primary liquid phase is transferred to the BFW to cool the concentrated primary liquid phase prior to entry into the one or more secondary steam generators.
39. The process of claim 38, wherein the pressure of the cooled concentrated primary liquid phase is boosted prior to entry into the secondary steam generator.
40. The process of any one of claims 37 to 39, further comprising a flash step to reduce the pressure of the secondary liquid phase to generate low pressure steam or vapour and a concentrated secondary liquid phase.
41. The process of claim 40, wherein the flash step reduces the pressure of the secondary liquid phase to atmospheric pressure.
42. The process of claim 6, wherein the primary wet steam and the secondary wet steam are fed into a common steam separator to generate a common liquid phase that is discharged to the one ore more secondary wet steam generators.
43. The process of claim 42, wherein the common liquid phase is cooled prior to entry into the one or more secondary wet steam generators.
44. The process of claim 39, wherein the common liquid phase is cooled by transferring a portion of heat therefrom to the BFW.
45. The process of any one of claims 42 to 44, wherein the primary and secondary wet steam generators are once-through steam generators (OTSGs), heat recovery steam generators (HRSGs), or a combination thereof.
46. The process of claim 45, wherein the primary and secondary wet steam generators are OTSGs.
47. The process of any one of claims 1 to 46, wherein all or a portion of the dry steam produced is injected into a reservoir.
48. The process of claim 47, wherein all of the dry steam produced is injected into the reservoir.
49. The process of any one of claims 1 to 46, wherein the wet or dry steam generated is used to support an oil recovery or mining operation.
50. The process of claim 49, wherein the wet or dry steam generated is used to support an oil recovery operation, and wherein the oil recovery operation is a thermal in-situ heavy oil recovery operation.
51. The process of claim 50, wherein the thermal in-situ heavy oil recovery operation is steam-assisted gravity drainage (SAGD), cyclic steam stimulation (CSS) or a derivative thereof.
52. The process of claim 51, wherein the derivative thereof is solvent-assisted SAGD
(SA-SAGD), steam and gas push (SAGP), combined vapor and steam extraction (SAVEX), expanding solvent SAGD (ES-SAGD), constant steam drainage (CSD), liquid addition to steam enhancing recovery (LASER), or a water flooding or steam flooding process.
53. The process of claim 52, wherein the thermal in-situ oil recovery operation is steam-assisted gravity drainage (SAGD).
54. A system for generating steam, comprising:
(a) one or more primary wet steam generators for generating primary wet steam from boiler feed water (BFW) of sufficient quality;
(b) at least one primary steam separator in communication with the one or more primary wet steam generators for receiving the wet steam and separating it into primary steam and a primary liquid phase; and (c) one ore more secondary steam generators in communication with the at least one steam separator for receiving the primary liquid phase and generating secondary steam therefrom.
55. The system of claim 54, wherein the primary steam generated is primary dry steam.
56. The system of claim 55, wherein the one or more secondary steam generators are secondary wet steam generators for generating secondary wet steam.
57. The system of claim 56, further comprising at least one secondary steam separator in communication with the one ore more secondary wet steam generators, the at least one secondary separator for receiving the secondary wet steam and separating it into secondary dry steam and a secondary liquid phase.
58. The system of claim 56 or claim 57 wherein the one or more primary wet steam generators and the one or more secondary wet steam generators comprise once-through steam generators (OTSGs), heat recovery steam generators (HRSGs), or a combination thereof.
59. The system of any one of claims 54 to 58, wherein 2 to 24 said primary wet steam generators are configured in parallel.
60. The system of claim 59, wherein 2 to 12 said primary wet steam generators are configured in parallel.
61. The system of claim 60, wherein 2 to 8 said primary wet steam generators are configured in parallel.
62. The system of claim 61, wherein 3 to 6 said primary wet steam generators are configured in parallel.
63. The system of claim 62, wherein 4 primary wet steam generators are configured in parallel.
64. The system of any one of claims 58 to 63, wherein the primary wet steam generators are OTSGs.
65. The system of any one of claims 54 to 64, wherein one said secondary steam generator is configured in series with said one or more primary wet steam generators.
66. The system of claim 65, wherein the secondary steam generator is a OTSG.
67. The system of any one of claim 54 to 65, wherein the one or more primary wet steam generators and the one or more secondary steam generators are each once-through steam generators.
68. The system of claim 67, wherein each said once-through steam generator is substantially identical in design and operation.
69. The system of claim 58, wherein one said primary wet steam generator is configured in series with one said secondary wet steam generator.
70. The system of claim 69, wherein the primary wet steam generator is a HRSG
and the secondary wet steam generator is a OTSG capable of handling the primary liquid phase from the HRSG.
71. The system of any one of claims 56 to 70, wherein the primary and secondary wet steam generators are suitable for operation at about 60% to about 85% steam quality.
72. The system of claim 71, wherein primary and secondary wet steam generators are suitable for operation at about 75% to about 80% steam quality.
73. The system of any one of claims 54 to 72, wherein a high pressure boiler feed water pump is positioned upstream of the one or more primary steam generators.
74. The system of any one of claims 73, further comprising a heat exchange element for transferring a portion of heat from the primary liquid phase to the BFW to reduce the temperature of the primary liquid phase prior to being fed to the secondary steam generator.
75. The system of claim 74, wherein the heat exchange element is positioned downstream of the high pressure boiler feed water pump and upstream of the one or more primary wet steam generators.
76. The system of any one of claims 57 to 75, further comprising a primary dry steam line from the primary steam separator for carrying the primary dry steam; a secondary dry steam line from the secondary steam separator for carrying the secondary dry steam;
and a common dry steam line connected to the primary and secondary dry steam lines in which the primary dry steam and the secondary dry steam are combined.
77. The system of claim 76, further comprising at least one pressure regulating device for adjusting the pressure in the primary dry steam line, the secondary dry steam line, or both, such that the pressures are compatible prior to combination in the common dry steam line.
78. The system of claim 77, wherein the at least one pressure regulating device is a pressure regulator positioned on the primary dry steam line for reducing the pressure of the primary dry steam to produce a reduced pressure primary steam.
79. The system of claim 78, further comprising a heat exchange element positioned downstream of the pressure regulator, wherein a portion of heat from the primary liquid phase is transferred to the reduced pressure primary steam to improve the quality thereof and to thereby cool the primary liquid phase prior to entering the secondary steam generator.
80. The process claim 77, wherein the at least one pressure regulating device is a pressure boosting device positioned on the secondary dry steam line for increasing the pressure of the secondary dry steam.
81. The system of any one of claims 72 to 80, further comprising a flash unit comprising a pressure regulating device and a flash vessel positioned downstream of the primary steam separator for reducing the pressure of the primary liquid phase to generate a low pressure utility steam and a concentrated primary liquid phase, wherein the concentrated primary liquid phase is directed to the secondary steam generator.
82. The system of claim 81, further comprising a high pressure pump positioned downstream of the flash vessel for boosting the pressure of the concentrated primary liquid phase prior to entry into the secondary steam generator.
83. The system of claim 72 to 82, further comprising a flash unit comprising a pressure regulator and a flash vessel positioned downstream of the secondary steam separator for reducing the pressure of the secondary liquid phase to generate a low pressure utility steam or vapour and a concentrated secondary liquid phase.
84. The system of any one of claims 81 to 83, further comprising a crystallizer.
85. The system of claim 84, wherein all or a portion of the utility steam generated is used to power the crystallizer.
86. The system of claim 56, wherein the primary wet steam separator is a common wet steam separator for receiving the primary wet steam and the secondary wet steam and generating a common liquid phase therefrom that is discharged to the one or more secondary wet steam generators.
87. The system of claim 86, wherein the primary and secondary wet steam generators are once-through steam generators (OTSGs).
88. The system of claim 86 or 87, further comprising a heat exchange element for transferring a portion of heat from the common liquid phase to the BFW to thereby cool the common liquid phase prior to being fed to the one or more secondary steam generators.
89. The system of any one of claims 54 to 88, wherein all or a portion of the dry steam produced is injected into a reservoir.
90. The system of any one of claims 54 to 88, wherein the steam generated is used to support an oil recovery or mining operation operation.
91. The system of claim 90, wherein the steam generated is used to support an oil recovery operation, and wherein the oil recovery operation is a thermal in-situ heavy oil recovery operation.
92. The system of claim 91, wherein the thermal in-situ heavy oil recovery operation is steam-assisted gravity drainage (SAGD), cyclic steam stimulation (CSS) or a derivative thereof.
93. The system of claim 92, wherein the derivative thereof is solvent-assisted SAGD (SA-SAGD), steam and gas push (SAGP), combined vapor and steam extraction (SAVEX), expanding solvent SAGD (ES-SAGD), constant steam drainage (CSD), liquid addition to steam enhancing recovery (LASER), or a water flooding or steam flooding process.
94. The system of claim 92, wherein the thermal in-situ oil recovery operation is steam-assisted gravity drainage (SAGD).
95. A process for generating steam to support an in-situ heavy oil recovery operation, comprising:

(a) feeding boiler feed water (BFW) of sufficient quality through 2 to 12 primary once-through steam generators (OTSGs) configured in parallel to generate primary wet steam having a steam quality of about 60% to about 85%;
(b) separating the primary wet steam in a primary steam separator to produce primary dry steam having a steam quality of greater than about 90% and a primary liquid phase;
(c) feeding the primary liquid phase to a secondary once-though steam generator configured in series to generate secondary wet steam having a steam quality of about 60%
to about 85%; and (d) separating the secondary wet steam in a secondary steam separator to produce secondary dry steam having a steam quality of greater than about 90% and a secondary liquid phase.
96. The process of claim 95, wherein 4 to 8 primary OTSGs are configured in parallel.
97. The process of claim 96, wherein 4 primary OTSGs are configured in parallel.
98. The process of any one of claims 95 to 97, wherein the primary and secondary wet steam has a steam quality of about 75% to about 80%, and wherein the primary and secondary dry steam has a steam quality of greater than about 95%.
99. The process of any one of claims 95 to 98, wherein the in-situ heavy oil recovery operation is a steam-assisted gravity drainage (SAGD) operation and wherein the dry steam produced is utilized for reservoir injection.
CA2621991A 2008-02-21 2008-02-21 Method and system for generating steam in the oil industry Active CA2621991C (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
CA2621991A CA2621991C (en) 2008-02-21 2008-02-21 Method and system for generating steam in the oil industry
PCT/US2009/032019 WO2009105309A1 (en) 2008-02-21 2009-01-26 Method and system for generating steam in the oil industry

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Application Number Priority Date Filing Date Title
CA2621991A CA2621991C (en) 2008-02-21 2008-02-21 Method and system for generating steam in the oil industry

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Cited By (5)

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US8166925B2 (en) 2007-10-26 2012-05-01 Fccl Partnership Method and apparatus for steam generation
US8770289B2 (en) 2011-12-16 2014-07-08 Exxonmobil Upstream Research Company Method and system for lifting fluids from a reservoir
US9359868B2 (en) 2012-06-22 2016-06-07 Exxonmobil Upstream Research Company Recovery from a subsurface hydrocarbon reservoir
WO2017192766A1 (en) * 2016-05-03 2017-11-09 Energy Analyst LLC. Systems and methods for generating superheated steam with variable flue gas for enhanced oil recovery
CN113883490A (en) * 2020-07-23 2022-01-04 中国石油天然气股份有限公司 Downhole dry steam generation system

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US8240370B2 (en) 2009-12-18 2012-08-14 Air Products And Chemicals, Inc. Integrated hydrogen production and hydrocarbon extraction
CA2742563C (en) * 2011-06-10 2018-07-24 Imperial Oil Resources Limited Methods and systems for providing steam
US9593563B2 (en) 2011-10-05 2017-03-14 Statoil Petroleum As Method and apparatus for generating steam for the recovery of hydrocarbon
CN102854294B (en) * 2011-10-17 2015-10-14 中国石油天然气股份有限公司 For detecting the system and method for water quality standard in the superheated steam injection technique of oil field
US20140110109A1 (en) * 2012-10-24 2014-04-24 Conocophillips Company Direct steam generation of boiler blowdown
US20140224192A1 (en) * 2013-02-13 2014-08-14 Lawrence E. Bool, III Steam quality boosting
US9328601B2 (en) 2013-04-30 2016-05-03 General Electric Company System and method for enhanced recovery of oil from an oil field
CN104763998B (en) * 2015-03-11 2016-07-06 中国石油大学(华东) The split type steam raising plant of waste heat two-stage reclaiming type
EP3318800A1 (en) 2016-11-02 2018-05-09 NEM Energy B.V. Evaporator system
CA2972203C (en) 2017-06-29 2018-07-17 Exxonmobil Upstream Research Company Chasing solvent for enhanced recovery processes
CA2974712C (en) 2017-07-27 2018-09-25 Imperial Oil Resources Limited Enhanced methods for recovering viscous hydrocarbons from a subterranean formation as a follow-up to thermal recovery processes
CA2978157C (en) 2017-08-31 2018-10-16 Exxonmobil Upstream Research Company Thermal recovery methods for recovering viscous hydrocarbons from a subterranean formation
CA2983541C (en) 2017-10-24 2019-01-22 Exxonmobil Upstream Research Company Systems and methods for dynamic liquid level monitoring and control

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US4489679A (en) * 1983-12-12 1984-12-25 Combustion Engineering, Inc. Control system for economic operation of a steam generator
US4730577A (en) * 1983-12-21 1988-03-15 Shell California Production Inc. Steam generator for thermal recovery system
US7428926B2 (en) * 1999-05-07 2008-09-30 Ge Ionics, Inc. Water treatment method for heavy oil production
US6988549B1 (en) * 2003-11-14 2006-01-24 John A Babcock SAGD-plus

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8166925B2 (en) 2007-10-26 2012-05-01 Fccl Partnership Method and apparatus for steam generation
US8770289B2 (en) 2011-12-16 2014-07-08 Exxonmobil Upstream Research Company Method and system for lifting fluids from a reservoir
US9359868B2 (en) 2012-06-22 2016-06-07 Exxonmobil Upstream Research Company Recovery from a subsurface hydrocarbon reservoir
WO2017192766A1 (en) * 2016-05-03 2017-11-09 Energy Analyst LLC. Systems and methods for generating superheated steam with variable flue gas for enhanced oil recovery
US10641481B2 (en) 2016-05-03 2020-05-05 Energy Analyst Llc Systems and methods for generating superheated steam with variable flue gas for enhanced oil recovery
CN113883490A (en) * 2020-07-23 2022-01-04 中国石油天然气股份有限公司 Downhole dry steam generation system

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Publication number Publication date
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CA2621991C (en) 2010-09-14

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