Steam driven direct contact steam generation

• US 9,114,406 B2
• Filed: 09/12/2011
• Issued: 08/25/2015
• Est. Priority Date: 12/10/2009
• Status: Expired due to Fees

• Current Assignee: Ex-Tar Technologies Inc.
• Original Assignee: Ex-Tar Technologies Inc.
• Inventors: Betzer Tsilevich, Maoz
• Primary Examiner(s): DiTrani, Angela M
• Application Number:
  US13/230,432
• Publication Number:
  US 20120000642A1
• Time in Patent Office: 1,443 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B01D 1/14 with heated gases or vapours or liquids in contact with the liquid
• CPC Class Codes: B03D 1/02 Froth-flotation processes
• CPC Class Codes: B03D 1/24 Pneumatic mixing gases or vapours with liquids B01F23/20
• CPC Class Codes: B03D 2203/006 Oil well fluids, oil sands, bitumen
• CPC Class Codes: E21B 43/24 using heat, e.g. steam injection
• CPC Class Codes: E21B 43/241 combined with solution mining of non-hydrocarbon minerals, e.g. solvent pyrolysis of oil shale
• CPC Class Codes: E21B 43/35 specially adapted for separating solids down-hole drilling fluid separation systems E21B21/002; separating solids from drilling fluids E21B21/065
• CPC Class Codes: E21B 43/40 Separation associated with re-injection of separated materials E21B43/385 takes precedence

Abstract

The system and method for steam production for oil production. The method includes generating steam from an indirect heat exchange system, mixing the steam with water containing solids and organics, separating solids, and injecting the steam through an injection well or using it above ground for oil recovery, such as for generating hot process water. The system includes a steam drive direct contact steam generator. The water feed can be hot produced water separated from a produced oil emulsion and/or low quality water salvaged from industrial plants, such as refineries and tailings from an oilsands mine.

Claims

1. A method for oil extraction, said method comprising the steps of:

generating a liquid stream having water, organics and solids from an oil production facility, wherein organics are comprised of hydrocarbons;

generating steam through indirect heat exchange so as to form a generated steam;

mixing said generated steam with said liquid stream so as to transfer said water from a liquid phase to a gas phase;

separating said solids to produce a process steam, said process steam being a solids lean gas phase comprised of steam; and

extracting oil with said process steam.

2. The method of claim 1, further comprising the step of:

heating a portion of said generated steam indirectly before the step of mixing said generated steam with said liquid stream, said portion forming a superheated steam.

3. The method of claim 2, wherein a heat exchanger heats said generated steam so as to form said superheated steam.

4. The method of claim 2, further comprising the step of:

circulating said portion of said generated steam in a steam ejector, wherein ejected steam for operating said steam ejector is added to said generated steam.

5. The method of claim 1, further comprising the step of:

injecting said process steam to recover oil through an oil injection well.

6. The method of claim 5, further comprising the step of:

adding solvents to process steam prior to the step of injecting.

7. The method of claim 1, wherein said hydrocarbons are comprised of processed hydrocarbons converted to gas and mixed with a previous process steam.

8. The method of claim 1, further comprising the step of:

mixing a portion of said process steam with saturated water so as to scrub contaminates from said process steam and generate a scrubbed steam; and

recycling said saturated water and scrubbed contaminates back to the step of mixing with said liquid stream.

9. The method of claim 8, further comprising the step of:

adding chemicals to said saturated water so as to improve scrubbing performance of contaminates.

10. The method of claim 1, further comprising the steps of:

producing oil and water from a production well, said water being comprised of hydrocarbons, solvents and solids contaminates;

separating said hydrocarbons, solvents, and solids contaminates from liquid water so as to form a production water; and

mixing said production water with said process steam.

11. A method for oil production, said method comprising the steps of:

generating a liquid stream having water, solids, and hydrocarbons;

generating steam through indirect heat exchange so as to form a generated steam;

gasifying said liquid stream with said generated steam by direct contact heat exchange so as to transfer said water from a liquid phase to a gas phase;

separating said gas phase to produce a process steam, said process steam being a solids lean gas phase steam;

condensing said process steam to generate process heat and process water; and

extracting oil with said process water.

12. The method of claim 11, further comprising the step of:

forming a superheated steam with a portion of said generated steam;

mixing said superheated steam with said liquid stream; and

recycling another portion of said generated steam to a heater generating said superheated steam.

13. The method of claim 11, further comprising the step of:

separating solvent from said process water.

14. The method of claim 11, wherein said hydrocarbons are comprised of solvents.

15. A system for producing steam for extracting heavy bitumen, the system comprising:

an indirect contact heat exchanger means, wherein system water is heated by said indirect contact heat exchanger means to generate a superheated steam;

a steam drive direct contact steam generator, mixing said superheated steam with a liquid discharge stream having water and solids, wherein said steam drive direct contact steam generator is in fluid connection to said indirect contact heat exchanger means; and

an enhanced oil recovery facility in fluid connection to said steam drive direct contact steam generator.

16. The system of claim 15, further comprising:

a production well producing a mixture of water, oil and gas;

a separator fluidly connected to said production well and in fluid connection to said steam drive direct contact steam generator, wherein said liquid discharge steam is comprised of water from said production well, and wherein said indirect heat exchanger means is comprised of a heater.

17. The system of claim 16, wherein said steam drive direct contact steam generator and said heater are located on a well pad in proximity to a steam injection well.

18. The system of claim 15, further comprising:

an ejector means for a pressurized steam supply, wherein said indirect contact heat exchanger means is comprised of a heater, and wherein produced steam from said steam drive direct contact steam generator recycles to said pressurized steam supply and said heater.