WO2011091501A1 - Procédé et appareil pour le chauffage de coulis de bitume stocké dans une cuve - Google Patents

Procédé et appareil pour le chauffage de coulis de bitume stocké dans une cuve Download PDF

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Publication number
WO2011091501A1
WO2011091501A1 PCT/CA2010/001136 CA2010001136W WO2011091501A1 WO 2011091501 A1 WO2011091501 A1 WO 2011091501A1 CA 2010001136 W CA2010001136 W CA 2010001136W WO 2011091501 A1 WO2011091501 A1 WO 2011091501A1
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WO
WIPO (PCT)
Prior art keywords
transfer fluid
heat transfer
exhaust
heat exchanger
engine
Prior art date
Application number
PCT/CA2010/001136
Other languages
English (en)
Inventor
Grant W. Hiebert
Steven Bradwell
Jack W. Fenkhuber
Nathan Q. Illerbrun
Gerald W. Clancy
Colin D. Mcmaster
Grant W. Meikle
Original Assignee
Hiebert Grant W
Steven Bradwell
Fenkhuber Jack W
Illerbrun Nathan Q
Clancy Gerald W
Mcmaster Colin D
Meikle Grant W
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hiebert Grant W, Steven Bradwell, Fenkhuber Jack W, Illerbrun Nathan Q, Clancy Gerald W, Mcmaster Colin D, Meikle Grant W filed Critical Hiebert Grant W
Publication of WO2011091501A1 publication Critical patent/WO2011091501A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02G—HOT GAS OR COMBUSTION-PRODUCT POSITIVE-DISPLACEMENT ENGINE PLANTS; USE OF WASTE HEAT OF COMBUSTION ENGINES; NOT OTHERWISE PROVIDED FOR
    • F02G5/00—Profiting from waste heat of combustion engines, not otherwise provided for
    • F02G5/02—Profiting from waste heat of exhaust gases
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • This invention relates to the field of heating devices used to separate heavy oil from a bitumen slurry consisting of heavy oil, sand and water, and in particular to a method and apparatus for heating the bitumen slurry which uses recaptured heat from a well head pump power plant.
  • CHOPS Cold Heavy Oil Production with Sand
  • a large storage tank for example of 750 or 1000 barrel capacity, is also provided at the site. It is used to contain the mixture of oil, sand and water which is extracted from the earth by the oil well pump. To be useful, for example so that the oil in the mixture may be processed for pumping through a pipeline, the mixture being pumped from the well must be separated during a primary separation process at the well site. The primary separation is achieved by maintaining the temperature of the mixture in the storage tank at approximately 80 degrees Celsius. At this temperature, the sand, water and oil in the mixture separates into distinct layers within the storage tank.
  • the oil component of the mixture is typically too viscous to effectively flow in a pipeline
  • the oil once separated is regularly drained from the storage tank into tanker trucks and delivered to local "upgrader" facilities where the oil is processed and thinned in order to make it suitable for introduction into a pipeline network,
  • the water that accumulates in the tank is drained as necessary and sand is also removed on a regular basis.
  • CHOPS sites Unlike most light oil wells, CHOPS sites often do not produce adequate amounts of well gas to provide fuel either for the power plant engine that generates hydraulic power for the well head pump or for the prior art large burner-style tank heaters that are placed inside the storage tanks and used to heat the oil once it is in the storage tank. Consequently propane to be consumed by the engine and storage tank heater has to be brought to the well sites at great expense due to the remote location of the well site and lack of usable onsite gas. Next to the actual trucking of the oil, propane consumption accounts for the most significant cost in the production of CHOPS oil.
  • St. Denis discloses appending an engine compartment to the peripheral side wall of a liquid storage tank.
  • An engine is disposed in the engine compartment. Heat given off f om the engine during operation heats the engine compartment and such heat is transferred through the peripheral sidewall to the interior of the liquid storage tank.
  • An exhaust conduit extends into the interior of the liquid storage tank. Heat from hot exhaust gases passing through the exhaust conduit heats the interior of the liquid storage tank.
  • Denis also discloses passing heated engine coolant through an engine coolant conduit positioned concentrically within the engine exhaust conduit leading from the engine so that heat from the engine coolant is added to the hot exhaust gases to further transmit heat the interior of the liquid storage tank.
  • an engine coolant conduit positioned concentrically within the engine exhaust conduit leading from the engine so that heat from the engine coolant is added to the hot exhaust gases to further transmit heat the interior of the liquid storage tank.
  • at least one conduit extends from the engine into the interior of the tank and back to the engine to circulate hot fluid from the engine through the conduit to thereby heat the interior of the tank.
  • An internal combustion engine which powers a prime mover for a bitumen slurry well head pump used at a CHOPS site to pump bitumen slurry from a well borehole.
  • a storage tank is also provided in a location adjacent to the CHOPS site. Bitumen slurry is pumped from the CHOPS site and stored in the storage tank. When running at its operating temperature the engine provides heated exhaust along an exhaust conduit and into an exhaust inlet of a first heat exchanger in an exhaust-to-heat transfer fluid heat exchanger.
  • Heat transfer fluid for example glycol
  • Heat transfer fluid-to-bitunaen slurry heat exchanger mounted in the storage tank to thereby heat the bitumen slurry in the storage tank.
  • the exhaust-to-heat transfer fluid heat exchanger includes: i) an engine exhaust duct having the exhaust inlet and an engine exhaust outlet in gas-flow communication along said exhaust duct with said exhaust inlet; and, ii) a heat transfer fluid duct having said exhaust duct adjacent to and isolated from said fluid duct so as to transfer heat but not said gas-flow or said fluid between said exhaust duct and said fluid duct.
  • the engine exhaust is directed along an exhaust conduit from the engine into the engine exhaust inlet of the exhaust-to-heat transfer fluid heat exchanger.
  • the heat transfer fluid is pumped by a heat transfer fluid pump from the heat transfer fluid inlet to the heat transfer fluid outlet of the exhaust-to-heat transfer fluid heat exchanger.
  • Heat transfer fluid from the heat transfer fluid outlet of the exhaust-to-heat transfer fluid heat exchanger is directed along a heat transfer fluid conduit into the heat transfer fluid-to-bitumen slurry heat exchanger so as to transfer heat from the heat transfer fluid to bitumen slurry in the storage tank.
  • the heat transfer fluid is re-circulated from the heat transfer fluid-to-bitumen slurry heat exchanger back to the heat transfer fluid inlet of the exhaust-to-heat transfer fluid heat- exchanger.
  • the re-circulating circuit between the exhaust-to-heat transfer fluid heat exchanger and the heat transfer fluid-to-bitumen slurry heat exchanger re-circulates the beat transfer fluid continuously therealong.
  • an inlet temperature sensor for monitoring temperature of the heat transfer fluid entering the heat transfer fluid inlet
  • an outlet temperature sensor for monitoring temperature of the heat transfer fluid exiting the exhaust-to-heat transfer fluid heat exchanger from the heat transfer fluid outlet.
  • a selectively actuable flow diverter for diverting exhaust into an exhaust bypass to inhibit the exhaust from entering the exhaust inlet
  • a controller and/or processor for comparing at least one of the monitored temperatures with a threshold temperature of the heat transfer fluid, wherein the threshold temperature maybe substantially an upper maximum desired temperature range of the heat transfer fluid, for example to avoid at least vapourization of the fluid, and if the monitored temperature substantially equals or exceeds the threshold temperature then the diverter is actuated to bypass the exhaust from the exhaust inlet and into the exhaust bypass.
  • the controller and/or processor also monitors at least one of the temperature sensors for a drop in temperature of the heat transfer fluid. When said temperature of the heat transfer fluid drops below the threshold temperature, the exhaust is directed back into said exhaust inlet.
  • the method of the present invention may further include the step of capturing heat from the engine by directing the liquid coolant into the heat transfer fluid-to-bitumen slurry heat exchanger.
  • the liquid coolant is of the same composition as the heat transfer fluid.
  • the liquid coolant thus is mingled with the heat transfer fluid, for example inter-mingled downstream of the radiator and downstream of the heat transfer fluid outlet of said exhaust-to-heat transfer fluid heat exchanger, and upstream of the heat transfer fluid-to-bitumen slurry heat exchanger, so that a mixture of the heat transfer fluid and the liquid coolant enters the heat transfer fluid-to-bitumen slurry heat exchanger.
  • an engine coolant temperature sensor is provided to monitor the liquid coolant temperature.
  • the liquid coolant is directed as between the radiator and the heat transfer fluid-to-bitumen slurry heat exchanger so as to maintain an operational engine temperature in the engine while optimizing heat transfer from the liquid coolant to the heat transfer fluid-to-bitumen slurry heat exchanger.
  • a bitumen slurry temperature sensor may be provided for monitoring the temperature of the bitumen slurry.
  • the controller compares the bitumen slurry temperature and determines or estimates (herein collectively referred to as determines) when bitumen slurry separation has substantially occurred, whereupon the controller performs at least one further step chosen from the group: continue heating the bitumen slurry, reduce heating of the bitumen slurry, send out a signal indicating status of separation of the bitumen slurry.
  • the heat transfer fluid-to-bitumen slurry heat exchanger may include a helical or other coil heat exchanger, and die exhaust-to-heat transfer fluid heat exchanger may include a counter-flow heat exchanger.
  • Figure 1 is a top perspective view of a portion of the apparatus according to the present invention including an internal combustion engine, an exhaust-to-heat transfer fluid heat exchanger and an exhaust bypass.
  • Figure 2 is in perspective view, a representation of a storage tank and one embodiment of a heat transfer fluid-to-bitumen slurry heat exchanger mounted therein.
  • Figure 3 is, in partially cut-away perspective view, the exhaust conduits of Figure 1 directing engine exhaust from the internal combustion engine of Figure 1 to an exhaust bypass and an exhaust-to-heat transfer fluid heat exchanger.
  • Figure 4 is, in schematic view, the exhaust, heat transfer fluid and engine coolant heat recapture circuits according to one aspect of the present invention.
  • Figure 5 is, an enlarged partially cut-away view of the heat exchanger Figure 2.
  • Figure 6 is, in partially cut-away perspective view, a further embodiment of a heat transfer fluid-to-bitumen slurry heat exchanger mounted in a storage tank.
  • Figure 6a is an enlarged partially cut-away view of the heat exchanger of Figure
  • FIG. 7 is a further embodiment of the heat exchanger system according to the present invention. Detailed Description of Embodiments of the Invention
  • the present invention reclaims heat that is currently wasted from the exhaust system and in a preferred embodiment also the cooling jacket of an internal combustion engine 10 used to power a hydraulic well pump.
  • Engine 10 may run on propane, but this is not intended to be limiting as other fuel services would also work.
  • the reclaimed heat from engine 10 is used to heat, and thereby to separate, a mixture of heavy oil (bitumen), sand and water (referred to herein as bitumen slurry) pumped by the well pump into an elevated storage tank 12.
  • the exhaust gases from engine 10 are routed through an exhaust gas-to-heat transfer liquid heat exchanger 14.
  • the heat transfer fluid e.g. glycol
  • the heat transfer fluid may in one embodiment be combined with the liquid coolant from the heated water jacket and radiator circuit 16 of engine 10.
  • the heat transfer fluid heated in heat exchanger 14, in the preferred embodiment combined with the liquid coolant from circuit 16, is pumped in direction A by pump(s) 18 for the heat transfer fluid flowing through check valve(s) 20a in direction A' into the inlet port 36a of heat exchanger 14, and for the engine coolant circuit through, for example, diverter valve 20b into the inlet 22a of a heat transfer fluid-to-bitumen slurry heat exchanger 22 mounted in storage tank 12.
  • the temperature of the engine exhaust gas from engine 10 (which may typically be 800 degrees Celsius) will usually necessitate that controls be used to ensure that the glycol, or other heat transfer fluid, does not vapourize during the heat transfer process.
  • a system of sensors and control software in a controller monitors the heat reclamation system according to the present invention and makes the necessary control decisions to prevent the vapourization of the heat transfer fluid (glycol) in heat exchanger 14.
  • a pressure relieving system for example pressure relief valve 50 may be incorporated into heat exchanger 14 to allow the safe release of pressurized glycol gas in the event that vapourization occurs.
  • Figure 1 depicts one embodiment of exhaust heat exchanger 14 mounted on exhaust manifolds 10a of engine 10
  • Figure 3 is a further embodiment and is not intended to limiting.
  • the various exhaust and fluid circuits for this embodiment of the present invention are illustrated schematically in Figure 4.
  • Examples of storage tank 12 containing examples of heat exchanger 22 are illustrated in Figures 5 and 6.
  • the two exhaust diverter valves 24a and 24b are biased to divert the exhaust gas flow in direction C through heat exchanger 14. If the measured circulating glycol temperature is also below the maximum allowable engine cooling jacket temperature then the engine liquid coolant is diverted in direction D away from radiator 32 through check valve 34 so as to be mixed with the glycol outlet flow in direction A from heat exchanger 14.
  • This glycol outlet flow from heat exchanger 14 exits from outlet port 36b into outflow conduit 38 (shown in dotted outline in Figure 1, partially cut-away, and in Figure 4) which carries the heated glycol through check valve 38a to inlet 22a of heat exchanger 22.
  • the glycol circuit may include an expansion tank 38b and corresponding pressure relief valve 38c.
  • heat exchanger 22 may be helical as in Figure 6, or, for example as seen in Figure 5, may be non-helical so long as heat from the glycol is transferred efficiently to the bitumen slurry 40 in tank 12.
  • the remaining circulating glycol is allowed to continue receiving heat from heat exchanger 14 until such time as either the desired bitumen slurry temperature is reached as measured by sensor 42 or the maximum safe temperature of the glycol is reached as indicated for example by a temperature sensor mounted in tank 12 or for example by measurements by temperature sensor 44.
  • the engine exhaust from manifolds 10a and flowing through exhaust conduit 46 is diverted into bypass conduit 26 and thereby around exhaust heat exchanger 14 so as to flow directly into engine exhaust silencer 28.
  • This control method is used to continuously monitor the temperature of the circulating glycol and add heat to it as required from either of the two engine heat sources.
  • an additional inline, gas fired glycol heater (not shown) may be used to supplement the heat provided by engine 10.
  • gas fired glycol heaters are typically much more efficient than the burner type commonly used in the prior art as described above and therefore the amount of propane consumed by such gas-fired glycol heaters is less than typically encountered in the prior art.
  • sensors 42, 44 are used to monitor the temperature and sensor 48 monitors flow rate of the glycol in the recirculation loop (A - E).
  • the temperature is measured by sensor 42 just prior to the glycol coming into the recirculation glycol pump(s) 18, which may have parallel circuits as seen in dotted outline in Figure 4, and then again by sensor 44 just downstream of heat exchanger 14 and downstream of where heat transfer fluid (glycol) is mixed with the cooling jacket fluid (glycol also).
  • Flow meter 48 is used to ensure that the glycol is flowing at an acceptable rate.
  • the controller actuates valves 24a, 24b to force the exhaust into conduit 26 to bypass heat exchanger 14 and ensure that the glycol does not vapourize due to excessive heat input.
  • the sensors located in the circuit may also be used to provide data as to how much energy is being recovered and therefore, how much propane is not being consumed (such as would be consumed by the standard tank heater). To calculate the energy being recovered the temperature of the glycol is measured as it enters and exits the engine recirculation loop as well as the mass flow rate of the glycol.
  • Expansion joints 52 may be included on heat exchanger 14 and exhaust bypass
  • the slurry that is pumped into the storage tank typically contains both oil and water.
  • the slurry is pumped into the storage tank at the bottom of the tank, and droplets of oil in the slurry are then allowed to rise.
  • the droplets of oil settle in an oil pool over the water below the oil.
  • the water below the oil pool is herein referred to as the water zone or water portion of the storage tank.
  • the oil pool is herein also referred to as the oil portion of the storage tank.
  • the tank may be drawn down completely. This allows for the cleaning of the tank, and in particular the cleaning out of sand which accumulates in the bottom of the tank.
  • the heating of the oil in the tank directly using exhaust gases risks explosion, for example if the exhaust conduit tube in the tank is exposed when the oil/slurry is drawn down, or if the exhaust conduct tube has a leak and, again, the tank is drawn down too far so as to expose the tube.
  • two heating zones may be employed, one in the lower, water portion and one higher up in the tank in the oil portion of the tank.
  • no direct engine fluids or gases such as the engine coolant or exhaust go directly from the engine into the storage tank.
  • an exhaust gas heat exchanger is used in series with, that is, in addition to and in-line with, the glycol (or other liquid coolant) heat exchanger.
  • the additional heat recovery is thought to possibly add a further 5 - 10 °C to the heat transfer fluid in the tube going into the oil/slurry in the tank over the otherwise limiting temperature of the engine operating temperature.
  • the engine coolant operating temperature is 98°C then the use of the two heat exchangers, one coolant, the other exhaust, in series may provide for a temperature of 108°C in the heat transfer fluid going into the storage tank.
  • a second heat exchanger 54 is included in series with, and downstream of, heat exchanger 14.
  • Heat exchanger 14 is, in the preferred embodiment, an engine coolant, for example, glycol heat exchanger, and heat exchanger 54 is an engine exhaust heat exchanger.
  • Coolant for heat exchanger 14 is pumped by motor 30a driving pumps 30, and diverted to the heat exchanger 14 by actuation of diverter valves 21a and 21b from the coolant circuit through radiator 32, radiator 32 having an associated radiator fan 32a.
  • the particular form of heat exchanger used for heat exchangers 14 or 54 for example, whether linear counter-flow, helical coil, etc would be a design choice known to one skilled in the art.
  • temperature sensors 44a and 44b are mounted, respectively, between heat exchangers 14 and 54, and downstream of heat exchanger 54.
  • Gate valves 38b, 38c and 38d are provided, replacing one-way valve 38a in Figure 4, so as to regulate flow of heated heat transfer fluid into tank 12, and in particular into upper heat exchanger portion 22c corresponding to the oil portion of the tank, and, alternatively, also into lower heat exchanger portion 22d corresponding to the water portion of the tank.
  • Gate valves 18a and 18b-18d are associated with corresponding pumps 18 pumping heat transfer fluid through the heat exchangers 14 and 54.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Heat-Pump Type And Storage Water Heaters (AREA)

Abstract

Un moteur à combustion interne fait fonctionner une pompe de tête pour pomper du coulis de bitume à partir d'un puits de forage. Une cuve de stockage stocke le coulis de bitume en un endroit adjacent à un site CHOPS. Le gaz d'échappement chaud provenant du moteur circule dans une conduite de gaz d'échappement et vers un échangeur de chaleur gaz d'échappement-glycol. Le glycol est pompé dans un circuit de recirculation à partir de l'échangeur de chaleur gaz d'échappement-glycol vers un échangeur de chaleur glycol-coulis de bitume et dans celui-ci pour de cette manière chauffer le coulis de bitume présent dans la cuve de stockage. Le glycol refroidi est renvoyé vers l'échangeur de chaleur gaz d'échappement-glycol. Le liquide de refroidissement du moteur peut être mêlé au glycol circulant vers l'échangeur de chaleur glycol-coulis de bitume. En variante, le liquide de refroidissement du moteur est pompé dans un second échangeur de chaleur, un échangeur de chaleur liquide de refroidissement du moteur-glycol en série avec l'échangeur de chaleur gaz d'échappement-glycol, pour faire monter la température du glycol entrant dans l'échangeur de chaleur avec le coulis.
PCT/CA2010/001136 2010-01-28 2010-07-22 Procédé et appareil pour le chauffage de coulis de bitume stocké dans une cuve WO2011091501A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US28236010P 2010-01-28 2010-01-28
CA2691389A CA2691389A1 (fr) 2010-01-28 2010-01-28 Methode et appareil de chauffage pour boue de bitume stockee dans un reservoir
CA2,691,389 2010-01-28
US61/282,360 2010-01-28

Publications (1)

Publication Number Publication Date
WO2011091501A1 true WO2011091501A1 (fr) 2011-08-04

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PCT/CA2010/001136 WO2011091501A1 (fr) 2010-01-28 2010-07-22 Procédé et appareil pour le chauffage de coulis de bitume stocké dans une cuve

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5098036A (en) * 1986-10-30 1992-03-24 Zwick Energy Research Organization, Inc. Flameless deicer
US5222696A (en) * 1986-10-30 1993-06-29 Zwick Energy Research Organization, Inc. Flameless deicer
US5335728A (en) * 1992-07-31 1994-08-09 Strahan Ronald L Method and apparatus for disposing of water at gas wells
US5988280A (en) * 1996-12-23 1999-11-23 Ambar, Inc. Use of engine heat in treating a well bore
US6032732A (en) * 1998-04-27 2000-03-07 Yewell; Ronald E. Well head heating system
US7726298B2 (en) * 2003-03-07 2010-06-01 Newco Tank Corp. Method and apparatus for heating a liquid storage tank

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5098036A (en) * 1986-10-30 1992-03-24 Zwick Energy Research Organization, Inc. Flameless deicer
US5222696A (en) * 1986-10-30 1993-06-29 Zwick Energy Research Organization, Inc. Flameless deicer
US5335728A (en) * 1992-07-31 1994-08-09 Strahan Ronald L Method and apparatus for disposing of water at gas wells
US5988280A (en) * 1996-12-23 1999-11-23 Ambar, Inc. Use of engine heat in treating a well bore
US6032732A (en) * 1998-04-27 2000-03-07 Yewell; Ronald E. Well head heating system
US7726298B2 (en) * 2003-03-07 2010-06-01 Newco Tank Corp. Method and apparatus for heating a liquid storage tank

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