Apparatus, methods, and systems for extracting petroleum using a portable coal reformer

• US 7,654,330 B2
• Filed: 05/19/2007
• Issued: 02/02/2010
• Est. Priority Date: 05/19/2007
• Status: Active Grant

• Current Assignee: Pioneer Energy, Inc.
• Original Assignee: Pioneer Energy, Inc.
• Inventors: Zubrin, Robert M., Berggren, Mark H.
• Primary Examiner(s): Gay; Jennifer H
• Assistant Examiner(s): Harcourt; Brad
• Application Number:
  US11/751,011
• Publication Number:
  US 20080283249A1
• Time in Patent Office: 990 Days
• Field of Search: 166/257, 166/266, 166/267, 166/268, 166/263, 166/369, 166/65.1, 166/75.11
• US Class Current: 166/369
• CPC Class Codes: C01B 2203/0405 Purification by membrane separation
• CPC Class Codes: C01B 2203/043 Regenerative adsorption process in two or more beds, one for adsorption, the other for regeneration
• CPC Class Codes: C01B 2203/047 the impurity being carbon monoxide
• CPC Class Codes: C01B 2203/0475 the impurity being carbon dioxide
• CPC Class Codes: C01B 2203/048 the impurity being an organic compound
• CPC Class Codes: C01B 3/501 by diffusion
• CPC Class Codes: C01B 3/505 Membranes containing palladium
• CPC Class Codes: C01B 3/56 by contacting with solids; Regeneration of used solids C01B3/508 takes precedence
• CPC Class Codes: C10J 2300/093 Coal
• CPC Class Codes: C10J 2300/0973 Water
• CPC Class Codes: C10J 2300/16 Integration of gasification processes with another plant or parts within the plant
• CPC Class Codes: C10J 2300/1606 Combustion processes
• CPC Class Codes: C10J 2300/1621 Compression of synthesis gas
• CPC Class Codes: C10J 2300/1671 with the production of electricity
• CPC Class Codes: C10J 2300/1838 Autothermal gasification by injection of oxygen or steam
• CPC Class Codes: C10J 2300/1853 Steam reforming, i.e. injection of steam only
• CPC Class Codes: C10J 2300/1876 with one stream being combustion gas
• CPC Class Codes: C10J 2300/1884 with one stream being synthesis gas
• CPC Class Codes: C10J 3/00 Production of combustible gases containing carbon monoxide from solid carbonaceous fuels destructive distillation processes C10B
• CPC Class Codes: C10J 3/20 Apparatus; Plants
• CPC Class Codes: C10J 3/482 : Gasifiers with stationary fluidised bed
• CPC Class Codes: E21B 43/168 : Injecting a gaseous medium
• CPC Class Codes: E21B 43/34 : Arrangements for separating materials produced by the well
• CPC Class Codes: Y02P 30/00 : Technologies relating to oil refining and petrochemical industry

Abstract

Apparatus, methods, and systems for extracting oil or natural gas from a well using a portable coal reformer. In one example, the method may include reforming coal by reaction with water to generate driver gas (comprising carbon dioxide and hydrogen gas), and injecting the driver gas into the well. The driver gas reduces the viscosity and pressurizes the oil to help extract the oil from the oil well. The coal reforming operation may include combusting coal or other combustible material with ambient oxygen to release energy, and heating coal and water with the energy released to a temperature above that required for the coal reforming reaction to proceed, thereby reforming coal and water into driver gas. The driver gas may be purified by filtering out particles and sulfur before injecting into the well. A portion of the hydrogen gas may be separated from the driver gas and used to generate electrical power.

Claims

1. A portable oil recovery apparatus for substantially rejuvenating a near-depleted oil well, comprising:

a portable coal reformer adapted to steam reform a quantity of coal with a quantity of water to generate driver gas comprising hydrogen gas, carbon dioxide gas, and carbon monoxide gas, wherein sufficient water is provided to ensure a substantial majority of the coal is converted directly into carbon dioxide gas and hydrogen gas in a single step;

a gas separator module having a hydrogen outlet and a carbon dioxide outlet, operatively coupled to the portable coal reformer and adapted to separate at least a portion of the carbon dioxide gas from the driver gas;

a power generator module having a hydrogen inlet operatively coupled to the hydrogen outlet of the gas separator module, and adapted to generate electric power using the hydrogen gas received from the gas separator module via the hydrogen inlet;

a compressor module having a carbon dioxide inlet operatively connected to the carbon dioxide outlet of the gas separator module and adapted to compress the carbon dioxide gas separated by the gas separator module to a pressure appropriate for the near-depleted oil well; and

a carbon dioxide output on the compressor module adapted to eject the compressed carbon dioxide gas out of the portable apparatus and into the near-depleted oil well.

2. The apparatus of claim 1, wherein a substantial portion of the carbon dioxide gas is injected into the near-depleted oil well, thereby allowing oil to be recovered from the near-depleted oil well while generating electricity with low carbon dioxide emissions.

3. The apparatus of claim 1, further comprising:

a filter module, operatively coupled to the portable coal reformer and positioned between the portable coal reformer and the gas separator module, and adapted to remove particles from the driver gas produced by the portable coal reformer before the driver gas is separated by the gas separator module.

4. The apparatus of claim 1, further comprising:

a heat recovery module operatively connected to the portable coal reformer and adapted to recover a portion of heat released by the portable coal reformer.

5. The apparatus of claim 1, further comprising:

a steam generator module adapted to convert water into steam, wherein the steam generator module is positioned adjacent to the power generator module such that heat from the power generator module is used to convert water into steam entering the portable coal reformer.

6. The apparatus of claim 1, further comprising:

a hopper operatively connected to an inlet on the portable coal reformer and adapted to feed the coal into the portable coal reformer.

7. The apparatus of claim 1, wherein the coal and the water are mixed to create coal-water slurry that is fed via an inlet to the portable coal reformer.

8. The apparatus of claim 1, wherein the portable coal reformer is a fixed bed reformer.

9. The apparatus of claim 1, further comprising:

a reaction chamber for reacting a quantity of oxygen with a combustible material, wherein energy released from combustion of the oxygen and the combustible material in the reaction chamber is used to heat the portable coal reformer in order to reform the coal and the water in the portable coal reformer into the driver gas.

10. A method for substantially rejuvenating a near-depleted oil well, comprising:

providing a portable coal reformer at a site of the near-depleted oil well;

feeding a quantity of coal and a quantity of water into the portable coal reformer;

steam reforming the coal and the water in the portable coal reformer to generate a driver gas comprising a mixture of hydrogen gas, carbon dioxide gas, and carbon monoxide gas, wherein sufficient water is provided to ensure a substantial majority of the coal is converted directly into carbon dioxide gas and hydrogen gas in a single step;

separating the driver gas into a substantially carbon dioxide gas stream and a substantially hydrogen gas stream;

generating power using the hydrogen gas stream;

compressing the carbon dioxide gas stream to a pressure appropriate for the near-depleted oil well;

injecting the compressed carbon dioxide gas stream into the near-depleted oil well; and

recovering oil from the near-depleted oil well, thereby rejuvenating the near-depleted oil well.

11. The method of claim 10, wherein a substantial portion of the carbon dioxide gas is injected into the near-depleted oil well, thereby allowing oil to be recovered from the near-depleted oil well while generating electricity with low carbon dioxide emissions.

12. The method of claim 10, further comprising:

purifying the driver gas by filtering particles from the driver gas exiting the portable coal reformer.

13. The method of claim 12, further comprising:

recycling intermediate-sized particles into the portable coal reformer.

14. The method of claim 10, further comprising:

adding a quantity of oxygen to the portable coal reformer;

reacting the oxygen with a combustible material in the portable coal reformer; and

reforming the coal and the water in the portable coal reformer utilizing energy released from combustion of the oxygen and the combustible material.

15. The method of claim 10, further comprising:

reacting a quantity of oxygen with a combustible material in a separate reaction chamber; and

reforming the coal and the water in the portable coal reformer utilizing energy released from combustion of the oxygen and the combustible material in the separate reaction chamber.

16. The method of claim 15, wherein the combustible material is coal or a derivative of coal.

17. The method of claim 10, further comprising:

removing sulfur from the driver gas exiting the portable coal reformer.

18. The method of claim 10, further comprising:

converting water into steam by recycling heat released by the hot driver gas exiting the portable coal reformer.

19. The method of claim 10, further comprising:

converting water into steam by utilizing heat released from the power generation step before feeding the steam into the portable coal reformer.

20. A portable apparatus for substantially rejuvenating a near-depleted oil well, comprising:

transportation means for transporting the portable apparatus to the near-depleted oil well;

reformation means for reforming a quantity of coal with a quantity of water to generate driver gas, the driver gas comprising hydrogen gas, carbon dioxide gas, and carbon monoxide gas, wherein sufficient water is provided to ensure a substantial majority of the coal is converted directly into carbon dioxide gas and hydrogen gas in a single step;

separation means for separating a portion of the carbon dioxide gas from the driver gas, the separation means operatively connected to the reformation means;

power generation means for generating power using the hydrogen gas, the generation means operatively coupled to the separation means;

pressurization means for pressurizing the carbon dioxide gas to a pressure appropriate for injection into the near-depleted oil well, the pressurization means operatively connected to the separation means; and

injection means for injecting the pressurized carbon dioxide gas into the near-depleted oil well, the injection means operatively coupled to the pressurization means,

wherein the transportation means supports and transports the reformation means, the separation means, the power generation means, the pressurization means, and the injection means.

21. The apparatus of claim 20, wherein a substantial portion of the carbon dioxide gas is injected into the near-depleted oil well, thereby allowing oil to be recovered from the near-depleted oil well while generating electricity with low carbon dioxide emissions.

22. The apparatus of claim 20, further comprising:

steam generation means for converting water into steam, wherein the steam generation means is positioned adjacent to the power generation means such that heat from the power generation means is used to convert water into steam entering the reformation means.