WO2012100320A1 - Modular transportable system for sagd process - Google Patents
Modular transportable system for sagd process Download PDFInfo
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- WO2012100320A1 WO2012100320A1 PCT/CA2011/000465 CA2011000465W WO2012100320A1 WO 2012100320 A1 WO2012100320 A1 WO 2012100320A1 CA 2011000465 W CA2011000465 W CA 2011000465W WO 2012100320 A1 WO2012100320 A1 WO 2012100320A1
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- evaporator
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/16—Enhanced recovery methods for obtaining hydrocarbons
- E21B43/24—Enhanced recovery methods for obtaining hydrocarbons using heat, e.g. steam injection
- E21B43/2406—Steam assisted gravity drainage [SAGD]
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H5/00—Buildings or groups of buildings for industrial or agricultural purposes
- E04H5/02—Buildings or groups of buildings for industrial purposes, e.g. for power-plants or factories
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/34—Arrangements for separating materials produced by the well
- E21B43/40—Separation associated with re-injection of separated materials
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
- C10G2300/40—Characteristics of the process deviating from typical ways of processing
- C10G2300/4068—Moveable devices or units, e.g. on trucks, barges
Definitions
- SAGD Steam Assisted Gravity Drainage
- Non-continuous process whereby fluids undergo some degree of processing followed by transfer in and out of the tank farm only to undergo further processing.
- the environmental impact of current oil sands production techniques are raising significant international and domestic concerns and present a real threat to the oil sands industry as a whole.
- Current SAGD facilities have a large footprint when considering the land disturbance for the CPF, well pads, interconnecting roads and pipelines and camp facilities for construction, maintenance and operating staff.
- they have significant water use and disposal requirements and are energy intensive, leading to greenhouse gas generation.
- a transportable modular process for exploiting a remote heavy oil resource or the like using steam assisted gravity drainage technology or the like.
- Said process comprising transportable preassembled and commissioned / tested modules which when interconnected adjacent to said remote heavy oil resource provide the ability to exploit said heavy oil resource or the like.
- Each module being preassembled and commissioned at the time of manufacture with the necessary piping and electrical wiring and other essential equipment for each module prior to being transported to adjacent the resource.
- Each module being, when transported to adjacent said resource, able to be readily interconnected with other process modules to enable an entire SAGD process or the like to be constructed adjacent said resource,
- said modular process may be disassembled and transported to a different remote resource, and subsequently reassembled at said different remote resource in the same manner.
- Said process comprises several transportable modules selected from the following group of modules: a) Oil and water separation modules
- VRU Vapor Recovery Unit
- Cooling system modules for example glycol cooling system
- the modules are designed to be direct coupled on one or two levels with pipe racks integral to each module. This reduces the overall size of the complete SAGD process plant and minimizes the need for long pipe racks typical of current SAGD facilities. This is also a critical feature required to support the portability concept incorporated into the design.
- a transportable modular system for hydrocarbon extraction using a Process or the like comprising of several of the following interconnected modules assembled into said process at a desired site, but each module being commissioned where constructed prior to being transported: a) Module 1 comprising inlet coolers, an inlet separator, a de-sand unit, and Free Water Knock-Out and Oil Treating vessels.
- Module 2 comprising of an Induced Gas Floatation Unit, distillate tank and Dilbit cooler.
- Module 3 comprising the evaporator exchanger.
- Module 4 comprising an evaporator compressor, evaporator recirculation pumps and chemical addition machinery.
- Module 5 comprising boiler feed water pumps, instrument air systems and electrical systems.
- Module 6 comprising a boiler.
- Module 7 comprising power generation and a Heat Recovery Steam Generator.
- Module 8 comprising a glycol cooler or other cooling system.
- Module 9 comprising a flash drum, flash drum condenser, and dump condenser.
- Module 10 comprising a glycol expansion drum, fuel gas drum, and heat exchangers.
- Said modules being assembled and interconnected into said process by the provision of the boundaries of said modules being adapted to be securely connected by mechanical means, and by connecting electrical lines and piping runs extending from module to module.
- the modules are interconnected and once this is done further comprising the necessary equipment, machinery, piping and tubing, fastening means, electrical lines and sets of controllers required for the operation of the modular process/system.
- At least one of the said above modules is selected from the following list of: a) Third party evaporator modified to incorporate emeX weir and a set of controllers; and/or
- a method of transporting a SAGD process or the like to a remote hydrocarbon reservoir comprising:
- modules which collectively substantially make up the process when assembled together to substantially form said process including preferably modules 1 to 10 listed above.
- modules can be manufactured and assembled at single location or at multiple locations and tested at those locations or transported to one location and commissioned prior to the delivery to the remote location. According to another aspect of the invention there is provided a process comprising several modules selected from the following group of modules:
- VRU Vapor Recovery Unit
- Cooling system modules for example glycol cooling system
- a process for hydrocarbon extraction from a resource using an SAGD process, said process comprising the following modules: a) Module 1 comprising inlet coolers, an inlet separator, a de-sand unit, and Free Water Knock-Out and Oil Treating vessels.
- Module 2 comprising of an Induced Gas Floatation Unit, distillate tank and Dilbit cooler.
- Module 3 comprising an evaporator exchanger.
- Module 4 comprising an evaporator compressor, evaporator recirculation pumps and chemical addition machinery.
- Module 5 comprising boiler feed water pumps, instrument air systems and electrical systems.
- Module 6 comprising a boiler.
- Module 7 comprising power generation and a Heat Recovery Steam Generator.
- Module 8 comprising a glycol cooler or other cooling system.
- Module 9 comprising a flash drum, flash drum condenser, and dump condenser
- Module 10 comprising a glycol expansion drum, fuel gas drum, and additional heat exchangers. wherein said modules or the like being interconnected into said process in order to exploit said hydrocarbon resource.
- the current objective is to engineer, construct, and operate a complete SAGD processing facility with a number of modules that are intended to be assembled and commissioned off site, relocated and joined with other modules to create the entire SAGD process and, when the resource is depleted or proven uneconomical, disassembled and relocated to a different resource to be reassembled to exploit said resource at that site.
- Figure 1 is a Conventional Process Flow Diagram (Evaporator/Boiler Design).
- Figure 2 is a 1 Site Flow Diagram illustrated in one embodiment of the invention.
- Figure 3 is an UltraLite Flow Diagram with evaporator having an external demister illustrated in one embodiment of the invention.
- Figure 4 is a Conventional FWKO and Treater.
- Figure 5 is a Desand/FWKO/Treater illustrated in one embodiment of the invention.
- Figure 6 is a Conventional Produced Water Cooler and Skim Tank.
- Figure 7 is Produced Water Flash Drum, Condenser illustrated in one embodiment of the invention.
- Figure 8 is a Dump Condenser illustrated in one embodiment of the invention.
- Figure 9 is a Vapour Recovery Units Systems illustrated in one embodiment of the invention.
- Figure 10 is a Desand/FWKO Treater Controls illustrated in one embodiment of the invention.
- Figure 1 1 is a Temperature Profile Comparison between conventional system and the systems of the current invention illustrated in one embodiment of the invention.
- Figure 12 is a layout of the assembled modular SAGD plant with ten modules illustrated in one embodiment of the invention.
- Figure 13 is an isometric view of module 1 comprising inlet coolers, inlet separator, de sand, FWKO treater vessel illustrated in one embodiment of the invention.
- FIG 14 is an isometric view of module 2 comprising IGF and Dilbit cooler and module 10 comprising evaporator with two heat exchangers illustrated in one embodiment of the invention.
- Figure 15 is an isometric view of module 3 comprising evaporator compressor, evaporator recirculation parts and chemicals additives illustrated in one embodiment of the invention.
- FIG. 16 is an isometric view of module 4 comprising pumps, air and electrical system illustrated in one embodiment of the invention.
- Figure 17 is an isometric view of module 6 comprising a package boiler illustrated in one embodiment of the invention.
- Figure 18 is an isometric view of module 5 comprising power generation and HRSG illustrated in one embodiment of the invention.
- Figure 19 is an isometric view of module 7 comprising a glycol cooler illustrated in one embodiment of the invention.
- Figure 20 is an isometric view of module 8 comprising a flash drum, flash drum condenser, and dump condenser illustrated in one embodiment of the invention.
- Figure 21 is an isometric view of module 9 comprising a glycol expansion drum, fuel gas drum, and small exchangers illustrated in one embodiment of the invention.
- FIG 22 is an isometric view of modules 4, 5 and 6 illustrated in one embodiment of the invention.
- Figure 23 is an isometric view of modules 1,2 and 10 illustrated in one embodiment of the invention while Module 10 comprises an evaporator with two heat exchanger towers.
- Figure 23 A is an isometric view of modules 1, 2 and 10 illustrated in second embodiment of the invention while Module 10 comprises an evaporator with a single heat exchanger tower.
- FIG. 24 is an isometric view of modules 2,8 and 10 illustrated in one embodiment of the invention.
- FIG. 25 is an isometric view of modules 7 and 8 illustrated in one embodiment of the invention.
- Figure 26 is an isometric view of modules 4 and 9 illustrated in one embodiment of the invention.
- Figure 27 is an isometric view of modules 3 and 9 illustrated in one embodiment of the invention, while module 9 is located on top of module 3.
- Figure 28 is an isometric view of modules 1 and 7 illustrated in one embodiment of the invention.
- Figure 29 is an isometric view module 1 mounted on a truck bed illustrated in one embodiment of the invention.
- Figure 30 is a schematic side view of module 10 - a heat exchanger of a compact Evaporator positioned on truck illustrated in one embodiment of the invention.
- KemeX has developed a new SAGD plant design that achieves the following:
- KemeX 1 Site UltraLite SAGD plant design Key features of the KemeX 1 Site UltraLite SAGD plant design include:
- a single pilot plant can be used across a number of sites.
- Modular and portable concept minimizes on-site construction (lower labour rates, higher productivity and no large construction camp and office facilities).
- This configuration is sized for the productive capacity (7,200 bpd) of a single well pad (typically 6-10 SAGD well pairs) and is intended as the "commercial production” model, which is readily scalable as multiple pads are developed.
- the main processing facility fits on an approximately 125 foot by 125 foot plot space. Modules (24 feet wide by 24 feet high by 100+ feet long) are sized to be transported within the "High Load Corridor" in Alberta.
- This configuration is sized for productive capacity of one to two well pairs (1,200 bpd). This is the "exploration" model that provides the owner with a reusable/movable pilot plant that can be incorporated into a much more comprehensive exploration program, before committing the significant capital needed for full commercial production.
- the UltraLite unit is fully functional and economically viable for commercial production on its own. Modules are sized to be transported on most roadways using conventional tractor trailers.
- the modular / portable SAGD concept dramatically improves key environmental performance parameters.
- Water emissions from an evaporator are less than half of those from a conventional hot / warm lime softener and OTSG system. Further, by generating 100% quality steam, our design does not require blowdown ponds for start-up of the generators.
- Land disturbance for our SAGD facility is much less that other oil sands recovery methods and is actually less than conventional oil on a per unit of production basis.
- Our plant and well pad on same lease size as a conventional well pad and has eliminated or minimized process ponds, interconnecting pipelines and roads.
- the modular / portable SAGD plant can reduce the overall project by one to two years. By shifting the majority of the construction to an off-site module fabrication shop, the site construction is much less and can be undertaken in parallel with the module construction without interference. Further, once the designs are finalized, the engineering work can be reused to immediately start procurement and fabrication of the next plant. This can take 6 months to a year off of the schedule.
- This section provides an overview description for the various systems in the modular processing facility. The description is written to accompany the attached figures and attached process sketches. The reader is referred to the KemeX other prior filed provisional United States patent applications (which are incorporated herein by reference ) covering: a) A SAGD System Utilizing a Flash Drum (Application no. 61376300)
- KemeX design For areas not specifically mentioned in the above listed patent applications, the description includes a typical KemeX design. For areas outside of the above patents, the modular design is meant to encompass process design variations that are well known to someone versed in the prior art.
- Production fluids are received from the well pads and the first step in the process is to disengage gases (steam, light hydrocarbons) from the liquid phase.
- the degassed production liquids are cooled by cross exchange with boiler feed water (BFW) in the Inlet Coolers.
- BFW boiler feed water
- a separate inlet cooler utilizing glycol is also installed and used for trim cooling or for the full service cooling when the BFW coolers are out of service for maintenance.
- the outlet temperature is typically controlled at 120-125°C, which is optimum for gravity separation and loss of light hydrocarbon components to the fuel system.
- Recycle streams as well as demulsifier and reverse demulsifier are combined with the produced liquids stream upstream of the desand and free water knock-out vessels.
- the combined stream enters a single vessel containing a desand volume, the Free
- the Desand vessel can be either combined with the FWKO/Treater in a single vessel, or be a separate vessel.
- Conventional designs do not provide a dedicated desand vessel upstream of the FWKO (Fig 1). Any sand present in the production fluids drop out in the Free Water Knockout and is flushed to downstream equipment. In our design, sand is collected in a Desand Section and periodically cleaned.
- the quality of water from both the FWKO and the Treater is monitored via on-line analyzers, and only if the water quality is acceptable are the streams mixed for processing. If the quality of water from either stream is unacceptable, only the unacceptable stream of water is diverted into an off-spec water system for clean-up, leaving the remainder of clean water directed to the normal water clean-up systems.
- Maintaining on-spec feed to downstream treating systems will result in better performance and reduced fouling (improved reliability) for the downstream equipment.
- early detection and segregation of off-spec water will minimize the volumes that need to be further treated or disposed of offsite (and consequential increase in make-up water).
- an emulsion layer typically collects at the interface between the oil and water ( Figure 4) as its density falls between that of a pure oil phase and a pure water phase.
- this emulsion or "rag layer” will accumulate at the interface until operations manually initiates a draw of fluid from just below the interface level.
- the proposed design has continuously monitoring system for this accumulation and a constant small volume draw from just below the oil / water interface to prevent accumulation of a rag layer ( Figure 5 and Figure 10).
- the Dilbit product stream from the treater is cooled and sent to product storage and shipping.
- the FWKO / Treater system achieves the bulk oil water separation step.
- the produced water from these units requires further processing to remove trace quantities of free oil and is achieved in an Induced Gas Floatation Unit (IGF), which is operated just above atmospheric pressure.
- IGF Induced Gas Floatation Unit
- the IGF feed requires cooling to prevent flashing and boiling in the IGF.
- the conventional SAGD plant designs incorporate shell and tube heat exchangers to cool the produced water, then route the water through an atmospheric Skim Tank as a final bulk oil removal step, and finally transfer water from the Skim Tank to the IGF (Fig 6).
- the conventional produced water exchangers have proven to be an extreme fouling service with the exchangers requiring cleaning on as frequent as weekly.
- the exchangers fail to cool the produced water below its saturation point, the hot water flashes in the Skim Tank potentially causing an environmental release or in extreme events damaging the tank.
- the water is typically cooled well below its boiling point to around 80-90 deg C.
- the Skim Tank is also then used as a collection point for various recycle streams such that the water entering the Skim Tank from the FWKO/Treater is often cleaner than the water leaving the Skim Tank and going to the IGF.
- the proposed design utilizes a flash drum to cool the produced water rather than an exchanger (Figure 7). By dropping the pressure to slightly below atmospheric, the water flashes, with the liquid stream leaving the flash drum cooled to just below the boiling point of water.
- the vapours from the flash drum (which is mostly steam), is condensed in a glycol exchanger with the condensed liquids joining the liquids from the flash drum.
- This system easily controls cooling temperature at approximately 97 °C by maintaining flash pressure at or below atmospheric and without the dependence on a functioning glycol cooling system. This eliminates the need for an operating margin and the combined liquid stream going forward will be hotter which is better from an energy efficiency and capital cost perspective. Further, this system eliminates direct cooling of the produced water which can foul heat transfer surfaces. The duty is transferred from cooling a fouling liquid to essentially condensing steam which is non-fouling.
- the second change in the proposed design is the elimination of the Skim Tank, with our produced water flowing directly from the Flash Drum to the IGF. This ensures the quality of water from the Flash drum is the quality of water entering the IGF, and allows a higher feed temperature entering the IGF which should improve its ability to separate oil and water.
- the IGF outlet stream contains a low concentration of oil and suspended solids.
- the water stream is sent to the Water Treatment system.
- MVC Mechanical Vapour Compression
- the Water Treatment System is designed to process a feedwater stream containing dissolved solids and produce a distilled water product of sufficient quality to be used as feed to a conventional package boiler. Changes to a standard evaporator design have been covered under the KemeX United States Provisional Patent Applications no 61376301 and 61436723).
- MVC Mechanical Vapour Compression
- WAC weak acid cation
- produced water is transferred from the IGF outlet to the evaporator via a set of pumps.
- Various chemicals are added to the evaporator feed water. Feed water is introduced into the Evaporator sump and concentrated brine is removed from the sump for additional treatment or offsite disposal.
- Brine Circulation Pumps circulate brine from the Evaporator sump to the top of the tube side of the Evaporator falling film heat exchanger bundle. Brine flows through the tube side of the Evaporator exchanger as a falling film where a small mass fraction is evaporated.
- the present invention provides evaporator with several variants of heat exchangers arrangements.
- the first embodiment includes an evaporator with a single heat exchanger Figure 23 A.
- the second embodiment includes an evaporator with two heat exchangers Figure 23. In the second embodiment, there are several ways the heat exchangers can be used.
- Two heat exchangers can be connected in parallel wile receiving the liquid from the same sump.
- the heat exchangers can be connected in-line, while the discharge of the first sump is transferred into the sump of the second heat exchanger, whereby the concentration of the impurities in the sumps of second heat exchanger being higher compared to the concentration in the first heat exchanger.
- two heat exchangers can work simultaneously or separately while the second heat exchanger can be used as a replacement during shut down and maintenance procedures of the first heat exchanger.
- the proposed evaporator design differs from the standard design in four fundamental ways.
- the first way covered under the KemeX United States Provisional Patent Application no 61376301, is the method of blowing down the concentrated brine.
- a slipstream from the Brine Circulation Pumps is drawn off. This minimizes the equipment required and provides a means of controlling the brine concentration.
- the feed water to the evaporator contains small amounts of oil, the oil will accumulate at the top of the water in the evaporator sump eventually causing foaming and fouling in the evaporator.
- a manual oil skim nozzle is provided just below the expected liquid level, but this will require manual operator intervention and unless sump level is tightly controlled just above the skim nozzle, oil accumulation will occur.
- the proposed design includes an overflow weir into a brine disposal sump, which would be added to a third party evaporator.
- the weir will include a v- notch so that the main evaporator sump level can have some variance without flooding or starving the brine disposal sump.
- the brine blowdown with the oil will be taken off the brine disposal sump via a dedicated set of blowdown pumps for further treatment or disposal. Hence, the oil will be removed automatically and continuously, thus minimizing the foaming and fouling of the evaporator.
- the second change also covered under the KemeX United States Provisional Patent Application no 61376301, involves the control of the evaporator.
- the main difference here is the proposed design will measure the calcium hardness and silica concentration in the feed, calculate the saturation levels in the sump, and adjust the blowdown and the caustic addition to ensure the proper operation of the evaporator without calcium hardness or silica precipitation.
- the conventional design is to set the ratio of feed rate to blowdown rate (cycles of concentration) on an assumed hardness concentration in the feedwater. Independently the feedwater pH is controlled by adding to achieve a target pH.
- the real objective is to control the sump pH, which is significantly different than the pH of the feedwater due to the removal of distilled water from the brine and can vary with changes to the cycles of concentration.
- the practice is to set up the control system based on the worst case inlet conditions, with no adjustments to setpoints to reflect actual inlet conditions. This results in higher blowdown rates (higher disposal costs, higher water make-up rates), and higher caustic usage (and subsequent acid usage during subsequent treatment) than necessary.
- the third change is the use of the Produced Water Tank and Boiler Feed Water Tank. In the conventional design, water going to the evaporator flows through the Produced Water Tank and water leaving the evaporator flows through the Boiler Feed Water Tank ( Figure 1).
- both tanks are atmospheric tanks, it also means the water entering and leaving the evaporator must be cooled below the boiling point of water to ensure the water doesn't flash in the tanks causing and then must immediately be reheated when withdrawn from either tank.
- Produced Water Coolers are typically designed to cool the produced water from the FWKO / Treaters from 125°C to 80°C prior to entering the Produced Water Tank and then immediately reheated to 100°C for introduction in the warm lime softener or evaporator.
- the Produced Water Tank and Boiler Feed Water Tanks are used as available inventory to be accessed only during upset conditions.
- the general philosophy will be to operate with a low inventory in the Produced Water Tank and a high level in the Boiler Feed Water Tank.
- produced water would be routed to the Produced Water Tank and BFW would be withdrawn from the Boiler Feed Water Tank to allow production to continue a few hours while trying to restore the system back to service.
- the fourth change is to the Production Treating and Water treatment systems.
- the conventional design has Oil Removal Filters (ORF) located after the IGF and before the water treating system, whether it be a hot / warm lime softener or evaporator ( Figure 1). These filters are intended to provide final trim oil removal prior to routing to the water treating system.
- the system is required as the current water treating designs are not equipped to handle above 30 ppm free oil.
- the ORF's consists of 2x100% or 3 x50% units, generally filled with walnut/pecan shells, with each unit cleaned by backwashing with clean or filtered water every 24 hours, with backwash stream recycle back to the FWKO.
- the continuous oil skim from the evaporator provides a higher tolerance for oil contamination in the evaporator feed.
- the ORFs provide little capacity for large oil excursions and are high maintenance, which results in high cost and excessive recycling of water.
- a vapour recovery process unit for a SAGD system for a heavy oil recovery facility providing a venturi ejector having one active inlet, one passive inlet and one outlet.
- the active inlet being supplied with natural gas to provide the gas flow sufficient to operate the ejector, the passive inlet being connected to a mixture of vented vapours from storage tanks and low pressure equipment.
- the outlet supplying fuel to a system along with the natural gas. wherein the movement of the natural gas through the ejector creates a vacuum so as to draw the vapours from the tanks and low pressure equipment into the ejector and then toward the low pressure fuel system, wherein the vented vapours are burned, instead of being released to the atmosphere.
- the use of this equipment is fully disclosed in provisional US Patent Application 61376298 and incorporated herein by reference.
- a water recovery process comprising a flash drum, a flush drum condenser and the final water treating equipment, wherein the hot water produced is introduced into the flash drum, and separated into the cooled liquid and a vapour; the vapour being further cooled in the flush drum condenser, the condensed liquids from the exchanger is mixed with the cooled liquid, this mixture being transferred into the final water treating unit in which the impurities are removed from the water and the cleaned water transferred to the rest of the process or to atmospheric tanks for storage.
- the use of this equipment is fully disclosed in United States Provisional Application 61376300 and incorporated herein by reference.
- a water purification process in a SAGD the process comprising an evaporator, an oil skim weir and a set of controllers.
- the evaporator having a bottom with a sump provided at the bottom thereof and including an oil skimming weir dividing the sump into a main sump and a blowdown sump, while the water containing impurities flows over the weir from the main sump to the blowdown sump.
- the evaporator In a normal operating mode, the evaporator receiving water from the process and discharging distilled water from a distillate tank and discharging waste brine from the blowdown sump.
- the system also having a set of controllers including: a distilled water flow meter provided at the discharge of evaporator, a blowdown flow meter measuring the flow from the main sump to the blowdown sump, and a cycle calculator for calculating the ratio between the distilled water flow and blowdown flow and a total flow controller.
- the cycle calculator provides a set point to the total flow controller, thus the flow of the water into the evaporator does not directly depend on the level of the liquid in the main sump. This way, the operation of the evaporator functions in a contained closed loop environment.
- Distillate from the Evaporator Package is fed to the Steam Generation System by the Distillate Product Pumps. Chemicals (oxygen scavenger, dispersant, and neutralizing amine) are added.
- the high pressure pumps transfer the Boiler Feed water through the Inlet Coolers, where heat is recovered from the production fluids, and then to the Package Boiler.
- the Boiler produces superheated steam.
- the Boiler blowdown is sent to the Produced Water Flash Drum in the Produced Water De-Oiling system. Recycling this stream reduces the amount of makeup water required.
- the first is the steam pressure.
- Conventional SAGD facilities are designed to produce steam in the 6,000-12,000 kPa pressure range. Although most oil sands in the Athabasca region operate at a reservoir pressure of only 2,000-3,500 kPa, the high steam pressure is rationalized to deliver steam to distant pads at some point in the future.
- the proposed design can utilize standard boiler pressures (4,200 kPa). This is more energy efficient and the lower pressure reduces boiler and piping costs.
- the standard OTSG can only produce saturated steam, with some steam condensing due to heat losses as it is transported to and into the well.
- the proposed design superheats the steam.
- the heat losses in the steam in the transportation to the well removes the superheat rather than condensing the steam, and hence the full production of steam is provided to the well.
- the steam is superheated in the boiler and then desuperheated, which provides the capability to control the amount of superheat required to prevent condensation during transfer to the wellhead.
- the third change is the design and use of the Produced Gas Cooler as a dump condenser during start-up or standby operation (Figure 8).
- the Produced Gas Cooler is used to cool the produced gas from the wells, produced gases from the Inlet Separator along with vent gases from the Desand Vessel/FWKO/Treater.
- the resulting liquids are routed to the Produced Water Flash Drum for treatment in Produced Water Deoiling.
- the non-condensable gases are sent to the Mixed Fuel Gas Separator in the Fuel Gas System.
- the boiler can be operated smoothly from 0-100% of capacity.
- the boiler needs to operate below minimum fire for an extended period.
- this requires the boiler to be run at minimum fire, any excess steam vented, and correspondingly additional make-up water is required.
- This adds pressure during start-up to quickly ramp up rates to at least the boiler minimum fire rate, even if this is not the optimal start-up sequence.
- any excess steam up to minimum fire of the boiler will be condensed and the water recovered for reuse. Not only does this save water, it also allows the start-up sequence to be optimized for long term operability of the well and facility rather than minimization of steam venting and water loss.
- the Dump Condenser When the plant is not processing production fluids and heat is not being recovered from the process, the Dump Condenser will use steam to maintain the hot glycol supply temperature to prevent freezing in processing equipment.
- the Boiler can be brought to a stable operating point without needing to trip the Boiler. Because the steam is condensed and recycled back to the BFW Tank, the Boiler can be operated in this mode indefinitely and can be quickly brought back into normal service.
- Three-way valves are used to line up the feed to and liquids from the Dump Condenser in the different operating modes.
- Vapour Recovery System is a distinct utility system ( Figure 9). It uses a small liquid ring compressor to compress the low pressure vent gases from various locations and tanks in the process so that the gases can be sent into the fuel gas system for disposal. The reliability of these systems is typically very poor due to the wide range of capacities that the system must be designed for.
- the vapour recovery system is tied into the process in a couple of ways ( Figure 9).
- Figure 9 the design takes advantage of the high inlet natural gas pressure versus the pressure it is used at.
- An eductor is used utilizing the high pressure natural gas as motive fluid, the low pressure fuel gas header as the sink, and drawing a vacuum to collect the low pressure gases.
- the eductor is also used to provide the vacuum required for the flash drum. With no rotating or moving parts, the reliability of the eductor is high, and the capacity is limited primarily by the amount of natural gas used as the motive fluid, which is normally is large excess over what is required for a a SAGD facility. With the operation of the flash drum and hence the whole water de-oiling process requiring the vacuum, the higher reliability of the eductor vapour recovery system is important to this design.
- KemeX has been able to reduce operating costs by 5% to 10% compared to conventional large- scale SAGD facilities currently in design or operation. These reductions are achieved through the following:
- Examples include water balance control to proactively control the balance between - steam sent to the wells and the produced water treated from the wells, and controls directing water to and from the Produce Water Tank and Boiler Feed Water Tank.
- Onsite power generation is incorporated to further reduce operating costs and dependence on third party electrical power supply.
- KemeX has extended the widely accepted concept of modular construction to incorporate portability.
- Our process plant design consists of transportable close- coupled modules that can be assembled or dismantled in 30 days and moved via the existing high-load transport corridor in Alberta. This concept offers a number of distinct advantages as discussed in other sections of this document:
- KemeX adopted some unique concepts to efficiently achieve a design that was both modular and portable. These concepts are well suited to SAGD plants and could be extended to other processes.
- Module layout will generally locate equipment to one side of the module, to provide space for personnel access to equipment and instrumentation.
- Vapour handling systems located on the second level to minimize safety risks.
- Transformers, switchgear, and MCCs are installed on a single module to allow all interconnecting wiring to be accomplished off site.
- control system architecture is based on hardwired I/O modules installed in environmentally hardened enclosures installed on each process module.
- the modules will be test assembled, pressure checked, and commissioned before disassembly and reassembly at the first location. This will help prove out the assembly/reassembly requirements as well as significantly reduce the field fit-up, commissioning cost and schedule length.
- the pre-assembled modular units when removed from the trailer are positioned at the remote location on prepared foundation / support such as concrete foundation, concrete columns, rock base or any other foundation preparation known in the art.
- prepared foundation / support such as concrete foundation, concrete columns, rock base or any other foundation preparation known in the art.
- the trailer might be adapted with a set of jacks or other means to support the modules in the location without removing them from the truck. Further the trailer might be a specially designed trailer for transport the module and support the module at the remote location.
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- Engineering & Computer Science (AREA)
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- Life Sciences & Earth Sciences (AREA)
- Mining & Mineral Resources (AREA)
- Geochemistry & Mineralogy (AREA)
- Fluid Mechanics (AREA)
- Environmental & Geological Engineering (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Physics & Mathematics (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Heat Treatment Of Water, Waste Water Or Sewage (AREA)
- Installation Of Indoor Wiring (AREA)
- Gas-Insulated Switchgears (AREA)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
- Engine Equipment That Uses Special Cycles (AREA)
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
RU2013139463/03A RU2013139463A (en) | 2011-01-28 | 2011-04-27 | MODULAR TRANSPORTED COMPLEX FOR GRAVITATIONAL DRAINAGE FOR VAPOR INJECTION |
AU2011357584A AU2011357584A1 (en) | 2011-01-28 | 2011-04-27 | Modular transportable system for SAGD process |
BR112013018814A BR112013018814A2 (en) | 2011-01-28 | 2011-04-27 | TRANSPORTABLE MODULAR SYSTEM FOR SAGD PROCESS. |
MX2013008727A MX2013008727A (en) | 2011-01-28 | 2011-04-27 | Modular transportable system for sagd process. |
SG2013057203A SG192173A1 (en) | 2011-01-28 | 2011-04-27 | Modular transportable system for sagd process |
CN2011800663127A CN103370493A (en) | 2011-01-28 | 2011-04-27 | Modular transportable system for sagd process |
Applications Claiming Priority (10)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201161437292P | 2011-01-28 | 2011-01-28 | |
US61/437,292 | 2011-01-28 | ||
US13/074,265 | 2011-03-29 | ||
US13/074,283 | 2011-03-29 | ||
US13/074,275 | 2011-03-29 | ||
US13/074,275 US9095784B2 (en) | 2010-08-24 | 2011-03-29 | Vapour recovery unit for steam assisted gravity drainage (SAGD) system |
US13/074,283 US8945398B2 (en) | 2010-08-24 | 2011-03-29 | Water recovery system SAGD system utilizing a flash drum |
US13/074,265 US9028655B2 (en) | 2010-08-24 | 2011-03-29 | Contaminant control system in an evaporative water treating system |
US13/087,708 US8951392B2 (en) | 2011-01-27 | 2011-04-15 | Compact evaporator for modular portable SAGD process |
US13/087,708 | 2011-04-15 |
Publications (1)
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WO2012100320A1 true WO2012100320A1 (en) | 2012-08-02 |
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PCT/CA2011/000465 WO2012100320A1 (en) | 2011-01-28 | 2011-04-27 | Modular transportable system for sagd process |
Country Status (10)
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US (1) | US20120193093A1 (en) |
CN (1) | CN103370493A (en) |
AU (1) | AU2011357584A1 (en) |
BR (1) | BR112013018814A2 (en) |
CA (1) | CA2738259A1 (en) |
MX (1) | MX2013008727A (en) |
PL (1) | PL406240A1 (en) |
RU (1) | RU2013139463A (en) |
SG (1) | SG192173A1 (en) |
WO (1) | WO2012100320A1 (en) |
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US10323200B2 (en) | 2016-04-12 | 2019-06-18 | Enservco Corporation | System and method for providing separation of natural gas from oil and gas well fluids |
US10458140B2 (en) | 2009-12-18 | 2019-10-29 | Fluor Technologies Corporation | Modular processing facility |
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- 2011-04-27 US US13/095,318 patent/US20120193093A1/en not_active Abandoned
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Also Published As
Publication number | Publication date |
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CA2738259A1 (en) | 2012-07-28 |
CN103370493A (en) | 2013-10-23 |
MX2013008727A (en) | 2013-12-09 |
AU2011357584A1 (en) | 2013-08-01 |
RU2013139463A (en) | 2015-03-10 |
PL406240A1 (en) | 2014-11-10 |
SG192173A1 (en) | 2013-08-30 |
US20120193093A1 (en) | 2012-08-02 |
BR112013018814A2 (en) | 2017-08-29 |
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