Integrated CO2 Recycle for Syngas-Driven Enhanced Oil Recovery
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Solution Overview
Problem
The use of CO2 for enhanced oil recovery (EOR) faces challenges due to the need for large quantities of CO2, limited availability, and the expense and environmental concerns associated with transporting supercritical CO2 over long distances, as well as the venting of co-produced CO2, which is undesirable from an environmental perspective.
Innovation Solution
An integrated process that produces a synthesis gas stream and co-treats it with a gaseous hydrocarbon stream to generate a carbon dioxide-rich recycle stream, which is then pressurized and injected into an underground hydrocarbon reservoir for enhanced oil recovery, minimizing atmospheric release and pipeline requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If CO2 is used for enhanced oil recovery, then oil production is improved, but large quantities of CO2 are required which are limited in availability
Solution Approach 1:
The patent combines the EOR process with a synthesis gas production operation at the same site. The CO2 generated during synthesis gas production (from coal gasification or natural gas reforming) is captured and used for EOR, merging two industrial processes to solve the CO2 availability problem while enhancing oil recovery.
Solution Approach 2:
The synthesis gas production operation serves its own CO2 needs for EOR. The CO2 that would normally be vented or require separate capture is instead utilized internally by the same facility for oil recovery, creating a self-sufficient system that eliminates external CO2 supply dependencies.
2Quantity of substance
If CO2 is transported via pipeline over long distances, then CO2 can be delivered to EOR sites, but construction and maintenance costs are high and supercritical CO2 is hazardous
Solution Approach 1:
The patent extracts the CO2 generation step from separate ge locations and places it at the same site as the EOR operation. By co-locating the synthesis gas production and EOR activities, the need for long-distance CO2 transport infrastructure is eliminated entirely.
Solution Approach 2:
The patent uses a shared acid gas removal unit as an intermediary facility that processes CO2 from synthesis gas production and prepares it for EOR injection. This intermediate processing step occurs on-site, eliminating the need for long-distance transport of supercritical CO2 through hazardous pipelines.
3Quantity of substance
If CO2 is separated from combustion gases, then CO2 can be captured for use, but separation is difficult and not economical
Solution Approach 1:
The patent changes the source and concentration parameters of CO2. Instead of separating CO2 from dilute combustion flue gases, the system generates CO2-rich streams (80-95% CO2) directly from synthesis gas production processes, where CO2 is already concentrated by the chemistry of gasification and reforming reactions.
Solution Approach 2:
Rather than capturing CO2 from combustion exhaust as conventional approaches attempt, the patent inverts the approach by generating CO2-rich synthesis gas through controlled gasification/reforming processes that naturally produce high-concentration CO2 streams suitable for EOR without difficult separation.
4Productivity
If CO2 is vented to atmosphere from synthesis gas production, then CO2 is removed from process, but environmental concerns make this undesirable
Solution Approach 1:
The patent converts the harmful CO2 emission from synthesis gas production into a beneficial resource for EOR. The CO2 that would be vented is instead captured and injected into oil reservoirs, transforming an environmental liability into an economic and environmental asset that enhances oil recovery while reducing greenhouse gas emissions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances oil recovery while reducing the need for long-distance CO2 transport and maximizing carbon capture and sequestration, improving the integration and efficiency of EOR and synthesis gas production processes.
Implementation Method 1
The high-pressure CO2 also acts as a solvent, dissolving the residual oil, thereby reducing its viscosity and improving its flow characteristics
Implementation Method 2
co-treating the gaseous hydrocarbon stream and the synthesis gas stream in an acid gas removal system
Data Source
AI summary
An enhanced oil recovery process that is integrated with a synthesis gas generation process, such as gasification or methane reforming, involving combined capture and recycle of carbon dioxide from both processes.