Water treatment method for heavy oil production

• US 7,967,955 B2
• Filed: 05/17/2010
• Issued: 06/28/2011
• Est. Priority Date: 05/07/1999
• Status: Expired due to Term

• Current Assignee: GE Ionics Incorporated (Veolia Environnement SA)
• Original Assignee: GE Ionics Incorporated (Veolia Environnement SA)
• Inventors: Heins, William F.
• Primary Examiner(s): Bhat; Nina
• Application Number:
  US12/781,768
• Publication Number:
  US 20100224364A1
• Time in Patent Office: 407 Days
• Field of Search: 203/10, 203/12, 203/26, 203/98, 203/48, 166/267, 210/664, 210/669, 210/805, 210/806, 196/98
• US Class Current: 203/12
• CPC Class Codes: C02F 1/02 by heating methods of steam generation F22B; preheating boiler feed-water or accumulating preheated boiler feed-water F22D
• CPC Class Codes: C02F 1/04 by distillation or evaporation
• CPC Class Codes: C02F 1/041 by means of vapour compression
• CPC Class Codes: C02F 1/048 Purification of waste water by evaporation
• CPC Class Codes: C02F 1/08 Thin film evaporation
• CPC Class Codes: C02F 1/40 Devices for separating or removing fatty or oily substances or similar floating material cleaning or keeping clear the surface of open water from oil or like materials E02B15/04; devices in sewers for separating liquid or solid substances from sewage E03F5/14, e.g. for use in drains leading to the sewer E03F5/16
• CPC Class Codes: C02F 1/42 by ion-exchange ion-exchange in general B01J
• CPC Class Codes: C02F 1/46 by electrochemical methods
• CPC Class Codes: C02F 1/469 by electrochemical separation, e.g. by electro-osmosis, electrodialysis, electrophoresis
• CPC Class Codes: C02F 1/56 Macromolecular compounds
• CPC Class Codes: C02F 1/66 by neutralisation; pH adjustment for degassing C02F1/20; using ion-exchange C02F1/42; for flocculation or precipitation of suspended impurities C02F1/52; for removing dissolved compounds C02F1/58
• CPC Class Codes: C02F 2103/023 Water in cooling circuits
• CPC Class Codes: C02F 2103/10 from quarries or from mining activities
• CPC Class Codes: C02F 2103/365 from petrochemical industry (e.g. refineries)
• CPC Class Codes: C02F 9/00 Multistage treatment of water, waste water or sewage
• CPC Class Codes: E21B 43/2406 Steam assisted gravity drainage [SAGD]
• CPC Class Codes: E21B 43/2408 SAGD in combination with other methods
• CPC Class Codes: Y10S 159/901 Promoting circulation
• CPC Class Codes: Y10S 203/17 Saline water conversion

Abstract

A process for treating produced water to generate high pressure steam. Produced water from heavy oil recovery operations is treated by de-oiling the produced water to provide a de-oiled evaporator feedwater that is fed to an evaporator. The pretreated produced water stream is evaporated to produce (1) a distillate having a trace amount of residual solutes therein, and (2) evaporator blowdown containing substantially all solutes from the de-oiled produced water feed. The distillate may be directly used, or polished to remove the residual solutes therein, before being fed to a steam generator. Steam generation in a once-through steam generator, or in a packaged boiler such as a water tube boiler having a steam drum and a mud drum with water cooled combustion chamber walls, produces high pressure steam for down-hole use.

Claims

1. A process for treatment of a produced water stream resulting from the production of oil from heavy oil reserves, said produced water stream comprising oil and dissolved solutes including hardness, alkalinity, and silica, wherein said process comprises:

(a) removing oil from said produced water to produce a de-oiled produced water stream;

(b) evaporation of said de-oiled produced water stream at a concentration factor (CF) of about ten (10) or greater, to produce (i) an evaporator blowdown stream comprising water, dissolved solutes, and precipitates comprising hardness and silica, and, (ii) a distillate stream;

(c) providing said distillate stream to a steam generator to generate a steam stream and generating a steam generator blowdown stream.

2. The process as set forth in claim 1, wherein said distillate stream comprises ninety five percent (95%) or more by weight of said de-oiled produced water stream.

3. The process as set forth in claim 1, wherein said distillate stream comprises ninety eight percent (98%) or more by weight of said de-oiled produced water stream.

4. The process as set forth in claim 3, where said steam generator blowdown stream is added to and mixed with said de-oiled produced water stream prior to evaporation of said de-oiled produced water stream.

5. The process as set forth in claim 4, wherein said steam generator blowdown stream is about two percent (2%) of said distillate stream.

6. The process as set forth in claim 3, wherein evaporation of said de-oiled produced water stream is accomplished in a falling film evaporator.

7. The process as set forth in claim 3, wherein evaporator of said de-oiled produced water stream is accomplished in a forced circulation evaporator.

8. The process as set forth in claim 1, wherein the de-oiled produced water stream is treated with acid to lower the pH to convert alkalinity to free carbon dioxide.

9. The process as set forth in claim 1, wherein said steam stream comprises about one hundred percent (100%) quality steam.

10. The process as set forth in claim 1, wherein said steam generator operates at from about one thousand pounds per square inch gauge (1000 psig) to about one thousand six hundred pounds per square inch gauge (1600 psig).

11. The process as set forth in claim 1 or in claim 10, wherein said steam generator comprises a once-through steam generator.

12. The process as set forth in claim 1, wherein said steam generator comprises a package boiler.

13. The process as set forth in claim 12, wherein said package boiler comprises a water tube boiler.

14. The process as set forth in claim 1, wherein said distillate stream comprises less than ten parts per million (10 ppm) of non-volatile inorganic total dissolved solids.

15. The process as set forth in claim 14, wherein said distillate stream comprises residual dissolved solids, and wherein said process further comprises removal of said residual dissolved solids.

16. The process as set forth in claim 15, wherein removal of said residual dissolved solids comprises cooling said distillate stream, and passing said distillate stream through an ion-exchange system.

17. The process as set forth in claim 16, wherein said ion-exchange system comprises a mixed bed type ion-exchange system.

18. The process as set forth in claim 16, further comprising regenerating said ion-exchange system to produce a regeneration waste stream, and wherein said regeneration waste stream is returned to said evaporator.

19. The process as set forth in claim 1, or in claim 15, wherein said process further comprises treatment of said evaporator blowdown stream in a zero discharge system to produce dry solids.

20. The process as set forth in claim 19, wherein said zero discharge system comprises a drum dryer.

21. The process as set forth in claim 19, wherein said zero discharge system comprises a crystallizer.

22. The process as set forth in claim 1 or in claim 15, wherein said process further comprises deep well injection of said evaporator blowdown stream.