Direct Steam Generator with Cyclone Separator for Exhaust Removal
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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 expenses, and insufficient size for heavy oil recovery, necessitating a cost-effective solution that separates exhaust constituents from steam and operates on air or low oxygen enriched air.
Innovation Solution
A large-scale direct steam generator system with an annular combustor and counter rotating hydrocyclones, coupled with an energy recovery system that utilizes a Vacuum Swing Absorption module to produce oxygen enriched air and reclaim energy from exhaust constituents, reducing capital and operational expenditures by minimizing the use of high-cost materials and pure oxygen.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If direct steam generation is used, then steam production efficiency is improved, but steam purity deteriorates due to exhaust gas dilution
Solution Approach 1:
The patent extracts and separates exhaust constituents from the steam-gas mixture using a cyclone separator. The cyclone creates a rotating flow that forces heavier exhaust particles to the outer wall where they are removed, while cleaner steam rises to the center and exits through the vortex finder. This extraction principle resolves the contradiction by maintaining high steam production efficiency while improving steam purity through physical separation.
Solution Approach 2:
The cyclone separator acts as an intermediary device between the combustion chamber and steam output. It mediates the mixture of steam and exhaust gases by introducing a centrifugal separation mechanism, allowing the system to maintain both high productivity and acceptable steam purity for hydrocarbon recovery applications.
2Power
If pure oxygen is used for combustion, then combustion efficiency is improved, but operational cost and safety risk worsen
Solution Approach 1:
The patent changes the combustion parameter from pure oxygen to air or low-oxygen enriched air. This parameter change reduces combustion intensity but simultaneously reduces operational costs and safety risks. The system compensates for lower combustion efficiency through improved heat transfer efficiency in the direct steam generation process and heat recovery from exhaust gases, maintaining adequate steam production while improving ease of operation.
3Manufacturing precision
If conventional boiler design is used, then steam purity is maintained, but system complexity and cost worsen
Solution Approach 1:
The patent removes the complex drum and tube bundle separation system found in conventional boilers. Instead of using complex mechanical separation, it extracts impurities through a simple cyclone separator that uses centrifugal force. This reduces device complexity while maintaining adequate steam purity for the intended application.
Solution Approach 2:
The cyclone separator utilizes pneumatic principles - specifically centrifugal force generated by rotating gas flow - to separate exhaust constituents from steam. This replaces complex mechanical separation systems with a simpler fluid dynamics-based solution, reducing overall system complexity while achieving the necessary steam purity.
4Device complexity
If exhaust constituents are not removed, then system simplicity is maintained, but steam quality for hydrocarbon recovery deteriorates
Solution Approach 1:
The cyclone separator serves as a simple intermediary device that adds minimal complexity to the system. It effectively improves steam quality by separating exhaust constituents through centrifugal action, making the system suitable for hydrocarbon recovery applications while maintaining overall system simplicity.
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 generates saturated or superheated steam efficiently, separates exhaust constituents, and recovers energy, making it cost-effective and scalable for hydrocarbon recovery processes, while reducing safety risks and operational costs associated with pure oxygen use.
Implementation Method 1
counter rotating hydrocyclones to generate saturated or superheated steam and combustion exhaust constituents
Implementation Method 2
counter rotating hydrocyclones
Implementation Method 3
exhaust constituent removal system
Implementation Method 4
energy recovery system that reclaims the energy from the exhaust constituents
Implementation Method 5
direct steam generator configured to generate saturated or superheated steam
Implementation Method 6
combustion exhaust constituents
Data Source
AI summary
Embodiments of the present disclosure can include a system for generating steam. The system can include a direct steam generator configured to generate saturated steam and combustion exhaust constituents. A close coupled heat exchanger can be fluidly coupled to the direct steam generator, the close coupled heat exchanger can be configured to route the saturated or superheated steam and combustion exhaust constituents through an exhaust constituent removal system. The system can include an energy recovery system that reclaims the energy from the exhaust constituents.