Direct Steam Generator with Exhaust Separation for Steam Purity
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Solution Overview
Problem
Direct Steam Generators (DSGs) are not well accepted in industries using SAGD, Steam Flood, and CSS technologies due to steam dilution with exhaust gas, high operational and capital costs, and insufficient size for heavy oil recovery, necessitating a cost-effective solution that separates exhaust constituents and operates on air or low oxygen enriched air.
Innovation Solution
A large-scale DSG system using a hydrocyclone design with an annular combustor and Vacuum Swing Absorption (VSA) module, capable of generating saturated or superheated steam, and an energy recovery system that minimizes the use of high-cost materials and reduces operational and capital expenditures by utilizing low oxygen enriched air and harvesting wasted energy from nitrogen and other exhaust constituents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If Direct Steam Generator (DSG) is used for steam generation, then steam production capability is improved, but steam purity deteriorates due to dilution with exhaust gas
Solution Approach 1:
The system separates the steam generation function from the exhaust gas discharge function by using multiple DSG units, each equipped with its own exhaust constituent separation system. This segmentation allows independent control of steam quality and exhaust treatment for each unit, resolving the contradiction between high steam production and steam purity maintenance.
Solution Approach 2:
The exhaust constituents are extracted and removed from the steam stream using dedicated separation systems (such as condensers, separators, or filtration devices). This extraction process isolates the harmful exhaust components from the generated steam, maintaining steam purity while preserving the high productivity benefit of DSG technology.
2Productivity
If conventional DSG systems are used, then steam generation is achieved, but system cost deteriorates due to high capital and operational expenditures
Solution Approach 1:
The DSG system incorporates self-service features including automatic feedwater injection, self-regulating combustion control, and integrated exhaust constituent separation that operates without external intervention. These self-service mechanisms reduce operational expenditures and simplify system operation, addressing the high cost issue while maintaining steam generation productivity.
Solution Approach 2:
The system optimizes operational parameters such as combustion temperature, feedwater injection rate, and oxygen concentration in the combustion air to achieve efficient steam generation at lower costs. By dynamically adjusting these parameters based on demand, the system reduces both capital and operational expenditures while maintaining required steam production levels.
3Ease of manufacture
If small scale DSG is used, then system cost is reduced, but effectiveness in heavy oil recovery deteriorates
Solution Approach 1:
The system uses a modular design where multiple DSG units are nested or arranged in parallel configurations. Each module can operate independently but can be combined to achieve the required scale for heavy oil recovery operations. This nesting approach allows the system to maintain cost-effectiveness of individual units while achieving the total productivity needed for effective heavy oil recovery.
Solution Approach 2:
The DSG system is designed with universal applicability to various steam generation requirements, including heavy oil recovery applications. By incorporating adjustable operational parameters and scalable configuration options, the system can adapt to different production scales without requiring completely different equipment, thus maintaining cost-effectiveness across different application sizes.
4Productivity
If oxygen enriched air is used for combustion, then steam generation efficiency is improved, but safety risk deteriorates
Solution Approach 1:
The combustion system incorporates feedback control mechanisms that continuously monitor oxygen concentration, combustion temperature, and exhaust gas composition. Based on this feedback, the system automatically adjusts the oxygen enrichment level and combustion parameters to maintain efficient steam generation while preventing safety hazards such as overheating or uncontrolled combustion reactions.
Solution Approach 2:
The system implements preliminary safety measures including oxygen concentration limits, emergency shutdown systems, and protective barriers before safety risks can materialize. By pre-establishing these protective mechanisms, the system can utilize oxygen enriched air for improved steam generation efficiency while preemptively preventing the safety risks that would otherwise arise from high oxygen concentrations.
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
The system achieves cost-effective steam generation, scalable for modern hydrocarbon recovery processes, with reduced operational and capital costs, and allows for precise control of exhaust constituents for re-injection, enhancing oil production and reducing safety risks.
Implementation Method 1
A large scale direct steam generator (DSG) using a hydrocyclone basis
Implementation Method 2
Vacuum Swing Absorption (VSA) module
Implementation Method 3
annular combustor and Vacuum Swing Absorption (VSA) module, capable of generating saturated or superheated steam
Implementation Method 4
an energy recovery system that minimizes the use of high-cost materials and reduces operational and capital expenditures by utilizing low oxygen enriched air and harvesting wasted energy from nitrogen and other exhaust constituents
Data Source
AI summary
Embodiments of the present disclosure include a system, method, and apparatus comprising a large scale direct steam generator operating on an oxidant of air or enriched air configured to generate steam and combustion exhaust constituents. An exhaust constituent separation system and an energy recovery system to reclaim energy and improve the efficiency of the thermodynamic cycle. An optional CO2 separation system and Non Condensable Gas injection system may be included.