WO2014058449A1 - Production, à émissions presque nulles, de vapeur propre haute pression - Google Patents

Production, à émissions presque nulles, de vapeur propre haute pression Download PDF

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Publication number
WO2014058449A1
WO2014058449A1 PCT/US2013/000233 US2013000233W WO2014058449A1 WO 2014058449 A1 WO2014058449 A1 WO 2014058449A1 US 2013000233 W US2013000233 W US 2013000233W WO 2014058449 A1 WO2014058449 A1 WO 2014058449A1
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WIPO (PCT)
Prior art keywords
water
high pressure
steam
gas generator
mixture
Prior art date
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PCT/US2013/000233
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English (en)
Inventor
Keith L. Pronske
Roger E. Anderson
Bradley J. Anderson
Daniel A. GREISEN
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Clean Energy Systems, Inc.
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Publication of WO2014058449A1 publication Critical patent/WO2014058449A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23L—SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
    • F23L7/00—Supplying non-combustible liquids or gases, other than air, to the fire, e.g. oxygen, steam
    • F23L7/002—Supplying water
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22—STEAM GENERATION
    • F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B1/00—Methods of steam generation characterised by form of heating method
    • F22B1/02—Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers
    • F22B1/18—Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being a hot gas, e.g. waste gas such as exhaust gas of internal-combustion engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J15/00—Arrangements of devices for treating smoke or fumes
    • F23J15/02—Arrangements of devices for treating smoke or fumes of purifiers, e.g. for removing noxious material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23L—SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
    • F23L15/00—Heating of air supplied for combustion
    • F23L15/02—Arrangements of regenerators
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23L—SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
    • F23L7/00—Supplying non-combustible liquids or gases, other than air, to the fire, e.g. oxygen, steam
    • F23L7/007—Supplying oxygen or oxygen-enriched air
    • 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
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/32—Direct CO2 mitigation
    • 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
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/34—Indirect CO2mitigation, i.e. by acting on non CO2directly related matters of the process, e.g. pre-heating or heat recovery

Definitions

  • the following invention relates to systems for production of high pressure substantially pure steam with heat from combustion of a hydrocarbon fuel. More particularly, this invention relates to production of high pressure steam utilizing combustion of a hydrocarbon fuel with a primarily oxygen stream such that zero emissions or near zero emissions combustion provides the heat to raise the high pressure steam.
  • Contaminates in the water/steam can include dissolved solids, such as those typically present in waste water; gases such as carbon dioxide which cause the water to be at least mildly acidic; and sea water or other salt water sources which are highly abundant but require or benefit from purification before utilization.
  • Hydrocarbon can also be such a contaminate and might be present in produced water coming out of a hydrocarbon recovery process which utilizes certain amounts of water to liberate the hydrocarbons from a geological formation.
  • Such produced hydrocarbons benefit from having the hydrocarbon fuel components removed therefrom both for beneficial use of the hydrocarbon fuel and to avoid fouling of processes and equipment which would otherwise be able to utilize higher purity steam.
  • Temperatures at which water boils into steam vary based on the pressure of the water. Thermodynamic efficiencies and hence overall efficiency of various industrial processes are enhanced when steps such as pumping to high pressure occur when the water is in a liquid state and when other steps in industrial processes occur when the water is steam or superheated steam at a temperature greater than the condensing temperature of the steam at the pressure involved.
  • steps such as pumping to high pressure occur when the water is in a liquid state and when other steps in industrial processes occur when the water is steam or superheated steam at a temperature greater than the condensing temperature of the steam at the pressure involved.
  • it is desirable that the steam be provided at a high pressure When referring to high pressure, a pressure of at least ten times standard atmospheric pressure is contemplated, and more typically more than fifty times atmospheric pressure, and extending up to one hundred or more times standard atmospheric pressure. At such higher pressures, the boiling point for water is significantly increased and significant heat is required to boil such high pressure water into steam.
  • a common prior art element for raising high pressure pure steam is a standard boiler utilized in a variety of different machinery and industrial processes.
  • Such boilers typically first have a feed water pump providing water at an elevated pressure.
  • the elevated pressure water is then fed through high pressure water handling tubes into walls of the boiler which surround a combustion region.
  • Fuel along with air are introduced into this combustion chamber and undergo a combustion reaction with significant production of heat and products of combustion. These products of combustion are routed to a smoke stack and discharged into the atmosphere.
  • the boiler smoke stack discharges a largest fraction in the form of nitrogen which is present in the air and does not participate in the combustion reaction.
  • Other constituents discharged into the atmosphere include steam, carbon dioxide, oxides of nitrogen, carbon monoxide, volatile organic compounds, ozone and potentially other compounds and pollutants which may have been present in the fuel utilized in the combustion reaction, including oxides of sulphur, mercury, other heavy metals and other toxic substances.
  • the water entered into the boiler is effectively heated into high pressure steam for utilization by downstream processes and machinery.
  • Boilers also require substantially thick walled pipes to withstand the pressure differential between the inside of the high pressure water lines lining the boiler and the outside of these pipes where the combustion reaction is taking place.
  • the thickness of these pipes adds significant cost to the materials which make up the boiler, the labor which goes into manufacture of the boiler, and also decreases a rate of heat transfer through the walls of the pipes when compared to thinner walled pipes which could be utilized if a lesser pressure differential existed between the hot and cold sides of the heat exchanger.
  • This disclosure defines a new process using pressurized oxy-fuel combustors, steam separators, oxy-fuel reheaters, and pressurized heat exchangers to: (1) produce clean water, (2) clean steam, and (3) a concentrated waste water stream from dirty/produced water supplies such as those resulting from the production of crude oil or bitumen.
  • the resulting clean steam and CO may be used for the production of additional crude oil or bitumen by processes such as steam assisted gravity drain (SAGD) or enhanced oil recovery (EOR) using CO, flooding or the steam and C0 2 may be used for other industrial purposes.
  • SAGD steam assisted gravity drain
  • EOR enhanced oil recovery
  • the disposal of the concentrated waste water steam may be accomplished by injection into a deep saline aquifer, evaporation in a pond with subsequent harvesting and disposal of the solid residue, processing in a crystallizer with subsequent disposal of the solids or further processed to recover useful products.
  • the overall scheme for producing clean steam and CO, from dirty/produced water using high-pressure oxy-fuel combustors, steam separators, oxy-fuel reheaters, and pressurized heat exchangers is depicted in Figure 1.
  • the oxy-fuel combustor operates on a gaseous fuel , substantially pure O, and dirty /produced water.
  • the gaseous fuel may be natural gas or other gaseous fuel composed primarily of light hydrocarbons, CO, CO,, and/or ⁇ ,.
  • the O is normally separated from air using various conventional commercial processes (e.g., cryogenic distillation, pressure- swing adsorption, ion transfer membranes).
  • the dirty/produced water refers to water containing substantial quantities of dissolved solids, gases, and dissolved or suspended oils (e.g., brackish water, waste water, water from saline aquifers, produced water from oil or bitumen production).
  • the O, and fuel gases are burned in near stoichiometric proportions in the presence of atomized dirty/produced water in an oxy-fuel combustor.
  • the products of combustion are composed predominantly of wet steam, CO,, and a concentrate of the feed water at high pressure and high temperature.
  • the quality of steam which is preferably delivered to a first separator is typically roughly 80% wt steam/CO, and 20% wt feed water concentrate but may be of higher or lower quality depending upon the nature of the dissolved solids.
  • the concentrated brine underflow from the first separator optionally passes through a heat exchanger (HX) to heat the incoming feed water and exits the system for disposal .
  • HX heat exchanger
  • Disposal may involve injection into a deep saline aquifer, evaporation in a pond with appropriate harvesting and disposal of the solid residue, or crystallization and disposal of the solids contained in the stream.
  • the saturated steam/CO, from the first separator passes preferably into an oxy- fuel reheater where it is direct-heated to a superheated state by near stoichiometric combustion of O, and a gaseous fuel , generally the same fuel that supplies the primary oxy-fuel combustor.
  • the superheated steam/CO flows to at least one heat exchanger such as a superheat exchanger (SuperHX) where it heats lower-pressure saturated clean steam to a superheated state.
  • SuperHX superheat exchanger
  • the steam/CO, from the SuperHX preferably flows to a second heat exchanger (SatHX) where it heats sub-cooled high-pressure clean water to the saturation conditions and the steam is partially condensed.
  • the wet steam/C0 2 mixture from the SatHX preferably then flows to a third heat exchanger (PreHX) where it preheats high-pressure clean water and additional steam is condensed.
  • PreHX third heat exchanger
  • the exiting wet steam/CO, mixture preferably flows to a condenser/separator where residual steam is condensed and the condensate is separated from CO,.
  • the condensate formed from the dirty/produced water is depressurized, such as through a let-down value or a hydro turbine device, and flows into the de-ionized water (DI ⁇ , ⁇ Storage) tank which serves as the water supply for the production of clean steam.
  • Depressurization (along with agitation or sparging, as required) causes dissolved gases (primarily CO,) to come out of solution and be vented (or captured).
  • the Dl H,0 Storage tank may incorporate cooling capabilities if necessary to meet downstream polisher temperature requirements.
  • the degassed water supply is pumped to a polisher to remove residual cations and anions.
  • the cool polished water is then pumped at high pressure through the condenser/separator and PreHX to a first Mix.
  • the preheated water is mixed with saturated lower-pressure water from the second Sep. and sent to the SatHX where it is heated to its saturation temperature by superheated steam/CO,.
  • the saturated high-pressure water is flashed via a throttling device into the second Sep. where saturated steam passes overhead and saturated water underflows to the first Mix. and, optionally, also to the second Mix. If the desired clean steam product is superheated steam, the saturated steam is passed through the SuperHX before exiting.
  • saturated steam it bypasses the SuperHX and directly exits. If wet stream is desired, it bypasses the SuperHX and enters the second Mix. along with saturated water from a liquid discharge of the second Sep. to form the desired steam quality and exits.
  • Figure 1 is a schematic of a system according to one embodiment of this invention including an oxy-fuel combustion gas generator to generate a mixture of steam and carbon dioxide and a multi-stage high pressure heat recovery steam generator for transferring heat from the steam/carbon dioxide mixture to a substantially pure water stream to produce substantially pure steam output.
  • Figure 2 is a table identifying exemplary temperature, pressure, flow rate and vapor fraction characteristics for fluids in the system of Figure 1 , at various different points in the system of Figure 1.
  • FIG 3 is a schematic of a process similar to that shown in Figure 1 but somewhat simplified to show the heat recovery steam generator as a single element.
  • Figure 4 is a flow chart identifying various inputs that can be potentially provided into a basic oxy-fuel combustion gas generator and pressurized heat recovery steam generator system and the various outputs from such a system according to this invention.
  • Figure 5 is a schematic flow chart similar to that which is disclosed in Figure 1 but further including depiction of an air separation unit (ASU) for provision of oxygen into the system and further including an oil and associated gas separator downstream from a source of water including hydrocarbon materials therein and with a fuel blender for blending of associated gas from the produced hydrocarbon into natural gas or other hydrocarbon fuels for the gas generator.
  • ASU air separation unit
  • Figure 6 is a flow chart similar to that which is depicted in Figure 5 and further generally depicting how associated gas and natural gas can be blended for both a gas generator and a reheater of the system in a simplified depiction of the system of Figure 5.
  • reference numeral 100 ( Figure 1) is directed to a typical embodiment system for production of substantially pure high pressure steam from a less pure source of water (referred to as produced water) and oxygen and fuel combusted together within an oxy-fuel combustion gas generator.
  • the system begins with a source of oxygen, a source of hydrocarbon fuel and a source of water which is typically less than pure water; and results in production of more pure high pressure steam.
  • the system 100 potentially also produces substantially pure carbon dioxide and deionized water, while concentrating contaminates in a concentrated brine discharge and without any atmospheric emissions.
  • FIG. 1 depicts variations on this typical system 100 when optimized for particular types of initially contaminated water, or when optimized to produce steam of different purity or output other products including carbon dioxide and deionized water or when optimized for utilization of hydrocarbons within produced hydrocarbons or extraction of hydrocarbons for collection away from the system 100.
  • This generalized high pressure substantially pure steam production system 60 generally includes a conceptual boundary 61 with process equipment inside the boundary 61 and various supplies of fluids into the boundaries of the system 61 and discharge of fluids out of the boundary 61.
  • Inputs into the boundary 61 generally include oxygen along line 64, natural gas or other hydrocarbon fuel along line 65, and water along line 66.
  • This water is depicted in the system 60 of Figure 4 as deionized water.
  • this water could be produced water which would most typically be water produced from a hydrocarbon extraction facility, such as a steam assisted gravity drain (SAGD) system or other enhanced oil recovery (EOR) system utilizing water and/or carbon dioxide and potentially other constituents, resulting in the produced water including at least some hydrocarbons therein.
  • SAGD steam assisted gravity drain
  • EOR enhanced oil recovery
  • produced water also broadly includes less pure water sources including waste water, sea water, and other water sources with dissolved solids, or other contaminating constituents therein.
  • the oxygen along line 64, natural gas or other fuel along line 65 and water along line 66 are fed into the gas generator 62.
  • the gas generator converts these inputs into a steam/CO, mixture along line 67 which is fed to a pressurized heat recovery steam generator (HRSG) 63.
  • HRSG pressurized heat recovery steam generator
  • An example of such a gas generator 62 can be found in U.S. Patent No. 6,206,684, incorporated herein by reference.
  • the steam/C0 2 mixture is discharged from this pressurized HRSG 63 along line 70.
  • This steam/CO, mixture is then discharged out of the boundary 61 and can have the steam and C0 2 separated from each other for use separately or remain together and utilized in processes calling for such a steam/CO, mixture.
  • at least a portion of the steam/CO, mixture can be recycled back to the water inlet along line 66 back to the gas generator 62.
  • a separate water source is also fed through the boundary 61 along line 68 into the pressurized HRSG 63.
  • This water along line 68 is substantially pure water at high pressure and is raised to steam within the pressurized HRSG 63 to produce high pressure steam within line 69 discharged out of the boundary 61 of the system for beneficial use of this steam.
  • Such use can be within an oil field to produce further produced water which might be fed back into the system along with the water at line 66, or the steam might be utilized in other steam utilizing processes.
  • the steam 69 could also have power extracted therefrom, such as by running steam through a steam turbine, and then utilizing the pure water for pure water utilizing processes including food processing, industrial processes which require substantially pure water, or as a drinking water source.
  • exemplary pressure, temperature and flow rate parameters are depicted consistent with the key also provided in Figure 4, with such numerical values merely being one typical set of values utilizable in the system 60 of Figure 4.
  • FIG. 1 the system 100 is described including elements within the system described with labels and various flow lines between equipment designated with reference numerals.
  • Figure 2 provides a table 110 with specific values for temperature, pressure, flow and vapor fraction for the fluid passing along these lines at the various different locations of Figure 1 , in this one exemplary example. It is understood that these values could be increased or decreased in various alternative embodiments, or fluctuate during the operation of a single embodiment. Also, some of the numerical values are identified as "TBD.” It is understood that one of skill in the art could use a variety of different optimization and design parameters to select an appropriate value which would balance the system and optimize performance.
  • the system is configured to take
  • produced water into the system as a water input.
  • This produced water in a most typical embodiment is water that includes a hydrocarbon therein and is in the form of water at an output of a hydrocarbon recovery operation or facility, such as a steam assisted gravity drain (SAGD) facility or outflow pumped from an oil well undergoing enhanced oil recovery (EOR) procedures, such as with water flooding or injection of steam or elevated temperature water with or without carbon dioxide.
  • SAGD steam assisted gravity drain
  • EOR enhanced oil recovery
  • produced water would be other water streams which are less than pure water.
  • Examples include waste water, such as effluent at a waste water treatment plant or other waste water coming from a discharge of some processing facility.
  • the waste water might include solid particulates which would be pre-filtered out of the water but also have dissolved solids which would enter into the system 100.
  • Produced water could also be in the form of sea water or other salt containing water.
  • produced water is generally provided to refer to any water which is less than substantially pure and typically either of a sufficiently poor quality that it cannot be utilized with optimal performance within a high pressure steam utilizing process or machine, or includes hydrocarbons of value either for their heating value or as separate commodities, such that it is desirable to either utilize the entrained hydrocarbons for heat or separate entrained hydrocarbons for collection away from the system.
  • An oxy-fuel combustor (also called a gas generator) is provided in the system 100 which receives oxygen 1 and fuel 2, typically at an injector end of an elongate combustion chamber.
  • An igniter would also typically be provided at the injector end to initiate combustion.
  • At least one water line 1 1 also feeds water inlets into the oxy- fuel combustion gas generator.
  • the water inlets are most preferably at multiple locations within the oxy-fuel combustor with at least one water inlet adjacent an injector end and near a fuel and oxygen inlet into the oxy-fuel combustor, and other water inlets downstream from an injection end of this oxy-fuel combustor. It is also conceivable that some of this water would be provided after the oxy-fuel combustor but before additional downstream equipment, especially if no hydrocarbons in the water 1 1 are to be combusted in the gas generator.
  • the water 1 1 entering into the oxy-fuel combustor is high pressure water typically elevated in pressure by a pump upstream of the oxy-fuel combustor. This water is also preferably heated before passing through the pump (or conceivably after passing through the pump). For instance, a produced water stream 5 passes through a heat exchanger which exchanges heat with concentrated brine 12 exiting a first separator. This concentrated brine 12 has reduced heat after passing through this heat exchanger and is discharged from the system as concentrated brine 6.
  • the oxy-fuel combustor combusts the hydrocarbon fuel with oxygen to produce products of combustion including steam and carbon dioxide.
  • the produced water 1 1 added to the oxy-fuel combustor is heated within the oxy-fuel combustor so that an outlet of the oxy-fuel combustor discharges a steam/CO, mixture 10.
  • This mixture 10 is fed into a first separator.
  • This first separator is provided to primarily remove salts and other dissolved solids from the steam/C0 2 mixture 10.
  • the pressure of the steam/CO, mixture is quite high (i .e. 1 ,500 psi) and the temperature is moderately high but not sufficient to cause the steam/CO, to be superheated, but rather to be saturated with some liquid fraction.
  • a degree of liquid fraction supplied in this steam/C0 2 mixture can be controlled by controlling an amount of the produced water 1 1 which bypasses the oxy-fuel combustor or enters later stages of the oxy-fuel combustor, but joins with the steam/CO, mixture before entry into the first separator.
  • the first separator can be shaped to optimize this separation further, such as by being shaped cylindrically and with an elongate form and with a gaseous outlet elevated above a liquid outlet.
  • an offset inlet such as in the form of a cyclone separator, can be provided to further enhance efficiency of separation.
  • Potentially catalysts or other inducers of solids separation from the steam in the form of materials or particular flow control element geometries could also be provided within the first separator to most effectively separate any dissolved solids into a small liquid fraction resulting in a concentrated brine 6.
  • the produced water 5 includes entrained hydrocarbons therein, beneficially such hydrocarbons entering said gas generator sufficiently close to the injector end of the oxy-fuel combustor and where sufficient temperature exists within the combustor to cause the hydrocarbons within the water to be combusted. Excess oxygen can be supplied sufficient to drive such combustion, preferably to complete combustion of any such hydrocarbons within the produced water, to complete reaction into steam and carbon dioxide.
  • a gaseous outlet from the first separator can be passed directly to a pressurized heat recovery steam generator.
  • the reheater includes an inlet for oxygen 3 and an inlet for fuel 4 along with wet steam/CO, and combusts the oxygen 3 with fuel 4 to produce additional products of combustion including steam and carbon dioxide which are then mixed with the steam/CO, mixture from the first separator to produce a final mixture of steam and carbon dioxide having a greater ratio of carbon dioxide to steam than the steam/CO, mixture 10.
  • This new steam/CO, mixture has been heated to a higher temperature and is a superheated steam/CO, mixture 13.
  • This mixture 13 is then fed into a high pressure heat recovery steam generator (HRSG) identified as a superheat exchanger (SuperHX).
  • HRSG high pressure heat recovery steam generator
  • SuperHX superheat exchanger
  • Pressure of the steam/CO, mixture 13 has remained similar as that when discharged from the original gas generator, and in this embodiment is identified for illustration purposes as approximately 1 ,500 psi .
  • HRSG high pressure heat recovery steam generator
  • SuperHX superheat exchanger
  • Pressure of the steam/CO, mixture 13 has remained similar as that when discharged from the original gas generator, and in this embodiment is identified for illustration purposes as approximately 1 ,500 psi .
  • a very high temperature and high pressure superheated gas mixture of steam and carbon dioxide 13 passes into the SuperHX where it gives up heat to a substantially pure steam 23 also entering the SuperHX before the steam/CO, mixture discharges from the SuperHX along line 14.
  • this steam/CO, mixture still contains one hundred percent vaporized steam, but typically near a saturation temperature
  • This steam/CO, mixture then passes into a second portion of the HRSG referred to as a saturated heat exchanger (SatHX).
  • SatHX saturated heat exchanger
  • further heat exchange to pure water 21 occurs until the steam/CO, mixture is discharged from the SatHX along line 15.
  • the high pressure steam/C0 2 mixture has now begun to condense and is typically a combination of liquid and gaseous water as well as gaseous carbon dioxide.
  • the steam/C0 2 mixture passes into a final stage of the pressurized HRSG of this embodiment which is referred to as a preheat exchanger (PreHX).
  • the steam/C0 2 mixture exists the PreHX along line 16 after giving up heat to substantially pure water 19 with the steam/C0 2 mixture now having little to no remaining gaseous steam along with gaseous carbon dioxide.
  • the steam/CO then passes into a condenser.
  • this condenser remaining vaporized water condenses into a liquid so that a majority of gases remaining within the condenser are in the form of carbon dioxide.
  • This carbon dioxide is discharged from the condenser through a gaseous outlet 9 from the condenser.
  • This CO, discharge 9 includes substantially pure CO, which may include other non-condensible gases which might include argon from an air separation unit or excess oxygen provided to drive combustion reactions within the gas generator and/or reheater to completion, and potentially small trace amounts of other non-condensible gases.
  • the CO can beneficially be utilized for enhanced oil recovery (EOR) or utilized for other processes which call for substantially pure carbon dioxide. If the carbon dioxide needs to be drier, it can be further cooled and otherwise processed to condense remaining water vapor from the carbon dioxide. The CCX can also be further pumped, if required to be at a higher pressure.
  • EOR enhanced oil recovery
  • a lower end of the condenser includes a water outlet 17 which leads to a water storage tank.
  • This water storage tank is referred to as a deionized water storage tank in this embodiment with it including a cooling water circuit as well as a vent for any non-condensible gases which might have remained with the water.
  • a polisher loop is preferably provided to route the water through a series of pumps and a polisher along line 18 to remove remaining ions from the water and supply the water as deionized water especially for systems which require that supplied water be deionized water.
  • Deionized water can be discharged from the system at various locations, including from the deionized water storage tank along line 8.
  • the polished water 18 is preferably fed back through the condenser where it acts as coolant to condense the steam/CO, mixture 16 and also to elevate temperature of this substantially pure water supply discharged from the condenser at 19.
  • the substantially pure water supply then passes through the PreHX to be heated further and pass into line 20.
  • the water Before this water further passes into the SatHX at line 21 , the water preferably passes into a first mixer.
  • This first mixer provides a location where condensed water vapor can be added to the pure water for further heating such water vapor supplied along line 25.
  • the water at line 21 is still preferably liquid at the high pressures involved.
  • the water then passes through the SatHX where it is further heated and discharged at line 22.
  • the water has been heated to close to a boiling point for the high pressure involved (approximately 1 ,450 psi).
  • This water then preferably passes through an expansion valve which drops the pressure somewhat and rapidly converts the high pressure high temperature water to slightly lower pressure and substantially entirely steam within a second separator.
  • This second separator includes a lower end for any remaining liquid water to exit along line 28 and be returned along line 25 back to the first mixer.
  • the substantially pure steam leaving the second separator can be passed to the SuperHX along line 30 or can bypass the superheat exchanger along line 31 or can pass directly into a second mixer along line 29.
  • This second mixer defines a location where some water directly from the second separator along line 29 can be mixed with water passing through the SuperHX and discharged along line 24 before passage into the mixer.
  • Liquid water from the second separator can also optionally be fed forward into this second mixer along line 26.
  • the resulting steam in this second mixer can have a quality and temperature and pressure optimized for discharge along line 27 and removal from the system 100 along line 7 as steam having desired properties for discharge from the system.
  • a system 40 is disclosed which is in many ways similar to the system 100 of Figure 1 but somewhat simplified.
  • a single heat recovery steam generator referred to as a SuperHX
  • the option of the produced water passing through the heat exchanger before supply along line 48 to water inlets along line 43 , or alternatively passing directly from a produced water supply 47 to the water inlet 43 of the oxy-fuel combustor, is disclosed.
  • the system 40 includes an oxygen inlet 41 and a fuel inlet 42 into the oxy-fuel combustor along with water inlets 43.
  • An outlet of the oxy-fuel combustor for a steam/CCX mixture is provided along line 44 which passes into a separator.
  • Concentrated brine discharges from the separator along line 45 and can optionally exchange heat with produced water 47 before being discharged from the system 40 as concentrated brine along line 46.
  • a high pressure gaseous flow from the separator along line 49 is passed through a reheater where a further combustion of oxygen 50 and fuel 51 superheats the steam/CO, mixture at line 52.
  • This superheated steam/CO, mixture then exchanges heat in the SuperHX with pure water along line 58.
  • This steam CO, mixture is then discharged from the SuperHX along line 53 and then passes into a condenser where a water portion of the steam/CCX mixture condenses into water and a gaseous portion in the form of substantially carbon dioxide discharges from the condenser at line 55.
  • An air separation unit can be provided which receives air and power and outputs oxygen upstream of the gas generator and reheater.
  • Produced water is referred to in the system 80 as "produced hydrocarbons" and includes hydrocarbons of some form which could be solid, liquid or gaseous.
  • a three phase oil separator is provided which receives the produced hydrocarbons. This three phase oil separator includes an output for oil and/or bitumen which can condense within or settle by gravity separation or other methods out of the three phase oil separator.
  • Associated gas is also removed from the three phase oil separator utilizing known techniques.
  • the associated gas could be discharged from the system.
  • this associated gas preferably passes on to a fuel blending process which also receives natural gas or other hydrocarbon fuel and the associated gas is blended with the natural gas or other fuel to produce fuel at a fuel inlet of the gas generator which has a heating value desired for the flow rate of oxygen also input into the gas generator.
  • the three phase oil separator also includes a water outlet which outlets produced water which also typically includes remaining hydrocarbons therein.
  • This produced water can be preheated by the stream of concentrated brine leaving the steam separator downstream of the gas generator (GG) and upstream of the reheater ( H).
  • the produced water is thus elevated in temperature before it also passes into the gas generator.
  • Hydrocarbons within the produced water can be combusted within the gas generator along with the fuel .
  • the gas generator thus discharges a mixture of steam/CO, at high pressure.
  • Other portions of the system 80 are configured similar to the systems 100 and 40.
  • a cooling water flow of water which is already substantially pure water passes through the condenser first and then passes through the pressurized heat recovery steam generator to raise substantially pure high pressure steam for other processes.
  • associated gas which could be provided downstream from a three phase oil separator, such as that depicted in Figure 5, is combined with natural gas or other hydrocarbon fuel upstream of either the gas generator (GG) or upstream of the reheater (RH).
  • the associated gas would also typically pass through some form of fuel blender such as that depicted in Figure 5.
  • Other portions of the system 90 depicted in Figure 6 are similar to details of the system 80 of Figure 5.
  • This invention exhibits industrial applicability in that it provides high pressure substantially pure steam from combustion of a hydrocarbon fuel without atmospheric pollution.
  • Another object of the present invention is to provide a high pressure heat exchanger which can exchange heat from a high pressure stream of steam and carbon dioxide to a stream of substantially pure high pressure water.
  • Another object of the present invention is to provide a high pressure heat recovery steam generator which generates substantially pure steam in multiple stages from a stream of high pressure high temperature mixed steam and carbon dioxide.
  • Another object of the present invention is to provide a method for generating substantially pure steam from a zero emissions combustion based heat source.
  • Another object of the present invention is to provide a substantially pure stream of high pressure steam from produced water including a variety of contaminates such as waste water, sea water or water and hydrocarbons produced from a hydrocarbon extraction facility.
  • Another object of the present invention is to provide a method for treatment of waste water.
  • Another object of the present invention is to provide a system for purification of sea water or other salt water for drinking water supply or other purposes requiring purified water.
  • Another object of the present invention is to provide a system for generating substantially pure high pressure water which utilizes at least a portion of impurities in the water as a fuel source for a combustor which generates heat for raising of the high pressure steam.
  • Another object of the present invention is to provide a system including an oxy-fuel combustion gas generator and a high pressure heat recovery steam generator which includes a separator therebetween to remove solids from a steam/C X mixture discharged from the oxy-fuel combustion gas generator.

Abstract

Selon l'invention, de la vapeur haute pression pratiquement pure est produite dans un échangeur de chaleur haute pression. La chaleur de l'échangeur de chaleur haute pression provient d'une sortie d'un générateur de gaz de combustion oxy-combustible qui évacue un mélange de vapeur/CO2 à une pression et une température élevées. Le générateur de gaz brûle de l'oxygène et du combustible hydrocarboné et les mélange avec de l'eau pouvant contenir des contaminants sous forme de matières et d'hydrocarbures dissouts. Un séparateur est généralement fourni en aval du générateur de gaz et en amont de l'échangeur de chaleur, et le mélange de vapeur/CO2 est évacué du générateur de gaz à une température de saturation. Une fraction d'eau du mélange de vapeur/CO2 est évacuée du séparateur avec les matières dissoutes sous forme de saumure concentrée. L'eau chauffée et transformée en vapeur par l'échangeur de chaleur peut être au moins partiellement séparée de l'eau dans un condensateur en aval de l'échangeur de chaleur.
PCT/US2013/000233 2012-10-08 2013-10-08 Production, à émissions presque nulles, de vapeur propre haute pression WO2014058449A1 (fr)

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