CA2847770C - Processes for treating reservoir fluid comprising material produced from a hydrocarbon containing reservoir - Google Patents
Processes for treating reservoir fluid comprising material produced from a hydrocarbon containing reservoir Download PDFInfo
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- CA2847770C CA2847770C CA2847770A CA2847770A CA2847770C CA 2847770 C CA2847770 C CA 2847770C CA 2847770 A CA2847770 A CA 2847770A CA 2847770 A CA2847770 A CA 2847770A CA 2847770 C CA2847770 C CA 2847770C
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- 229930195733 hydrocarbon Natural products 0.000 title claims abstract description 62
- 150000002430 hydrocarbons Chemical class 0.000 title claims abstract description 56
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- 239000012530 fluid Substances 0.000 title description 44
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- 239000007788 liquid Substances 0.000 claims abstract description 72
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 42
- 238000001704 evaporation Methods 0.000 claims abstract description 9
- 230000008020 evaporation Effects 0.000 claims abstract description 9
- 125000001183 hydrocarbyl group Chemical group 0.000 claims description 6
- 238000000926 separation method Methods 0.000 abstract description 43
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Abstract
There is provided a process for treating a reservoir fluid-comprising mixture, comprising: producing a reservoir fluid-comprising mixture, including oil and water, from a hydrocarbon containing reservoir; at a pressure that is greater than atmospheric pressure, separating an oil-lean mixture from the reservoir fluid-comprising mixture; at a pressure that is greater than atmospheric pressure, effecting separation, from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, by evaporation or ceramic membrane filtration; producing pressurized steam from the scale forming-lean liquid using a steam generator; and supplying the pressurized steam to the hydrocarbon containing reservoir for effecting mobilization of hydrocarbons within the hydrocarbon containing reservoir.
Description
PROCESSES FOR TREATING RESERVOIR FLUID COMPRISING MATERIAL
PRODUCED FROM A HYDROCARBON CONTAINING RESERVOIR
FIELD
[0001] The present disclosure relates to recovery and reuse of water from reservoir fluid comprising material produced from a hydrocarbon containing reservoir.
BACKGROUND
PRODUCED FROM A HYDROCARBON CONTAINING RESERVOIR
FIELD
[0001] The present disclosure relates to recovery and reuse of water from reservoir fluid comprising material produced from a hydrocarbon containing reservoir.
BACKGROUND
[0002] Some hydrocarbon production processes, such as Steam-Assisted Gravity Drainage ("SAGD"), inject steam into a hydrocarbon-containing reservoir to stimulate production of hydrocarbons. SAGD uses a pair of wells to produce a hydrocarbon from a hydrocarbon containing reservoir. Typically the well pair includes two horizontal wells vertically spaced from one another, with the upper well used to inject steam into the reservoir and the lower well to produce the hydrocarbon, The steam operates to generate a steam chamber in the reservoir, and thermal heat from the steam operates to lower the viscosity of the hydrocarbon, allowing for gravity drainage, and thereby production from the production well. The produced fluids typically include a mixture of hydrocarbons and water, the water resulting from the condensing of the steam (referred to as "produced water").
[0003] For economic and environmental reasons, it is desirable to recycle the produced water. Typically, the produced water is treated to remove, amongst other things, oils and solids, and then converted into steam using a steam generator.
[0004] The internal energy of produced fluids is not insignificant.
However, such energy is not being optimally used to drive existing treatment processes.
SUMMARY
However, such energy is not being optimally used to drive existing treatment processes.
SUMMARY
[0005] In one aspect, there is provided a process for treating a reservoir fluid-comprising mixture, comprising: producing a reservoir fluid-comprising mixture, including oil and water, from a hydrocarbon containing reservoir; at a pressure that is greater than atmospheric pressure, separating an oil-lean mixture from the reservoir fluid-comprising mixture such that the concentration of oil within the oil-lean mixture is greater than 10 ppra; at a pressure that is DOOSTOR: 2965059\1 greater than atmospheric pressure, effecting separation, from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, by evaporation or ceramic membrane filtration; producing pressurized steam from the scale forming-lean liquid using a steam generator; and upplying the pressurized steam to the hydrocarbon containing reservoir for effecting mobilization of hydrocarbons within the hydrocarbon containing reservoir.
[00061 In some implementations, the process further comprises, prior to producing the pressurized steam, supplying the scale forming-lean liquid to a tank, wherein the tank is disposed at a pressure that is greater than atmospheric pressure.
[0007] In some implementations, the concentration of oil within the oil-lean mixture is between 10 ppm and 250 ppm.
[00081 In some implementations, the concentration of oil within the oil-lean mixture is between 10 ppm and 100 ppm.
[0009] In some implementations, the concentration of oil within the oil-lean mixture is between 10 ppm and 30 ppm.
[0010i In some implementations, the pressure is at least 20 kPa above atmospheric pressure.
[0011] In another aspect, there is provided a process for treating a reservoir fluid-comprising mixture, being produced through a wellhead from a hydrocarbon containing reservoir, comprising: fluidically coupling the wellhead to a steam generator via a fluid passage of a fluid conductor; producing, through a wellhead, a reservoir fluid-comprising mixture, including oil and water, from a hydrocarbon containing reservoir; separating an oil-lean mixture from the reservoir fluid-comprising mixture such that the concentration of oil within the oil-lean mixture is greater than 10 ppm; supplying the oil-lean mixture to a scale-forming solids separator, wherein the scale-forming solids separator includes an evaporator or a ceramic membrane filtration unit operation; separating, from the oil-lean mixture, a scale forming-lean liquid and a scale forming-rich material, using the evaporator; such that each one of (i) the separating of the oil-lean mixture from the reservoir fluid-comprising mixture, (ii) the supplying of the oil-lean mixture to the evaporator, and (iii) the separating, Man the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, using the evaporator is effected within the fluid passage, and the entirety of the fluid passage is disposed at a pressure that is greater than DOCSTOR; 2985039 VI
atmospheric pressure; producing pressurized steam from the scale forming-lean liquid using the steam generator; and supplying the pressurized steam to the hydrocarbon containing reservoir to effect mobilization of hydrocarbons within the hydrocarbon containing reservoir.
[0012] In some implementations, the process further comprises, prior to producing the pressurized steam, supplying the scale forming-lean liquid to a tank, wherein the tank is disposed at a pressure that is greater than atmospheric pressure.
[0013] In some implementations, he concentration of oil within the oil-lean mixture is between 10 ppm and 250 ppm.
[0014] In some implementations, the concentration of oil within the oil-lean mixture is between 10 ppm and 100 ppm.
[0015] In some implementations, the concentration of oil within the oil-lean mixture is between 10 ppm and 30 ppm.
[0016] In some implementations, the pressure is at least 20 kPa above atmospheric pressure.
[0017] In another aspect, there is provided a process for treating a reservoir fluid-comprising mixture, comprising producing a reservoir fluid-comprising mixture, including oil and water, from a hydrocarbon containing reservoir; at a pressure that is greater than atmospheric pressure, separating an oil-lean mixture from the reservoir fluid-comprising mixture; at a pressure that is greater than atmospheric pressure, effecting separation, from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material; supplying the scale forming-lean liquid to a tank that is disposed at a pressure that is greater than atmospheric pressure; supplying the scale forming-lean liquid from the tank to a steam generator; producing pressurized steam from the scale fomiing-lean liquid using the steam generator; and supplying the pressurized steam to the hydrocarbon containing reservoir to effect mobilization of oil within the hydrocarbon containing reservoir.
[0018] In some implementations, the temperature of the scale forming-lean liquid within the tank is greater than 100 degrees Celsius.
[0019] In some implementations, the separation, from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, is effected by evaporation.
DOCSTOR; 29650,1911 [00201 In some implementations, the separation from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, is effected by pressurized hot lime softening, [0021] In some implementations, the separation, from the oil-lean mixture, of a. scale forming-lean liquid and a scale forming-rich material, is effected by ceramic membrane filtration.
[0022] In some implementations, the pressure is at least 20 kPa above atmospheric pressure.
[00231 In another aspect, there is provided a process for treating a reservoir fluid-comprising mixture, being produced through a wellhead from a hydrocarbon containing reservoir, comprising: fluidically coupling the wellhead to a steam generator via a fluid passage of a fluid conductor; producing, through a wellhead, a reservoir fluid-comprising mixture, including oil and water, from a hydrocarbon containing reservoir; separating an oil-lean mixture from the reservoir fluid-comprising mixture; supplying the oil-lean mixture to a scale forming solids separator; separating, from the oil-lean mixture, a scale forming-lean liquid and a scale forming-rich material, using the scale forming solids separator; supplying the scale forming-lean liquid to a tank that is disposed at a pressure that is greater than atmospheric pressure; supplying the scale forming-lean liquid from the tank to a steam generator; such that each one of (i) the separating of the oil-lean mixture from the reservoir fluid-comprising mixture, (ii) the supplying of the oil-lean mixture to the scale forming solids separator, (iii) the separating, from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, using the scale forming solids separator, (iv) the supplying of the scale forming-lean liquid to a tank that is disposed at a pressure that is greater than atmospheric pressure, and (v) the supplying of the scale forming-lean liquid from the tank to the steam generator is effected within the fluid passage, and the entirety of the fluid passage is disposed at a pressure that is greater than atmospheric pressure;
producing pressurized steam from the scale forming-lean liquid using the steam generator; and supplying the pressurized steam to the hydrocarbon containing reservoir to effect mobilization of hydrocarbons within the hydrocarbon containing reservoir.
[00241 In some implementations, the temperature of the scale forming-lean liquid within the tank is greater than 100 degrees Celsius.
OdenSTOR; 285503911 [0025] In some implementations, the separation, from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, is effected by evaporation.
[00261 In some implementations, the separation from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, is effected by pressurized hot lime softening, [0027] In some implementations, the separation, from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, is effected by ceramic membrane filtration.
[0028] In some implementations, the pressure is at least 20 Oa above atmospheric pressure.
[0029] In another aspect, there is provided a process for treating a reservoir fluid-comprising mixture, being produced through a wellhead from a hydrocarbon containing reservoir, comprising: fluidically coupling the wellhead to a steam generator via a fluid passage of a fluid conductor; producing, through a wellhead, a reservoir fluid-comprising mixture, including oil and water, from a hydrocarbon containing reservoir; separating an oil-lean mixture from the reservoir fluid-comprising mixture; supplying the oil-lean mixture to a scale forming solids separator including an evaporator; separating, from the oil-lean mixture, a scale forming-lean liquid and a scale forming-rich material, using the scale forming solids separator; such that each one of (1) the separating of the oil-lean mixture from the reservoir fluid-comprising mixture, (ii) the supplying of the oil-lean mixture to the scale forming solids separator, and (iii) the separating, from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, using the scale forming solids separator is effected within the fluid passage, and the entirety of the fluid passage is disposed at a pressure that is greater than atmospheric pressure;
producing pressurized steam from the scale forming-lean liquid using the steam generator; and supplying the pressurized steam to the hydrocarbon containing reservoir to effect mobilization of hydrocarbons within the hydrocarbon containing reservoir.
[0030] In some implementations, the pressure is at least 20 Icria above atmospheric pressure.
[0031] In some implementations, the process further comprises progressively reducing pressure along a section of the fluid passage, from downstream of the wellhead to the evaporator.
DOCSTOR: 295503911 100321 In another aspect, there is provided a process for treating a reservoir fluid-comprising mixture, being produced through a wellhead from a hydrocarbon containing reservoir, comprising: fluidically coupling the wellhead to an evaporator via a fluid passage of a fluid conductor extending upstream from the evaporator; producing, through a wellhead, a reservoir fluid-comprising mixture, including oil and water, from a hydrocarbon containing reservoir;
separating an oil-lean mixture from the reservoir fluid-comprising mixture;
supplying the oil-lean mixture to the evaporator; separating, from the oil-lean mixture, an aqueous liquid distillate and a scale forming-rich material, using the evaporator; such that each one of (i) the separating of the oil-lean mixture from the reservoir fluid-comprising mixture, (ii) the supplying of the oil-lean mixture to the evaporator, and (iii) the separating, from the oil-lean mixture, of an aqueous liquid distillate and a scale forming-rich material, using the evaporator is effected within the fluid passage, and the entirety of a section of the fluid passage, that is upstream of the evaporator, is disposed at a temperature of at least (i.e. greater than or equal to) the boiling point temperature of the oil-lean mixture at the pressure within the evaporator;
producing pressurized steam from the aqueous liquid distillate using the steam generator; and supplying the pressurized steam to the hydrocarbon containing reservoir to effect mobilization of hydrocarbons within the hydrocarbon containing reservoir.
100331 In some implementations, the temperature is at least the boiling point temperature of water at 20 kl)a above atmospheric pressure.
100341 In some implementations, the process further comprises, after the separating, from the oil-lean mixture, a scale forming-lean liquid and a scale forming-rich material, using the evaporator, and prior to the producing pressurized steam from the scale forming-lean liquid using the steam generator, cooling the reservoir fluid-comprising mixture with the scale forming-lean liquid.
[0035] In some implementations, the effected cooling is such that the oil-lean mixture has a temperature of at least the boiling point temperature of the oil-lean mixture at the pressure within the evaporator.
[00361 In some implementations, the effected cooling is such that the oil-lean mixture has a temperature of at least the boiling point temperature of water at 20 IcPa above atmospheric pressure.
DOCSTOR: 290503911
[00061 In some implementations, the process further comprises, prior to producing the pressurized steam, supplying the scale forming-lean liquid to a tank, wherein the tank is disposed at a pressure that is greater than atmospheric pressure.
[0007] In some implementations, the concentration of oil within the oil-lean mixture is between 10 ppm and 250 ppm.
[00081 In some implementations, the concentration of oil within the oil-lean mixture is between 10 ppm and 100 ppm.
[0009] In some implementations, the concentration of oil within the oil-lean mixture is between 10 ppm and 30 ppm.
[0010i In some implementations, the pressure is at least 20 kPa above atmospheric pressure.
[0011] In another aspect, there is provided a process for treating a reservoir fluid-comprising mixture, being produced through a wellhead from a hydrocarbon containing reservoir, comprising: fluidically coupling the wellhead to a steam generator via a fluid passage of a fluid conductor; producing, through a wellhead, a reservoir fluid-comprising mixture, including oil and water, from a hydrocarbon containing reservoir; separating an oil-lean mixture from the reservoir fluid-comprising mixture such that the concentration of oil within the oil-lean mixture is greater than 10 ppm; supplying the oil-lean mixture to a scale-forming solids separator, wherein the scale-forming solids separator includes an evaporator or a ceramic membrane filtration unit operation; separating, from the oil-lean mixture, a scale forming-lean liquid and a scale forming-rich material, using the evaporator; such that each one of (i) the separating of the oil-lean mixture from the reservoir fluid-comprising mixture, (ii) the supplying of the oil-lean mixture to the evaporator, and (iii) the separating, Man the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, using the evaporator is effected within the fluid passage, and the entirety of the fluid passage is disposed at a pressure that is greater than DOCSTOR; 2985039 VI
atmospheric pressure; producing pressurized steam from the scale forming-lean liquid using the steam generator; and supplying the pressurized steam to the hydrocarbon containing reservoir to effect mobilization of hydrocarbons within the hydrocarbon containing reservoir.
[0012] In some implementations, the process further comprises, prior to producing the pressurized steam, supplying the scale forming-lean liquid to a tank, wherein the tank is disposed at a pressure that is greater than atmospheric pressure.
[0013] In some implementations, he concentration of oil within the oil-lean mixture is between 10 ppm and 250 ppm.
[0014] In some implementations, the concentration of oil within the oil-lean mixture is between 10 ppm and 100 ppm.
[0015] In some implementations, the concentration of oil within the oil-lean mixture is between 10 ppm and 30 ppm.
[0016] In some implementations, the pressure is at least 20 kPa above atmospheric pressure.
[0017] In another aspect, there is provided a process for treating a reservoir fluid-comprising mixture, comprising producing a reservoir fluid-comprising mixture, including oil and water, from a hydrocarbon containing reservoir; at a pressure that is greater than atmospheric pressure, separating an oil-lean mixture from the reservoir fluid-comprising mixture; at a pressure that is greater than atmospheric pressure, effecting separation, from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material; supplying the scale forming-lean liquid to a tank that is disposed at a pressure that is greater than atmospheric pressure; supplying the scale forming-lean liquid from the tank to a steam generator; producing pressurized steam from the scale fomiing-lean liquid using the steam generator; and supplying the pressurized steam to the hydrocarbon containing reservoir to effect mobilization of oil within the hydrocarbon containing reservoir.
[0018] In some implementations, the temperature of the scale forming-lean liquid within the tank is greater than 100 degrees Celsius.
[0019] In some implementations, the separation, from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, is effected by evaporation.
DOCSTOR; 29650,1911 [00201 In some implementations, the separation from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, is effected by pressurized hot lime softening, [0021] In some implementations, the separation, from the oil-lean mixture, of a. scale forming-lean liquid and a scale forming-rich material, is effected by ceramic membrane filtration.
[0022] In some implementations, the pressure is at least 20 kPa above atmospheric pressure.
[00231 In another aspect, there is provided a process for treating a reservoir fluid-comprising mixture, being produced through a wellhead from a hydrocarbon containing reservoir, comprising: fluidically coupling the wellhead to a steam generator via a fluid passage of a fluid conductor; producing, through a wellhead, a reservoir fluid-comprising mixture, including oil and water, from a hydrocarbon containing reservoir; separating an oil-lean mixture from the reservoir fluid-comprising mixture; supplying the oil-lean mixture to a scale forming solids separator; separating, from the oil-lean mixture, a scale forming-lean liquid and a scale forming-rich material, using the scale forming solids separator; supplying the scale forming-lean liquid to a tank that is disposed at a pressure that is greater than atmospheric pressure; supplying the scale forming-lean liquid from the tank to a steam generator; such that each one of (i) the separating of the oil-lean mixture from the reservoir fluid-comprising mixture, (ii) the supplying of the oil-lean mixture to the scale forming solids separator, (iii) the separating, from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, using the scale forming solids separator, (iv) the supplying of the scale forming-lean liquid to a tank that is disposed at a pressure that is greater than atmospheric pressure, and (v) the supplying of the scale forming-lean liquid from the tank to the steam generator is effected within the fluid passage, and the entirety of the fluid passage is disposed at a pressure that is greater than atmospheric pressure;
producing pressurized steam from the scale forming-lean liquid using the steam generator; and supplying the pressurized steam to the hydrocarbon containing reservoir to effect mobilization of hydrocarbons within the hydrocarbon containing reservoir.
[00241 In some implementations, the temperature of the scale forming-lean liquid within the tank is greater than 100 degrees Celsius.
OdenSTOR; 285503911 [0025] In some implementations, the separation, from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, is effected by evaporation.
[00261 In some implementations, the separation from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, is effected by pressurized hot lime softening, [0027] In some implementations, the separation, from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, is effected by ceramic membrane filtration.
[0028] In some implementations, the pressure is at least 20 Oa above atmospheric pressure.
[0029] In another aspect, there is provided a process for treating a reservoir fluid-comprising mixture, being produced through a wellhead from a hydrocarbon containing reservoir, comprising: fluidically coupling the wellhead to a steam generator via a fluid passage of a fluid conductor; producing, through a wellhead, a reservoir fluid-comprising mixture, including oil and water, from a hydrocarbon containing reservoir; separating an oil-lean mixture from the reservoir fluid-comprising mixture; supplying the oil-lean mixture to a scale forming solids separator including an evaporator; separating, from the oil-lean mixture, a scale forming-lean liquid and a scale forming-rich material, using the scale forming solids separator; such that each one of (1) the separating of the oil-lean mixture from the reservoir fluid-comprising mixture, (ii) the supplying of the oil-lean mixture to the scale forming solids separator, and (iii) the separating, from the oil-lean mixture, of a scale forming-lean liquid and a scale forming-rich material, using the scale forming solids separator is effected within the fluid passage, and the entirety of the fluid passage is disposed at a pressure that is greater than atmospheric pressure;
producing pressurized steam from the scale forming-lean liquid using the steam generator; and supplying the pressurized steam to the hydrocarbon containing reservoir to effect mobilization of hydrocarbons within the hydrocarbon containing reservoir.
[0030] In some implementations, the pressure is at least 20 Icria above atmospheric pressure.
[0031] In some implementations, the process further comprises progressively reducing pressure along a section of the fluid passage, from downstream of the wellhead to the evaporator.
DOCSTOR: 295503911 100321 In another aspect, there is provided a process for treating a reservoir fluid-comprising mixture, being produced through a wellhead from a hydrocarbon containing reservoir, comprising: fluidically coupling the wellhead to an evaporator via a fluid passage of a fluid conductor extending upstream from the evaporator; producing, through a wellhead, a reservoir fluid-comprising mixture, including oil and water, from a hydrocarbon containing reservoir;
separating an oil-lean mixture from the reservoir fluid-comprising mixture;
supplying the oil-lean mixture to the evaporator; separating, from the oil-lean mixture, an aqueous liquid distillate and a scale forming-rich material, using the evaporator; such that each one of (i) the separating of the oil-lean mixture from the reservoir fluid-comprising mixture, (ii) the supplying of the oil-lean mixture to the evaporator, and (iii) the separating, from the oil-lean mixture, of an aqueous liquid distillate and a scale forming-rich material, using the evaporator is effected within the fluid passage, and the entirety of a section of the fluid passage, that is upstream of the evaporator, is disposed at a temperature of at least (i.e. greater than or equal to) the boiling point temperature of the oil-lean mixture at the pressure within the evaporator;
producing pressurized steam from the aqueous liquid distillate using the steam generator; and supplying the pressurized steam to the hydrocarbon containing reservoir to effect mobilization of hydrocarbons within the hydrocarbon containing reservoir.
100331 In some implementations, the temperature is at least the boiling point temperature of water at 20 kl)a above atmospheric pressure.
100341 In some implementations, the process further comprises, after the separating, from the oil-lean mixture, a scale forming-lean liquid and a scale forming-rich material, using the evaporator, and prior to the producing pressurized steam from the scale forming-lean liquid using the steam generator, cooling the reservoir fluid-comprising mixture with the scale forming-lean liquid.
[0035] In some implementations, the effected cooling is such that the oil-lean mixture has a temperature of at least the boiling point temperature of the oil-lean mixture at the pressure within the evaporator.
[00361 In some implementations, the effected cooling is such that the oil-lean mixture has a temperature of at least the boiling point temperature of water at 20 IcPa above atmospheric pressure.
DOCSTOR: 290503911
6 _ _ [0037] In some implementations, the effected cooling is such that the temperature of the cooled reservoir fluid-comprising mixture is such that the specific gravity of water, within the cooled reservoir fluid-comprising mixture, is greater than the specific gravity of oil, within the cooled reservoir fluid-comprising mixture, by a difference of between 20 kg/m3 and 70 kg/m3.
[0038] In some implementations, the temperature of the aqueous liquid distillate is greater than 100 degrees Celsius.
[0039] In some implementations, the process further comprises, progressively reducing temperature along the section of the fluid passage, from downstream of the wellhead to the evaporator.
[0040] In some implementations, the hydrocarbon containing reservoir is an oil sands reservoir.
10040a1 In another aspect, there is provided a process for recovering hydrocarbons from a hydrocarbon-bearing reservoir, comprising:
injecting steam into the hydrocarbon-bearing reservoir to heat and mobilize hydrocarbons therein;
at a pressure that is greater than atmospheric pressure, producing a reservoir fluid-comprising mixture from the hydrocarbon-bearing reservoir at a wellhead, the reservoir fluid-comprising mixture comprising hydrocarbons and produced water;
at a pressure that is above atmospheric pressure, separating at least a portion of the produced water from the reservoir fluid-comprising mixture; and at a pressure that is above atmospheric pressure, supplying the at least a portion of the produced water to a steam generator for generating the steam.
BRIEF DESCRIPTION OF DRAWINGS
[0041] The preferred embodiments will now be described with the following accompanying drawings, in which:
[0038] In some implementations, the temperature of the aqueous liquid distillate is greater than 100 degrees Celsius.
[0039] In some implementations, the process further comprises, progressively reducing temperature along the section of the fluid passage, from downstream of the wellhead to the evaporator.
[0040] In some implementations, the hydrocarbon containing reservoir is an oil sands reservoir.
10040a1 In another aspect, there is provided a process for recovering hydrocarbons from a hydrocarbon-bearing reservoir, comprising:
injecting steam into the hydrocarbon-bearing reservoir to heat and mobilize hydrocarbons therein;
at a pressure that is greater than atmospheric pressure, producing a reservoir fluid-comprising mixture from the hydrocarbon-bearing reservoir at a wellhead, the reservoir fluid-comprising mixture comprising hydrocarbons and produced water;
at a pressure that is above atmospheric pressure, separating at least a portion of the produced water from the reservoir fluid-comprising mixture; and at a pressure that is above atmospheric pressure, supplying the at least a portion of the produced water to a steam generator for generating the steam.
BRIEF DESCRIPTION OF DRAWINGS
[0041] The preferred embodiments will now be described with the following accompanying drawings, in which:
7 [0042] Figure 1 is a schematic illustration of a well pair in an oil sands reservoir for implementation of a steam-assisted gravity drainage process;
[0043] Figure 2 is a process flow diagram illustrating a system for practising an embodiment of the process described herein.
DETAILED DESCRIPTION
[0044] Referring to Figures 1 and 2, there is provided a system 100 for recovering and reusing water contained within a reservoir fluid-comprising mixture 110 that is produced from a hydrocarbon-containing reservoir 30. The recovered water is converted to high pressure steam 200 and conducted into the hydrocarbon-containing reservoir for effecting production of hydrocarbons from the reservoir. Amongst other things, the processes employed within the system are configured to minimize energy losses from the water being recovered, and thereby reduce energy requirements for converting the recovered water into steam with a steam generator 190. In this respect, in some implementations, the process is carried out at a pressure that is greater than atmospheric pressure. In some implementations, the pressure is at least 20 kPa above atmospheric pressure.
7a [0045] For illustrative purposes below, an oil sands reservoir from which bitumen is being produced using Steam-Assisted Gravity Drainage ("SAGD") is described. However, it should be understood, that the techniques described could be used in other types of hydrocarbon containing reservoirs and/or with other types of thermal recovery methods that use steam.
[0046] The reservoir fluid-comprising mixture 110 is produced from an oil sands reservoir using a SAGD well pair. Referring to Figure 1, in a typical SAGD well pair, the wells are spaced vertically from one another, such as wells 10 and 20, and the vertically higher well, i.e., well 10, is used for steam injection the SAGD operation, and the lower well, i.e., well 20, is used for producing bitumen. During the SAGD operation, steam injected through the well 10 (typically referred to as the "injection well") is conducted into the reservoir 30. The injected steam mobilizes the bitumen within the oil sands reservoir 30. The mobilized bitumen and steam condensate drains through the interwell region 15 by gravity to the well 20 (typically referred to as the "production well"), collects in the well 20, and is surfaced through tubing or by artificial lift to the surface, where it is produced through a wellhead 25.
[0047] The reservoir fluid-comprising mixture 110 includes oil and water.
In some embodiments, for example, the reservoir fluid-comprising mixture 110 has a temperature between 150 degrees Celsius and 250 degrees Celsius. The pressure of the reservoir fluid-comprising mixture 110 can range from 1000 ¨ 4000 kPa (gauge), and is dependent on the pressure within the reservoir 30.
00481 In some embodiments, for example, the reservoir fluid-comprising mixture 110 is conditioned, prior to separation into its material components, to produce a treated reservoir fluid-comprising mixture. For example, conditioning of the reservoir fluid-comprising mixture 110 can includes cooling of the reservoir fluid-comprising mixture 110.
[0049] Downstream separation processes effect separation of an oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 (see below), and, in some embodiments, for example, such separation processes are temperature dependent. Temperature affects both density and viscosity, and both of these parameters affect separation efficiency. To improve such separation, the reservoir fluid-comprising mixture 110 may be coaled prior to effecting the separation. In cases where the fluid temperature of the reservoir fluid-comprising mixture 110 is relatively low (such as, for example, 165 degrees Celsius or less), limited or no cooling may be required.
DOCSTOR: 2965039\1
[0043] Figure 2 is a process flow diagram illustrating a system for practising an embodiment of the process described herein.
DETAILED DESCRIPTION
[0044] Referring to Figures 1 and 2, there is provided a system 100 for recovering and reusing water contained within a reservoir fluid-comprising mixture 110 that is produced from a hydrocarbon-containing reservoir 30. The recovered water is converted to high pressure steam 200 and conducted into the hydrocarbon-containing reservoir for effecting production of hydrocarbons from the reservoir. Amongst other things, the processes employed within the system are configured to minimize energy losses from the water being recovered, and thereby reduce energy requirements for converting the recovered water into steam with a steam generator 190. In this respect, in some implementations, the process is carried out at a pressure that is greater than atmospheric pressure. In some implementations, the pressure is at least 20 kPa above atmospheric pressure.
7a [0045] For illustrative purposes below, an oil sands reservoir from which bitumen is being produced using Steam-Assisted Gravity Drainage ("SAGD") is described. However, it should be understood, that the techniques described could be used in other types of hydrocarbon containing reservoirs and/or with other types of thermal recovery methods that use steam.
[0046] The reservoir fluid-comprising mixture 110 is produced from an oil sands reservoir using a SAGD well pair. Referring to Figure 1, in a typical SAGD well pair, the wells are spaced vertically from one another, such as wells 10 and 20, and the vertically higher well, i.e., well 10, is used for steam injection the SAGD operation, and the lower well, i.e., well 20, is used for producing bitumen. During the SAGD operation, steam injected through the well 10 (typically referred to as the "injection well") is conducted into the reservoir 30. The injected steam mobilizes the bitumen within the oil sands reservoir 30. The mobilized bitumen and steam condensate drains through the interwell region 15 by gravity to the well 20 (typically referred to as the "production well"), collects in the well 20, and is surfaced through tubing or by artificial lift to the surface, where it is produced through a wellhead 25.
[0047] The reservoir fluid-comprising mixture 110 includes oil and water.
In some embodiments, for example, the reservoir fluid-comprising mixture 110 has a temperature between 150 degrees Celsius and 250 degrees Celsius. The pressure of the reservoir fluid-comprising mixture 110 can range from 1000 ¨ 4000 kPa (gauge), and is dependent on the pressure within the reservoir 30.
00481 In some embodiments, for example, the reservoir fluid-comprising mixture 110 is conditioned, prior to separation into its material components, to produce a treated reservoir fluid-comprising mixture. For example, conditioning of the reservoir fluid-comprising mixture 110 can includes cooling of the reservoir fluid-comprising mixture 110.
[0049] Downstream separation processes effect separation of an oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 (see below), and, in some embodiments, for example, such separation processes are temperature dependent. Temperature affects both density and viscosity, and both of these parameters affect separation efficiency. To improve such separation, the reservoir fluid-comprising mixture 110 may be coaled prior to effecting the separation. In cases where the fluid temperature of the reservoir fluid-comprising mixture 110 is relatively low (such as, for example, 165 degrees Celsius or less), limited or no cooling may be required.
DOCSTOR: 2965039\1
8 = Pk [0050] In some embodiments, the temperature of the cooled reservoir fluid-comprising mixture 110 is such that the specific gravity of water, within the cooled reservoir fluid-comprising mixture 110, is greater than the specific gravity of oil, within the cooled reservoir fluid-comprising mixture 110, by a difference of between 20 kg/m3 and 70 kg/m3, [00511 In some embodiments, the conditioning of the reservoir fluid-comprising mixture 110 includes admixing diluent 220 with the reservoir fluid-comprising mixture.
The admixing of the diluent 220 enables transport of the recovered oil through a pipeline. The diluent also affects the separation of an oil-lean mixture 120 from the cooled reservoir fluid-comprising mixture 110.
The more diluent that is added, the greater the density difference between the diluted oil and the water. Diluent is expensive and there are some losses to the gas phase.
Accordingly, diluent addition is minimized and limited to what is required such that the diluted oil meets the sales pipeline specifications. In some embodiments, the treating may include both cooling of the reservoir fluid-comprising mixture and admixing of the reservoir fluid-comprising mixture with diluent, in any order.
[0052] In other embodiments, instead of cooling the reservoir fluid-comprising mixture 110, the conditioning of the reservoir fluid-comprising mixture 110 includes heating the reservoir fluid-comprising mixture 110 such that the density of oil becomes sufficiently greater than the density of water so as to enable a desired separation of an oil-lean mixture 120 from the reservoir fluid-comprising mixture 110. In this case, no diluent is added. In some implementations, the separation of an oil-lean mixture 120 from the heated reservoir fluid-comprising mixture 110 is effected at about a temperature of 225 degrees Celsius.
[0053] The oil-lean mixture 120 is separated from the reservoir fluid-comprising mixture 110 (conditioned or unconditioned) within an oil separator 138. In some embodiments, in separating the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110, an oil-rich mixture 130 becomes separated from the oil-lean mixture 120. In some embodiments, the oil separator 138 includes three stages 140, 150, and 155. Typically, separation in stages 140 and 150 is effected by gravity separation, while separation in stage 155 functions to provide final polishing after the gravity separation to effect production of the oil-lean mixture 120. The total number of stages being determined based on a desired separation efficiency, while in keeping with a desire to optimize utilization of capital.
DOCSTOR: 286603011
The admixing of the diluent 220 enables transport of the recovered oil through a pipeline. The diluent also affects the separation of an oil-lean mixture 120 from the cooled reservoir fluid-comprising mixture 110.
The more diluent that is added, the greater the density difference between the diluted oil and the water. Diluent is expensive and there are some losses to the gas phase.
Accordingly, diluent addition is minimized and limited to what is required such that the diluted oil meets the sales pipeline specifications. In some embodiments, the treating may include both cooling of the reservoir fluid-comprising mixture and admixing of the reservoir fluid-comprising mixture with diluent, in any order.
[0052] In other embodiments, instead of cooling the reservoir fluid-comprising mixture 110, the conditioning of the reservoir fluid-comprising mixture 110 includes heating the reservoir fluid-comprising mixture 110 such that the density of oil becomes sufficiently greater than the density of water so as to enable a desired separation of an oil-lean mixture 120 from the reservoir fluid-comprising mixture 110. In this case, no diluent is added. In some implementations, the separation of an oil-lean mixture 120 from the heated reservoir fluid-comprising mixture 110 is effected at about a temperature of 225 degrees Celsius.
[0053] The oil-lean mixture 120 is separated from the reservoir fluid-comprising mixture 110 (conditioned or unconditioned) within an oil separator 138. In some embodiments, in separating the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110, an oil-rich mixture 130 becomes separated from the oil-lean mixture 120. In some embodiments, the oil separator 138 includes three stages 140, 150, and 155. Typically, separation in stages 140 and 150 is effected by gravity separation, while separation in stage 155 functions to provide final polishing after the gravity separation to effect production of the oil-lean mixture 120. The total number of stages being determined based on a desired separation efficiency, while in keeping with a desire to optimize utilization of capital.
DOCSTOR: 286603011
9 [0054] In some embodiments, the stage 150 is effected within a vessel including electrostatic grids to assist in the separation. In some embodiments, the stage 150 may not necessarily be effected within a vessel, but rather a separation device that uses accelerated gravity forces, such as a hydrocyclone or a centrifuge, In some embodiments, the stages 140 and 150 may be combined into a single stage.
[00551 The heavier liquid phase products 142, 152, generated from, respectively, stages 140, 150, are combined into an intermediate oil-lean mixture 118. The oil-rich mixture 130 is conducted to a product holding tank 160. Gaseous material 144, 154, produced from, respectively, stages 140, 150, is managed by a vapour handling system.
[00561 The intermediate oil-lean mixture 118 is supplied to a de-oiling separator 155 for effecting separation of an oil-rich separation product 124 and the oil-lean mixture 120. The separation can be effected by any one, or any combination, of gravity separation, filters (coalescing, granular media, cartridge, membrane, screen, pre-coat or types otherwise capable of filtering oil droplets), gas flotation units, hydrocyclones, centrifuges, and devices to improve coalescing such as plate packs.
100571 The oil-lean mixture 120 is supplied to a scale forming solids separator 160 for effecting separation, from the oil-lean mixture 120, of a scale forming-lean liquid 170 and a scale forming-rich material 165. The scale forming-rich material can be, for example, dissolved solids, suspended solids, or free oil. This separation can be effected, for example, by evaporation, pressurized hot lime softening in combination with ion exchange, or ceramic membrane filtration in combination with ion exchange. In this respect, in some embodiments, the scale forming solids separator 160 may include an evaporator, a presstuized hot lime softening unit operation, or a ceramic membrane filtration unit operation.
Scale forming solids that are concentrated within the scale foiming-rich material, by virtue of the separation, include calcium-comprising compounds, magnesium-comprising compounds, and silica. In some embodiments, for example, the scale forming-lean liquid 170 is disposed at a temperature that is greater than 100 degrees Celsius. Removal of scale-forming materials, prior to supplying of the liquid 170 to the steam generator 200, is desirable so as to mitigate scaling with the steam generator 200.
DOCSTOR: 296503911 [0058] In some embodiments, for example, prior to the supplying of the oil-lean mixture 120 to the scale forming solids separator 160, the oil-lean mixture 120 is admixed with chemical agents 125 for supporting or enabling processes effected within the separator 160, or for mitigating against undesirable process conditions within the separator 160. In some embodiments, for example, where the separator 160 is an evaporator, the chemical agents 125 can be a pH attenuating agent for mitigating against scale formation. The chemical agents 125 are typically introduced downstream of the separation of the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 so as not to unnecessarily consume the chemical agents 125 prior to introduction to the separator 160.
[0059] In some embodiments, for example, prior to the supplying of the oil-lean mixture 120 to the scale forming solids separator 160, the oil-lean mixture 120 is admixed with make-up water 122. The make-up water 122 may be added to compensate for reservoir losses of steam, and losses within the processing system, such as losses within purge streams.
The make-up water 122 is typically introduced downstream of the separation of the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 so as not to use up capacity within the oil separator 138.
[0060] The scale forming-lean liquid 170 is conducted to a steam generator 190 for conversion to pressurized steam 200 for use in recovering oil from the hydrocarbon containing reservoir 30. In this respect, the pressurized steam is conducted to the hydrocarbon containing reservoir 30 to effect mobilization of bitumen within the oil sands reservoir 30.
[0061] In one aspect, the separating of an oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 is such that the concentration of oil within the oil-lean mixture is greater than 10 ppm. In some embodiments, for example, the concentration of oil within the oil-lean mixture is between 10 ppm and 250 ppm, In some embodiments, for example, the concentration of oil within the oil-lean mixture is between 10 ppm and 100 ppm. In some embodiments, for example, the concentration of oil within the oil-lean mixture is between 10 ppm and 30 ppm.
Separation processes, for effecting the separation, from the oil-lean mixture 120, of the scale forming-lean liquid 170, in the form of evaporation, or ceramic membrane filtration in combination with ion exchange, are, typically, better able to process an oil-lean mixture 120 having relatively higher oil contents, than other separation processes. As a result, less costly de-DOCSTOR; 295503811 oiling equipment is required to effect the production of the oil-lean mixture 120, having a relatively higher oil content, when such separation processes are employed.
[00621 In another aspect, prior to being conducted to the steam generator 190, the scale forming-lean liquid 170 can be supplied to a tank 230. In some embodiments, for example, the tank 230 has a volume equivalent to that of providing for a residence time, for scale forming-lean liquid 170 being received from the separator 160, of at least about 15 minutes. In some embodiments, the tank 230 functions as a buffer for receiving surges in production of the scale forming-lean liquid 170, and for allowing steam generation to continue during upsets within upstream equipment (such as for example, when operation of the separator 160 becomes suspended) or allowing production of scale forming-lean liquid 170 to continue during upsets within downstream equipment (such as, for example, when the steam generator 190 shuts down).
[0063] The wellhead 25 is fluidly coupled the steam generator 190 via a fluid passage within a fluid conductor 300 for supplying water contained within the reservoir fluid-comprising mixture to the steam generator 190. In some embodiments, the conditioning of the reservoir fluid-comprising mixture 110 (if any), the separating of the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 (conditioned or unconditioned), the supplying of the oil-lean mixture 120 to the separator 160, and the separating of the scale forming-lean liquid 170 from the oil-lean mixture 120 is effected within the fluid passage. In other embodiments, for example, the fluid passage extends from the heat exchanger 210 to the steam generator 190, such that the separating of the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110, the supplying of the oil-lean mixture 120 to the separator 160, the separating of the scale forming-lean liquid 170 from the oil-lean mixture 120, the cooling of the reservoir fluid-comprising mixture 110 by the scale forming-lean liquid 170, and the supplying of the scale forming-lean liquid 170 to the steam generator 190 is effected within the fluid passage.
[00641 In another aspect, the entirety of the fluid passage of the fluid conductor 300 is disposed at a pressure that is greater than atmospheric pressure. In some implementations, additional compression machinery, downstream of the wellhead 25, for pressurizing the conducted fluid (in these instances, for example, such pressurization is effected by subsurface pumps), is not provided (in other embodiments, compression machinery may be provided immediately downstream of the wellhead 25 for assisting with production from the well) yet the DOCSTOR: 296503011 oil-lean mixture 120 is supplied to the separator 160 at a pressure that is greater than atmospheric pressure. In this respect, the pressure within the fluid passage of the fluid conductor 300 becomes progressively less up to at least the separator 160, but is still maintained above the pressure within the separator 160. In some implementations, each one of: (i) the conditioning (such as heating or cooling) of the reservoir fluid-comprising mixture, (ii) the separating of an oil-lean mixture from the cooled reservoir fluid-comprising mixture, (iii) the supplying of the oil-lean mixture to the separator 160, (iv) the separating of the scale forming-lean liquid 170 from the oil-lean mixture 120, (v) the cooling of the reservoir fluid-comprising mixture 110 by the scale forming-lean liquid 170, and (vi) the supplying of the scale forming-lean liquid 170 to the steam generator 190 is effected at a pressure that is greater than atmospheric pressure. In some of these implementations, for example, this pressure is at least 20 Oa above atmospheric pressure. In some of these implementations, for example, pressure along a section of fluid passage, from downstream of the wellhead to the evaporator, is progressively reduced.
[0065] By avoiding having to, e.g., as an intermediate step between the wellhead and the separator 160, reduce fluid pressure within the fluid passage, such as, to atmospheric pressure, and then elevate the fluid pressure to above atmospheric pressure (e.g., when an intermediate unit operation is provided and operated at atmospheric pressure, such as an atmospheric storage tank), it may be possible to avoid capital cost associated with additional compression machinery that may be required to effect the supply of the scale-forming lean liquid 170 to the steam generator 190 at a sufficiently high pressure. Such compression machinery may include compression machinery disposed upstream of the separator 160 for supplying the oil-lean mixture to the separator 160 at a pressure that is greater than atmospheric pressure.
[0066] When the separator 160 includes an evaporator, by supplying the oil-lean mixture 120 to the evaporator at a pressure that is greater than atmospheric pressure, the evaporator may be operated more efficiently or may occupy a smaller footprint.
[0067] When the separator 160 includes an evaporator, the evaporator effects evaporation of a portion of the oil-lean mixture to produce the scale forming-lean liquid 170 in the form of an aqueous liquid distillate. The residue remaining after the evaporation of a portion of the oil-lean mixture includes dissolved solids. Periodically, this residue is purged from the evaporator 160 as the scale forming-rich material 165 for disposal.
DOCSTOR: 2065039\1 10068] In some embodiments, the reservoir fluid-comprising mixture 110 is indirectly cooled by the scale forming-lean liquid 170. In this respect, the scale forming-lean liquid is supplied to the heat exchanger 210. Such supplying effects indirect heat transfer communication between the supplied scale forming-lean liquid 170 and the reservoir fluid-comprising mixture 110 within the heat exchanger 210. As a result, heat is transferred, within the heat exchanger 210, from the hotter reservoir fluid-comprising mixture 110 to the cooler scale forming-lean liquid 170, thereby effecting cooling of the reservoir fluid-comprising mixture 110, without requiring an external heat sink.
[0069J In another aspect, where the separator 160 includes an evaporator, an upstream fluid passage portion of the fluid conductor 300 is provided, and the upstream fluid passage portion extends upstream from the evaporator 160, and the entirety of the upstream fluid passage portion is disposed at a temperature that is at least (i.e .greater than or equal to) the boiling point temperature of the oil-lean mixture 120 at the pressure within the evaporator 160. In some implementations, for example, this temperature is at least the boiling point temperature of water at 20 IrPa above atmospheric pressure. In some implementations, each one of:
(i) the conditioning (such as heating or cooling) of the reservoir fluid-comprising mixture, (ii) the separating of an oil-lean mixture from the cooled reservoir fluid-comprising mixture, and (iii) the supplying of the oil-lean mixture to the separator 160 is effected at a temperature that is at least (i.e. greater than or equal to) the boiling point temperature of the oil-lean mixture 120 at the pressure within the evaporator 160, such as at least the boiling point temperature of water at 20 kPa above atmospheric pressure. In some implementations, the temperature along the section of fluid passage 300, from downstream of the wellhead to the evaporator, is progressively reduced to the boiling point temperature of the oil-lean mixture 120 at the pressure within the evaporator 160.
[00701 By avoiding having to, e.g., as an intermediate step between the wellhead and the separator 160, reduce temperature within the fluid passage below that of the boiling point temperature of the oil-lean mixture 120 at the pressure within the evaporator 160, and then to elevate the temperature to, or above, the boiling point temperature of the oil-lean mixture 120 at the pressure within the evaporator, it may be possible to avoid costs associated with additional heating of the scale-forming lean liquid 170 prior to supply to, or within, the evaporator.
DOCSTOR: 296503911 [0071) In a related aspect, the scale forming-lean liquid 170 is the aqueous liquid distillate, such that the aqueous liquid distillate 170 is supplied to the heat exchanger 210 to function as the cooling fluid. The reservoir fluid-comprising mixture 110 is cooled by the aqueous liquid distillate 170 to a temperature that is sufficient to enable the desired separation of the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 within the oil separator 138 but is maintained at a temperature that is greater than, or equal to, the boiling point temperature of the mixture 120 at the pressure within the evaporator 160 (for example, greater than, or equal to, the boiling point temperature of water at 20 kPa above atmospheric pressure). In some implementations, the cooling of the reservoir fluid-comprising mixture 110 is to a temperature that is sufficiently high such that, even with heat losses, after the separation of the oil-lean mixture from the cooled reservoir fluid-comprising mixture 110, the temperature of the oil-lean mixture 120 being supplied to the evaporator 160 is greater than, or equal to, the boiling point temperature of the oil-lean mixture at the pressure within the evaporator 160.
In some implementations, the temperature of the oil-lean mixture, supplied to the evaporator 160, is greater than, or equal to, the boiling point temperature of water at 20 kPa above atmospheric pressure. Again, this may potentially eliminate the requirement for either a heat exchange step between the hotter distillate 170 and the incoming feed of the oil-lean mixture 120 to the evaporator 160, or the input of additional heat within the evaporator processes.
[00721 In those embodiments where cooling of the reservoir fluid-comprising mixture 110 is being effected by the aqueous liquid distillate 170, in some of these embodiments, the cooling is such that a desired separation of the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 is facilitated, while still enabling the supply of the oil-lean mixture 120 to the evaporator at a temperature that is greater than, or equal to, the boiling point temperature of the oil-lean mixture at the pressure within the evaporator 160. In other embodiments, there is additional quenching effect provided by added diluent, make-up water, and other cooler process streams, and such additional quenching effect complements the heat exchange between the aqueous liquid distillate 170 and the reservoir fluid-comprising mixture 110 such that an additional external heat sink is not required for facilitating a desired separation of the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 while still enabling the supply of the oil-lean mixture 120 to the evaporator at a temperature that is greater than, or equal to, the boiling point temperature of the oil-lean mixture at the pressure within the evaporator 160, In DOCSTOR: 296503911 some cases, an additional external heat sink may be provided if such operational flexibility is desired and additional cooling, prior to supplying of the oil-lean mixture 120 to the evaporator 160, is required. Alternatively, the operating temperature of the evaporator 160 could be reduced (such as by reducing the pressure of the oil-lean mixture 120 being supplied to the evaporator) so as to avoid incorporation of an additional external heat sink.
[0073) Reference throughout the specification to "one embodiment/implementation," "an embodiment/implementation," "some embodiments/implementations," "one aspect,"
"an aspect,"
or "some aspects" means that a particular feature, structure, method, or characteristic described in connection with the embodiment/implementation or aspect is included in at least one embodiment/implementation of the present invention. In this respect, the appearance of the phrases "in one embodiment/implementation" or "in an embodiment/implementation" or "in some embodiments/implementations" in various places throughout the specification are not necessarily all referring to the same embodiment/implementation. Furthermore, the particular features, structures, methods, or characteristics may be combined in any suitable manner in one or more embodiments/implementations.
[0074] Each numerical value should be read once as modified by the term "about" (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. Also, in the summary and this detailed description, it should be understood that a concentration range listed or described as being useful, suitable, or the like, is intended that any and every concentration within the range, including the end points, is to be considered as having been stated. For example, "a range of from 1 to 10" is to be read as indicating each and every possible number along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or refer to only a few specific data points, it is to be understood that inventors appreciate and understand that any and all data points within the range are to be considered to have been specified, and that inventors have disclosed and enabled the entire range and all points within the range.
[0075] In the above description, for purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required in order to practice DOCSTOR: 2985039\1 the present disclosure. Although certain dimensions and materials are described for implementing the disclosed example embodiments, other suitable dimensions and/or materials may be used within the scope of this disclosure. All such modifications and variations, including all suitable current and future changes in technology, are believed to be within the sphere and scope of the present disclosure.
[00551 The heavier liquid phase products 142, 152, generated from, respectively, stages 140, 150, are combined into an intermediate oil-lean mixture 118. The oil-rich mixture 130 is conducted to a product holding tank 160. Gaseous material 144, 154, produced from, respectively, stages 140, 150, is managed by a vapour handling system.
[00561 The intermediate oil-lean mixture 118 is supplied to a de-oiling separator 155 for effecting separation of an oil-rich separation product 124 and the oil-lean mixture 120. The separation can be effected by any one, or any combination, of gravity separation, filters (coalescing, granular media, cartridge, membrane, screen, pre-coat or types otherwise capable of filtering oil droplets), gas flotation units, hydrocyclones, centrifuges, and devices to improve coalescing such as plate packs.
100571 The oil-lean mixture 120 is supplied to a scale forming solids separator 160 for effecting separation, from the oil-lean mixture 120, of a scale forming-lean liquid 170 and a scale forming-rich material 165. The scale forming-rich material can be, for example, dissolved solids, suspended solids, or free oil. This separation can be effected, for example, by evaporation, pressurized hot lime softening in combination with ion exchange, or ceramic membrane filtration in combination with ion exchange. In this respect, in some embodiments, the scale forming solids separator 160 may include an evaporator, a presstuized hot lime softening unit operation, or a ceramic membrane filtration unit operation.
Scale forming solids that are concentrated within the scale foiming-rich material, by virtue of the separation, include calcium-comprising compounds, magnesium-comprising compounds, and silica. In some embodiments, for example, the scale forming-lean liquid 170 is disposed at a temperature that is greater than 100 degrees Celsius. Removal of scale-forming materials, prior to supplying of the liquid 170 to the steam generator 200, is desirable so as to mitigate scaling with the steam generator 200.
DOCSTOR: 296503911 [0058] In some embodiments, for example, prior to the supplying of the oil-lean mixture 120 to the scale forming solids separator 160, the oil-lean mixture 120 is admixed with chemical agents 125 for supporting or enabling processes effected within the separator 160, or for mitigating against undesirable process conditions within the separator 160. In some embodiments, for example, where the separator 160 is an evaporator, the chemical agents 125 can be a pH attenuating agent for mitigating against scale formation. The chemical agents 125 are typically introduced downstream of the separation of the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 so as not to unnecessarily consume the chemical agents 125 prior to introduction to the separator 160.
[0059] In some embodiments, for example, prior to the supplying of the oil-lean mixture 120 to the scale forming solids separator 160, the oil-lean mixture 120 is admixed with make-up water 122. The make-up water 122 may be added to compensate for reservoir losses of steam, and losses within the processing system, such as losses within purge streams.
The make-up water 122 is typically introduced downstream of the separation of the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 so as not to use up capacity within the oil separator 138.
[0060] The scale forming-lean liquid 170 is conducted to a steam generator 190 for conversion to pressurized steam 200 for use in recovering oil from the hydrocarbon containing reservoir 30. In this respect, the pressurized steam is conducted to the hydrocarbon containing reservoir 30 to effect mobilization of bitumen within the oil sands reservoir 30.
[0061] In one aspect, the separating of an oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 is such that the concentration of oil within the oil-lean mixture is greater than 10 ppm. In some embodiments, for example, the concentration of oil within the oil-lean mixture is between 10 ppm and 250 ppm, In some embodiments, for example, the concentration of oil within the oil-lean mixture is between 10 ppm and 100 ppm. In some embodiments, for example, the concentration of oil within the oil-lean mixture is between 10 ppm and 30 ppm.
Separation processes, for effecting the separation, from the oil-lean mixture 120, of the scale forming-lean liquid 170, in the form of evaporation, or ceramic membrane filtration in combination with ion exchange, are, typically, better able to process an oil-lean mixture 120 having relatively higher oil contents, than other separation processes. As a result, less costly de-DOCSTOR; 295503811 oiling equipment is required to effect the production of the oil-lean mixture 120, having a relatively higher oil content, when such separation processes are employed.
[00621 In another aspect, prior to being conducted to the steam generator 190, the scale forming-lean liquid 170 can be supplied to a tank 230. In some embodiments, for example, the tank 230 has a volume equivalent to that of providing for a residence time, for scale forming-lean liquid 170 being received from the separator 160, of at least about 15 minutes. In some embodiments, the tank 230 functions as a buffer for receiving surges in production of the scale forming-lean liquid 170, and for allowing steam generation to continue during upsets within upstream equipment (such as for example, when operation of the separator 160 becomes suspended) or allowing production of scale forming-lean liquid 170 to continue during upsets within downstream equipment (such as, for example, when the steam generator 190 shuts down).
[0063] The wellhead 25 is fluidly coupled the steam generator 190 via a fluid passage within a fluid conductor 300 for supplying water contained within the reservoir fluid-comprising mixture to the steam generator 190. In some embodiments, the conditioning of the reservoir fluid-comprising mixture 110 (if any), the separating of the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 (conditioned or unconditioned), the supplying of the oil-lean mixture 120 to the separator 160, and the separating of the scale forming-lean liquid 170 from the oil-lean mixture 120 is effected within the fluid passage. In other embodiments, for example, the fluid passage extends from the heat exchanger 210 to the steam generator 190, such that the separating of the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110, the supplying of the oil-lean mixture 120 to the separator 160, the separating of the scale forming-lean liquid 170 from the oil-lean mixture 120, the cooling of the reservoir fluid-comprising mixture 110 by the scale forming-lean liquid 170, and the supplying of the scale forming-lean liquid 170 to the steam generator 190 is effected within the fluid passage.
[00641 In another aspect, the entirety of the fluid passage of the fluid conductor 300 is disposed at a pressure that is greater than atmospheric pressure. In some implementations, additional compression machinery, downstream of the wellhead 25, for pressurizing the conducted fluid (in these instances, for example, such pressurization is effected by subsurface pumps), is not provided (in other embodiments, compression machinery may be provided immediately downstream of the wellhead 25 for assisting with production from the well) yet the DOCSTOR: 296503011 oil-lean mixture 120 is supplied to the separator 160 at a pressure that is greater than atmospheric pressure. In this respect, the pressure within the fluid passage of the fluid conductor 300 becomes progressively less up to at least the separator 160, but is still maintained above the pressure within the separator 160. In some implementations, each one of: (i) the conditioning (such as heating or cooling) of the reservoir fluid-comprising mixture, (ii) the separating of an oil-lean mixture from the cooled reservoir fluid-comprising mixture, (iii) the supplying of the oil-lean mixture to the separator 160, (iv) the separating of the scale forming-lean liquid 170 from the oil-lean mixture 120, (v) the cooling of the reservoir fluid-comprising mixture 110 by the scale forming-lean liquid 170, and (vi) the supplying of the scale forming-lean liquid 170 to the steam generator 190 is effected at a pressure that is greater than atmospheric pressure. In some of these implementations, for example, this pressure is at least 20 Oa above atmospheric pressure. In some of these implementations, for example, pressure along a section of fluid passage, from downstream of the wellhead to the evaporator, is progressively reduced.
[0065] By avoiding having to, e.g., as an intermediate step between the wellhead and the separator 160, reduce fluid pressure within the fluid passage, such as, to atmospheric pressure, and then elevate the fluid pressure to above atmospheric pressure (e.g., when an intermediate unit operation is provided and operated at atmospheric pressure, such as an atmospheric storage tank), it may be possible to avoid capital cost associated with additional compression machinery that may be required to effect the supply of the scale-forming lean liquid 170 to the steam generator 190 at a sufficiently high pressure. Such compression machinery may include compression machinery disposed upstream of the separator 160 for supplying the oil-lean mixture to the separator 160 at a pressure that is greater than atmospheric pressure.
[0066] When the separator 160 includes an evaporator, by supplying the oil-lean mixture 120 to the evaporator at a pressure that is greater than atmospheric pressure, the evaporator may be operated more efficiently or may occupy a smaller footprint.
[0067] When the separator 160 includes an evaporator, the evaporator effects evaporation of a portion of the oil-lean mixture to produce the scale forming-lean liquid 170 in the form of an aqueous liquid distillate. The residue remaining after the evaporation of a portion of the oil-lean mixture includes dissolved solids. Periodically, this residue is purged from the evaporator 160 as the scale forming-rich material 165 for disposal.
DOCSTOR: 2065039\1 10068] In some embodiments, the reservoir fluid-comprising mixture 110 is indirectly cooled by the scale forming-lean liquid 170. In this respect, the scale forming-lean liquid is supplied to the heat exchanger 210. Such supplying effects indirect heat transfer communication between the supplied scale forming-lean liquid 170 and the reservoir fluid-comprising mixture 110 within the heat exchanger 210. As a result, heat is transferred, within the heat exchanger 210, from the hotter reservoir fluid-comprising mixture 110 to the cooler scale forming-lean liquid 170, thereby effecting cooling of the reservoir fluid-comprising mixture 110, without requiring an external heat sink.
[0069J In another aspect, where the separator 160 includes an evaporator, an upstream fluid passage portion of the fluid conductor 300 is provided, and the upstream fluid passage portion extends upstream from the evaporator 160, and the entirety of the upstream fluid passage portion is disposed at a temperature that is at least (i.e .greater than or equal to) the boiling point temperature of the oil-lean mixture 120 at the pressure within the evaporator 160. In some implementations, for example, this temperature is at least the boiling point temperature of water at 20 IrPa above atmospheric pressure. In some implementations, each one of:
(i) the conditioning (such as heating or cooling) of the reservoir fluid-comprising mixture, (ii) the separating of an oil-lean mixture from the cooled reservoir fluid-comprising mixture, and (iii) the supplying of the oil-lean mixture to the separator 160 is effected at a temperature that is at least (i.e. greater than or equal to) the boiling point temperature of the oil-lean mixture 120 at the pressure within the evaporator 160, such as at least the boiling point temperature of water at 20 kPa above atmospheric pressure. In some implementations, the temperature along the section of fluid passage 300, from downstream of the wellhead to the evaporator, is progressively reduced to the boiling point temperature of the oil-lean mixture 120 at the pressure within the evaporator 160.
[00701 By avoiding having to, e.g., as an intermediate step between the wellhead and the separator 160, reduce temperature within the fluid passage below that of the boiling point temperature of the oil-lean mixture 120 at the pressure within the evaporator 160, and then to elevate the temperature to, or above, the boiling point temperature of the oil-lean mixture 120 at the pressure within the evaporator, it may be possible to avoid costs associated with additional heating of the scale-forming lean liquid 170 prior to supply to, or within, the evaporator.
DOCSTOR: 296503911 [0071) In a related aspect, the scale forming-lean liquid 170 is the aqueous liquid distillate, such that the aqueous liquid distillate 170 is supplied to the heat exchanger 210 to function as the cooling fluid. The reservoir fluid-comprising mixture 110 is cooled by the aqueous liquid distillate 170 to a temperature that is sufficient to enable the desired separation of the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 within the oil separator 138 but is maintained at a temperature that is greater than, or equal to, the boiling point temperature of the mixture 120 at the pressure within the evaporator 160 (for example, greater than, or equal to, the boiling point temperature of water at 20 kPa above atmospheric pressure). In some implementations, the cooling of the reservoir fluid-comprising mixture 110 is to a temperature that is sufficiently high such that, even with heat losses, after the separation of the oil-lean mixture from the cooled reservoir fluid-comprising mixture 110, the temperature of the oil-lean mixture 120 being supplied to the evaporator 160 is greater than, or equal to, the boiling point temperature of the oil-lean mixture at the pressure within the evaporator 160.
In some implementations, the temperature of the oil-lean mixture, supplied to the evaporator 160, is greater than, or equal to, the boiling point temperature of water at 20 kPa above atmospheric pressure. Again, this may potentially eliminate the requirement for either a heat exchange step between the hotter distillate 170 and the incoming feed of the oil-lean mixture 120 to the evaporator 160, or the input of additional heat within the evaporator processes.
[00721 In those embodiments where cooling of the reservoir fluid-comprising mixture 110 is being effected by the aqueous liquid distillate 170, in some of these embodiments, the cooling is such that a desired separation of the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 is facilitated, while still enabling the supply of the oil-lean mixture 120 to the evaporator at a temperature that is greater than, or equal to, the boiling point temperature of the oil-lean mixture at the pressure within the evaporator 160. In other embodiments, there is additional quenching effect provided by added diluent, make-up water, and other cooler process streams, and such additional quenching effect complements the heat exchange between the aqueous liquid distillate 170 and the reservoir fluid-comprising mixture 110 such that an additional external heat sink is not required for facilitating a desired separation of the oil-lean mixture 120 from the reservoir fluid-comprising mixture 110 while still enabling the supply of the oil-lean mixture 120 to the evaporator at a temperature that is greater than, or equal to, the boiling point temperature of the oil-lean mixture at the pressure within the evaporator 160, In DOCSTOR: 296503911 some cases, an additional external heat sink may be provided if such operational flexibility is desired and additional cooling, prior to supplying of the oil-lean mixture 120 to the evaporator 160, is required. Alternatively, the operating temperature of the evaporator 160 could be reduced (such as by reducing the pressure of the oil-lean mixture 120 being supplied to the evaporator) so as to avoid incorporation of an additional external heat sink.
[0073) Reference throughout the specification to "one embodiment/implementation," "an embodiment/implementation," "some embodiments/implementations," "one aspect,"
"an aspect,"
or "some aspects" means that a particular feature, structure, method, or characteristic described in connection with the embodiment/implementation or aspect is included in at least one embodiment/implementation of the present invention. In this respect, the appearance of the phrases "in one embodiment/implementation" or "in an embodiment/implementation" or "in some embodiments/implementations" in various places throughout the specification are not necessarily all referring to the same embodiment/implementation. Furthermore, the particular features, structures, methods, or characteristics may be combined in any suitable manner in one or more embodiments/implementations.
[0074] Each numerical value should be read once as modified by the term "about" (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. Also, in the summary and this detailed description, it should be understood that a concentration range listed or described as being useful, suitable, or the like, is intended that any and every concentration within the range, including the end points, is to be considered as having been stated. For example, "a range of from 1 to 10" is to be read as indicating each and every possible number along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or refer to only a few specific data points, it is to be understood that inventors appreciate and understand that any and all data points within the range are to be considered to have been specified, and that inventors have disclosed and enabled the entire range and all points within the range.
[0075] In the above description, for purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required in order to practice DOCSTOR: 2985039\1 the present disclosure. Although certain dimensions and materials are described for implementing the disclosed example embodiments, other suitable dimensions and/or materials may be used within the scope of this disclosure. All such modifications and variations, including all suitable current and future changes in technology, are believed to be within the sphere and scope of the present disclosure.
Claims (5)
1. A process for recovering hydrocarbons from a hydrocarbon-bearing reservoir, comprising:
injecting steam into the hydrocarbon-bearing reservoir to heat and mobilize hydrocarbons therein;
at a pressure that is greater than atmospheric pressure, producing a reservoir fluid-comprising mixture from the hydrocarbon-bearing reservoir at a wellhead, the reservoir fluid-comprising mixture comprising hydrocarbons and produced water;
at a pressure that is greater than atmospheric pressure, separating at least a portion of the produced water from the reservoir fluid-comprising mixture; and at a pressure that is greater than atmospheric pressure, supplying the at least a portion of the produced water to a steam generator for generating the steam.
injecting steam into the hydrocarbon-bearing reservoir to heat and mobilize hydrocarbons therein;
at a pressure that is greater than atmospheric pressure, producing a reservoir fluid-comprising mixture from the hydrocarbon-bearing reservoir at a wellhead, the reservoir fluid-comprising mixture comprising hydrocarbons and produced water;
at a pressure that is greater than atmospheric pressure, separating at least a portion of the produced water from the reservoir fluid-comprising mixture; and at a pressure that is greater than atmospheric pressure, supplying the at least a portion of the produced water to a steam generator for generating the steam.
2. The process of claim 1, wherein the separating step includes an evaporation stage.
3. The process of any claims 1 or 2, wherein:
separating the at least a portion of the produced water from the reservoir fluid-comprising mixture further comprises separating a scale forming-lean liquid and a scale forming-rich material from the produced water; and supplying the produced water to the steam generator comprises supplying the scale forming-lean liquid to the steam generator for generating the steam.
separating the at least a portion of the produced water from the reservoir fluid-comprising mixture further comprises separating a scale forming-lean liquid and a scale forming-rich material from the produced water; and supplying the produced water to the steam generator comprises supplying the scale forming-lean liquid to the steam generator for generating the steam.
4. The process of claim 3, further comprising supplying the scale forming-lean liquid to a tank that is disposed at a pressure that is greater than atmospheric pressure, prior to supplying the scale forming-lean liquid to the steam generator.
5. The process as claimed in any one of claims 1 to 4, wherein the hydrocarbon containing reservoir is an oil sands reservoir.
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| CA2956736A CA2956736C (en) | 2014-02-06 | 2014-03-28 | Processes for treating reservoir fluid comprising material produced from a hydrocarbon containing reservoir |
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| US201461936808P | 2014-02-06 | 2014-02-06 | |
| US61/936,808 | 2014-02-06 |
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