Large-Scale Direct Steam Generation with Hydrocyclone Exhaust Separation

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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) for oxygen enrichment, combined with an energy recovery system to minimize costs and inefficiencies, allowing for precise control of exhaust constituents re-injection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If Direct Steam Generators are used to generate steam, then steam production is achieved, but the steam is diluted with exhaust gas from combustion

Engineering Contradiction:

Improvesteam productionVSAvoidsteam dilution with exhaust gas

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system separates the steam generation function from the combustion exhaust by using a heat exchanger. The combustion chamber and steam generator are segmented into distinct components, allowing steam to be generated without direct contact with exhaust gases, thus eliminating dilution while maintaining productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A heat exchanger serves as an intermediary between the combustion process and the steam generation process. It transfers thermal energy from combustion gases to feedwater without allowing direct mixing, enabling steam production while preventing exhaust gas dilution of the steam.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If conventional DSG systems are used, then steam generation capability is provided, but the systems are expensive to purchase and operate

Engineering Contradiction:

Improvesteam generation capabilityVSAvoidcapital and operational costs

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The system incorporates an energy recovery mechanism where exhaust heat is reused to preheat feedwater or generate steam. This self-service approach reduces external energy requirements and operational costs while maintaining steam generation capability, making the system more cost-effective.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system optimizes operational parameters such as combustion efficiency, heat transfer coefficients, and feedwater temperature to maximize steam generation while minimizing fuel consumption and operational costs. This enables cost-effective steam production without sacrificing capability.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If small-scale DSG systems are used, then equipment costs are reduced, but the systems are too small to be effective in heavy oil recovery

Engineering Contradiction:

Improveequipment costsVSAvoidsteam generation scale for heavy oil recovery

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The system uses a modular design where smaller DSG units can be nested or combined to achieve larger effective capacity. Multiple compact modules work together to provide the large-scale steam generation needed for heavy oil recovery while keeping individual unit costs low, effectively solving the scale-cost contradiction.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The DSG system is designed with multi-functionality to serve various scales of operation. The same basic design can be scaled from small to large capacities, allowing cost-effective deployment for different applications including heavy oil recovery, eliminating the need for specialized expensive large-scale equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 high-quality steam efficiently and cost-effectively, reducing capital and operational expenditures while ensuring safety and scalability, enabling effective hydrocarbon recovery processes.

Implementation Method 1

The DSG can include a hydrocyclone, as non-condensable gas removal is concerned

Methodology Applied

Scientific EffectCentrifugal separation: Centrifugal Separation

Implementation Method 2

Vacuum Swing Absorption (VSA) for oxygen enrichment

Methodology Applied

Scientific EffectVacuum Swing Absorption: Pressure Swing Adsorption

Implementation Method 3

annular combustor and Vacuum Swing Absorption (VSA) for oxygen enrichment

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 4

places the steam feedwater in direct contact with a heat source

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Data Source

PatentUS11262022B2Large scale cost effective direct steam generator system, method, and apparatus

Publication Date: 2022.03.01 HEAT IP HOLDCO LLC

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.