WO2014133869A1 - Réglage de débit de chaudière à des fins d'atténuation d'encrassement - Google Patents

Réglage de débit de chaudière à des fins d'atténuation d'encrassement Download PDF

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Publication number
WO2014133869A1
WO2014133869A1 PCT/US2014/017430 US2014017430W WO2014133869A1 WO 2014133869 A1 WO2014133869 A1 WO 2014133869A1 US 2014017430 W US2014017430 W US 2014017430W WO 2014133869 A1 WO2014133869 A1 WO 2014133869A1
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WO
WIPO (PCT)
Prior art keywords
pressure
feedwater
steam
steam generator
generator system
Prior art date
Application number
PCT/US2014/017430
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English (en)
Inventor
David William LARKIN
James P. Seaba
Original Assignee
Conocophillips Company
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 Conocophillips Company filed Critical Conocophillips Company
Priority to CA2900555A priority Critical patent/CA2900555A1/fr
Publication of WO2014133869A1 publication Critical patent/WO2014133869A1/fr

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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
    • 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
    • E21B36/00—Heating, cooling or insulating arrangements for boreholes or wells, e.g. for use in permafrost zones
    • E21B36/005—Heater surrounding production tube
    • 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
    • F22B1/22—Methods of steam generation characterised by form of heating method using combustion under pressure substantially exceeding atmospheric pressure
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22—STEAM GENERATION
    • F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B27/00—Instantaneous or flash steam boilers

Definitions

  • the invention relates to methods and systems for generating high pressure steam with minimal or eliminated fouling otherwise resulting largely from boiling nucleation.
  • SAGD Steam Assisted Gravity Drainage
  • the SAGD process requires high quality, high temperature and high pressure steam.
  • the SAGD process may call for 100% quality, 7,000 - 11,000 kilopascals (kPa) and 285-318°C temperature steam.
  • boiler feedwater is supplied by a high pressure feed- water pump at an elevated pressure around 13,000 kPa or less, which results in corresponding steam pressure that gradually decreases along the pipeline to aforementioned injection pressures due to the loss in transportation and eventually by choking to the desired injection pressure.
  • a once-through steam generator (OTSG), for example, generates around
  • OTSG is a large, continuous tube type steam generator in which the steam is produced at the outlet of the continuous tube. Feedwater is supplied at one end of the tube having low temperature, and then undergoes heating and boiling as it travels in a single pass along the tube.
  • an OTSG typically comprises a convection section (also called economizer section) and a radiant section.
  • the feedwater is preheated by heat exchange with a hot combustion gas, usually flue gas.
  • the radiant section the feedwater/wet steam is heated by the heat radiated from the furnace, resulting in about 80% quality steam, i.e. the weight ratio of water to steam at the outlet of the generator is about 1 :4.
  • Boiler feed- water (BFW) quality is critical because dissolved solids develop scales that are the major cause of boiler failure and efficiency losses. Therefore, the total dissolved solids (TDS) for BFW needs to be controlled under a certain level to prevent or alleviate the scaling issue.
  • Fouling is the contamination of the heating surface, and the build-up of contaminant eventually decreases the heat-flux and thus the heating efficiency. Therefore, the boiler has to be shut down several times a year to remove the fouling layer and/or repair the tubing. In addition to the repair cost, the downtime increases the cost of the SAGD operation.
  • the present disclosure provides a method of eliminating or minimizing the fouling caused by nucleate boiling and/or transition boiling of the feedwater in a steam generator.
  • the current invention significantly reduces or even eliminates fouling by heating the boiler feedwater at pressures significantly higher than the output steam delivery pressure, thereby maintaining the feedwater in liquid phase before flashing it off to generate steam.
  • the method therefore, minimizes or eliminates the fouling caused by nucleate boiling in the boiler. This approach can minimize the downtime of the boiler for repairing or removing the fouling, thereby, increasing the operating time.
  • the disclosure provides a method of preheating feedwater of a steam generator, comprising a) providing feedwater through a steam generator system under sufficient pressure to heat said feedwater and prevent the formation of steam; b) passing said heated feedwater out of said steam generator system to a pressure reducer where said heated feedwater is flashed to steam; and c) conveying said steam into a wellbore for mobilizing oil.
  • Any suitable valve can be used to flash the heated feedwater to steam, including a throttling valve, fine nozzle or orifice, and the like.
  • a throttling valve fine nozzle or orifice, and the like.
  • Armstrong- Yoshitake Inc. makes the GP-2000R valve, which is a high performance externally piloted throttling back pressure valve for large capacity applications, and they make many additional pressure reducing valves.
  • the pressure-reducing step can be performed before or after the feedwater enters the radiant section, depending on the system configuration, where fouling tends to build up, and other considerations.
  • the pressure-reducing step can be performed before or after the heating step at the radiant section.
  • the pressure-reducing step is performed after such heating.
  • the disclosure also provides a steam generator system, comprising the following components in fluid communication: a) a pressurizing element for increasing the pressure of said feedwater; b) an economizer for preheating the feedwater; c) a radiant section for further heating said feedwater from said economizer, and d) a pressure-reducing element for reducing the system pressure positioned as desired to at least minimize fouling.
  • the pressure reducing element can be after the preheating, or after the further heating steps.
  • the system can also be combined with a flash vessel or other separator, for separating steam from condensate, and the flash steam can be injected downhole, and condensate rerouted, for example to the economizer section, either as feedwater, or as a heat source for the economizer.
  • a flash vessel or other separator for separating steam from condensate
  • the flash steam can be injected downhole, and condensate rerouted, for example to the economizer section, either as feedwater, or as a heat source for the economizer.
  • an improved method of producing oil includes heating feedwater sufficiently to make steam to inject into a wellbore and mobilize oil for production, the improvement comprising heating feedwater under a pressure sufficient to prevent nucleate boiling, rapidly reducing said pressure to make fiash steam and injecting said fiash steam into a wellbore, thus mobilizing oil for production.
  • heat flux is the rate of heat energy transfer through a given surface, in other words, the heat rate per unit area
  • critical heat flux describes the thermal limit of a phenomenon where a phase change occurs during heating, which suddenly decreases the efficiency of heat transfer, thus causing localized overheating of the heating surface.
  • flash steam is the name given to the steam formed from hot condensate when the pressure is reduced. Flash steam is no different from normal steam, it is just a convenient name used to explain how the steam is formed. Normal or “live” steam is produced while heating at a boiler, steam generator, or waste heat recovery generator— whereas flash steam occurs when high pressure/high temperature condensate is exposed to a large pressure drop, such as when exiting a steam trap.
  • High temperature condensate contains high energy that cannot remain in liquid form at a lower pressure because there is more energy than that required to achieve saturated water at the lower pressure. The result is that some of the excess energy causes a percentage of the condensate to flash.
  • flash steam ratio The percentage of flash steam generated (flash steam ratio) can be calculated from:
  • economizer means the devices for reducing energy consumption in a steam-generating operation by preheating feedwater.
  • a high temperature fluid e.g., steam condensate, flue gas or other waste heat source
  • Economizers are mechanical devices intended to reduce energy consumption or to perform another useful function such as preheating a fluid. They are fitted to a boiler and save energy by using e.g., the exhaust gases from the boiler or other hot plant fluids to preheat the cold feedwater. It has been reported that approximately 35 to 50% of the total absorbed heat in OTSG is transferred in the economizer.
  • flash steam recovery vessel or “flash vessel” is that vessel used to separate flash steam from condensate. After condensate and flash steam enter the flash vessel, the condensate falls by gravity to the base of the vessel, from where it is drained, via a float trap, usually to a vented receiver from where it can be pumped. The flash steam in the vessel is piped from the top of the vessel to any appropriate pressure steam equipment or injected directly into the wellbore.
  • radiant section means the section in a steam generator where the heating of feedwater is primarily achieved by radiant heat transfer.
  • FIG. 1 illustrates one embodiment of the disclosure, where the pressurization of feedwater occurs prior to entering the economizer, and wherein the pressure- reducing step occurs within the economizer (but after preheating).
  • FIG. 2 illustrates another embodiment of the disclosure, where the feedwater is pressurized prior to entering the economizer, and wherein the depressurization step occurs outside the economizer.
  • FIG. 3 illustrates another embodiment of the disclosure, where the pressurization of feedwater occurs prior to entering the economizer, and the flash steam occurs after both the preheating and the further heating in the radiant section.
  • FIG. 4 illustrates a variation wherein a different heating system is used, but feedwater is still pressurized to prevent nucleate boiling, and the very hot water is flashed to steam after exiting the heating unit.
  • FIGs. 5 and 6 are pressure-enthalpy diagrams of embodiments illustrated in FIGs. 1-4.
  • the disclosure provides a novel method for generating steam with minimized or eliminated fouling caused by nucleate boiling and/or transition boiling.
  • the disclosure also provides a novel system for implementing the method. It is believed that by using the method and system of the methods described herein, fouling in the steam generator due to nucleate boiling can be greatly reduced or eliminated, thereby reducing the operational cost and downtime for repairing and maintaining the steam generator.
  • Methods and systems generate steam for thermal oil recovery, such as a steam assisted gravity drainage (SAGD) operation.
  • SAGD steam assisted gravity drainage
  • Feedwater is first pressurized to a pressure above that desired for steam injection in the SAGD operation before being heated to avoid at least some nucleate boiling.
  • the local boiling regime is beyond the nucleate boiling regime due to the local pressure drop and the enhanced mixing caused by the throttling process.
  • Two-phase liquid may continue through the boiler generating higher quality steam.
  • Nucleate boiling is considered one of the main reasons for fouling in heat transfer tubes. Nucleate boiling is characterized by the growth of bubbles on a heated surface, which rise from discrete points on a surface, whose temperature is only slightly above the liquid temperature. As the bubble enters the bulk flow, the bubble condenses back to liquid. In general, the number of nucleation sites are increased by an increasing surface temperature and by irregular surfaces of the boiling vessel.
  • Nucleate boiling takes place when the surface temperature is hotter than the saturated fluid temperature by a certain amount but where the heat flux is below the critical heat flux.
  • the critical heat flux defines a maximum heat flux between nucleate boiling and transition boiling. For example, nucleate boiling for water may occur when the surface temperature is higher than the saturation temperature (T s ) by between 4°C to 30°C.
  • an improved method of generating steam for SAGD and other heavy oil production uses wherein feedwater is pressurized, to e.g., about 14,000 kilopascals (kPa), thus minimizing or eliminating nucleate boiling.
  • the pressurized water is heated while maintaining a liquid phase, and then later flashed to steam, which can be used downhole.
  • the pressurized feedwater can be heated in liquid phase without vaporizing, and the absorbed enthalpy will transform the water into steam once the heated feedwater is flashed off.
  • the flash-off process involves little or no boiling, thereby reducing the fouling.
  • a system for generating steam comprising a pressurizing element for increasing the pressure of the system, an optional economizer for preheating feedwater, a radiant section for heating the feedwater from the economizer, and a pressure- reducing element for reducing the system pressure and producing flash steam.
  • the pressurizing element increases the pressure of the system before the feedwater is supplied to the economizer and/or radiant section.
  • all of the elements are in fluidic connection, such that pressure and fluid can travel from one part of the system to another.
  • a flash vessel can be used to separate flash steam from condensate, which can be routed back to e.g., the economizer for preheating feedwater.
  • the pressurizing element is upstream of the economizer, but not necessarily so.
  • the economizer if used, is preferably upstream of the radiant section, which is upstream of the pressure reducing valve, which is upstream of the flash vessel, and the condensate from the flash vessel preferably routes back to the pressurizing element or economizer.
  • the pressure reducing valve can be upstream of the radiant section if there is limited or no tendency to fouling in the radiant section.
  • the pressurizing element can be any device, such as a pump, known in the field to increase system pressure.
  • the pressure -reducing element can be any device known in the field to reduce system pressure. Non-limiting examples include orifices, valves, or a combination thereof.
  • the system pressure is increased to the extent that the feedwater can remain in liquid phase without boiling when being heated. Also, the system pressure may only be increased to the extent commercially feasible without incurring additional cost to replace the piping to withstand higher pressure. In one embodiment, the system pressure is increased to at least 20,000 kPa, at least 14,000 kPa or at least 10,000 kPa. Use of solvents and/or generation of the steam at a pad for injection instead of a central processing facility may enable lower pressure steam needs such that the increase of the system pressure may be to only at least 5000 kPa or at least 3500 kPa.
  • the placement of the pressure -reducing element in the system may vary, depending on where the fouling is to be reduced. For example, if fouling is serious in the economizer, but not in other parts of the OTSG, then the pressure-reducing element can be installed right after where the feedwater exits the economizer. If, on the other hand, the fouling is to be reduced throughout the OTSG, the pressure -reducing element can be installed after where the feedwater exits the radiant section, thereby maintaining the feedwater in liquid phase to avoid nucleate boiling throughout. In some embodiments, the pressure -reducing element accommodates pigging and may be located to enable and/or not interfere with other maintenance and operational needs.
  • the system pressure is reduced to the extent that the feedwater can rapidly convert from liquid to steam after being preheated or heated. This rapid phase conversion involves little or no boiling, and therefore can minimize the fouling associated with nucleate boiling.
  • the system pressure is reduced by at least 6500 kPa or at least 3500 kPa due to the pressure-reducing element.
  • FIG. 1 illustrates an embodiment of the present disclosure. Shown therein is a configuration of a steam generator, wherein feedwater is supplied first to an economizer section 101 for pre-heating, followed by a radiant section 102 to generate the steam of specified quality. A separator 103 then separates the steam 104 from the un- vaporized water 105, where the steam is supplied to SAGD operations and the hot water is discharged or recycled for further use.
  • the feedwater Prior to being supplied to the economizer 102, the feedwater is first pressurized by a pressurizing means 107.
  • the pressurizing means can be any mechanism that effectively pressurizes the system such that the boiling point of water is elevated.
  • the pressurizing means 107 is a pump for supplying water under pressurized condition.
  • FIG. 5 shows a pressure-enthalpy steam diagram for water.
  • the upper left region is the liquid region where all water remains liquid.
  • the upper right is the supercritical region where distinct liquid and gas phases do not exist.
  • the system is first pressurized to point 3, where the pressure is significantly higher than one atmosphere, and preferably higher than the highest pressure of the saturated region to the extent commercially feasible, and more preferably at least 14,000 kPa.
  • the feedwater under pressurized condition is then pre-heated at this pressure along the line between points 3 and 4.
  • the pressure of the system is then reduced (e.g., to between 5000 kPa and 13,000 kPa) after passing through the orifices, thus reaching point 5.
  • there could be a mixture of steam and liquid water which is then heated at the radiant section 102 as depicted by the line from point 5 to point 2.
  • the majority of nucleation boiling particularly corresponding to the path from point 1 to point 5 is avoided.
  • FIG. 2 shows a variation of the embodiment illustrated in FIG. 1.
  • the basic configuration of the steam generator still includes the economizer section 201, the radiant section 202 and the separator 203.
  • the feedwater is still supplied with the system pressurized by a pump 207 prior to entering the economizer 201.
  • the only difference between FIG. 1 and FIG. 2 is that in this embodiment, the pre-heated water circulates outside the economizer section 201 and the pressure is reduced at this point.
  • This embodiment shows that the inventive method can be applied to different OTSG configurations.
  • FIG. 3 illustrates another embodiment that still includes an economizer section 302 and a radiant section 303.
  • the pressurized feedwater 308 is supplied from a pump 307 to the economizer 302 for pre-heating, followed by further heating in the radiant section 303.
  • the heated water then goes through a pressure reducer 310 where flash steam is produced before entering the separator 304.
  • the separator 304 then separates the high pressure steam 305 from the residual water 306 (if any), which will e.g., be directed to heat exchanger 309 to further preheat the pressurized feedwater 308 before being discharged or recycled.
  • FIG. 6 shows a pressure-enthalpy diagram for this embodiment depicted in
  • FIG. 3 Similar to FIG. 5, the path from point 1 to 3 corresponds to the pressurizing step by the pump 307 in FIG. 3. However, as seen in FIG. 3, the pressure-reducing step is not performed until after all the heating steps, including preheating at the economizer and heating at the furnace, are completed, hence the end point 2 in this figure coincides with the reduced-pressure point 5 in FIG. 5. It is to be noted that the pressurizing-heating path of points 1-3-4-5-2 effectively bypasses the boiling nucleation, thereby reducing the fouling.
  • FIG. 4 is another embodiment of the method utilizing a heat exchanger
  • the heat exchanger 501 for heating water has a hot fluid inlet 502 for introducing a high temperature fluid, preferably having high thermal capacity, and a hot fluid exit 503 for discharging the hot fluid after heat exchange.
  • the high thermal capacity also helps the efficiency of the heat exchange.
  • the system is first pressured by pump 507, and feedwater 508 is then supplied to the heat exchanger 501 for heating to generate a very hot water.
  • the hot fluid preferably has a temperature significantly higher than the feedwater 508 such that the transferred heat would be sufficient to vaporize the feedwater 508 without the additional pressure that maintains the feedwater 508 in liquid phase.
  • a pressure reducer in this case a valve 510, reduces the pressure of the water for vaporization, which then enters the separator 504.
  • the high pressure steam 505 is then supplied to SAGD operations, whereas the water 506 can be introduced to another heat recovery device 509 to pre -heat the pressurized feedwater 508.
  • the heated high pressure feedwater flashes off at either the central processing facility or well pad operating pressure, depending on the steam generation location.
  • this method can reduce the pipe rack capital of the surface facility because now only water lines need to go to the well pads instead of steam lines since steam may be produced on site (i.e. at the well pads) and not before.

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Abstract

La présente invention concerne des procédés et des systèmes générant de la vapeur à des fins de récupération d'huile thermique, comme par une opération de drainage par gravité au moyen de vapeur (SAGD). Selon l'invention, de l'eau d'alimentation est d'abord mise sous pression à une pression supérieure à celle souhaitée pour une injection de vapeur lors de l'opération de SAGD avant d'être chauffée pour éviter au moins une certaine ébullition nucléée. Après le réglage du débit, le régime d'ébullition locale est supérieur au régime d'ébullition nucléée en raison de la chute de pression locale et du mélange enrichi provoqué par le traitement de réglage de débit. Le liquide à deux phases peut continuer à travers la chaudière en générant une vapeur de meilleure qualité.
PCT/US2014/017430 2013-03-01 2014-02-20 Réglage de débit de chaudière à des fins d'atténuation d'encrassement WO2014133869A1 (fr)

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Application Number Priority Date Filing Date Title
CA2900555A CA2900555A1 (fr) 2013-03-01 2014-02-20 Reglage de debit de chaudiere a des fins d'attenuation d'encrassement

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US201361771202P 2013-03-01 2013-03-01
US61/771,202 2013-03-01
US14/185,411 2014-02-20
US14/185,411 US20140246196A1 (en) 2013-03-01 2014-02-20 Throttling boiler for fouling mitigation

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WO2014133869A1 true WO2014133869A1 (fr) 2014-09-04

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Publication number Priority date Publication date Assignee Title
CA2799677C (fr) * 2011-12-22 2017-01-24 Cenovus Fccl Ltd. Generateur de vapeur et methode de production de vapeur
US10845048B2 (en) * 2017-05-31 2020-11-24 Solex Thermal Science Inc. Method and apparatus for recovery of heat from bulk solids
CA3098744A1 (en) 2019-11-12 2021-05-12 Innotech Alberta Inc. Electrical vapor generation methods and related systems
CA3128604A1 (fr) * 2020-08-26 2022-02-26 Cenovus Energy Inc. Procede de production de vapeur pour un procede de recuperation d'hydrocarbures

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3338219A (en) * 1965-09-09 1967-08-29 Frederick W Riehl Steam generating boiler or steam power plant
US3370573A (en) * 1966-12-12 1968-02-27 Combustion Eng Start-up system for combined circulation steam generator
US20120279903A1 (en) * 2010-09-13 2012-11-08 Maoz Betzer Tsilevich Steam drive non-direct contact steam generation

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3338219A (en) * 1965-09-09 1967-08-29 Frederick W Riehl Steam generating boiler or steam power plant
US3370573A (en) * 1966-12-12 1968-02-27 Combustion Eng Start-up system for combined circulation steam generator
US20120279903A1 (en) * 2010-09-13 2012-11-08 Maoz Betzer Tsilevich Steam drive non-direct contact steam generation

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CA2900555A1 (fr) 2014-09-04
US20140246196A1 (en) 2014-09-04

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