High-Pressure Evaporator with Bubble Generator for EOR Steam
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Solution Overview
Problem
Current water treatment and steam generation processes for enhanced oil recovery, such as SAGD, are energy-intensive, costly, and result in high greenhouse gas emissions due to inefficient temperature and phase changes, requiring multiple steps including water softening and separate steam generation, which are energy-consuming and prone to fouling.
Innovation Solution
A high-pressure, fouling-resistant evaporator system that generates steam directly from de-oiled produced water in a single step, using induced-gas flotation units and a high-pressure evaporator with a bubble generator to remove scales and solids, and optionally incorporating solar power for heating, eliminating the need for water softening and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional water softening and steam generation processes are used, then steam can be generated for enhanced oil recovery, but energy consumption is high and greenhouse gas emissions are significant
Solution Approach 1:
The patent combines water softening and steam generation into a single integrated evaporator system. The evaporator simultaneously performs softening by removing impurities through evaporation and generates steam for EOR operations, eliminating the need for separate treatment steps and reducing overall energy consumption.
Solution Approach 2:
The system changes the operating parameters by maintaining higher temperatures throughout the water treatment and steam generation process. This eliminates the traditional cool-then-reheat cycle, maintaining thermal energy and significantly reducing the energy required for steam generation.
2Reliability
If multiple processing steps including water softening are used, then water quality is improved for steam generation, but process complexity and capital costs increase
Solution Approach 1:
The evaporator integrates multiple functions: water softening, impurity removal, and steam generation in a single unit. This consolidation reduces the number of separate processing steps and equipment needed while maintaining high water quality suitable for steam generation.
Solution Approach 2:
The system extracts impurities and scales from the produced water through the evaporation process. By removing these contaminants during the steam generation process itself, the need for separate softening pretreatment is eliminated.
3Object-affected harmful factors
If produced water is cooled for water softening, then scaling is prevented, but energy is wasted due to subsequent reheating
Solution Approach 1:
Instead of cooling water to prevent scaling and then reheating it for steam generation, the system inverts the approach by maintaining high temperatures throughout the process and using evaporation to remove scaling substances. This eliminates the energy-wasting temperature cycle.
Solution Approach 2:
The system converts the potential harm of high-temperature scaling into a benefit by using the evaporation process to selectively remove scaling substances (impurities, salts) while maintaining the high temperature needed for efficient steam generation. The scaling prevention is achieved through impurity removal rather than temperature reduction.
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 energy efficiency, reduces capital costs, and minimizes environmental impact by streamlining the process, eliminating unnecessary temperature variations, and integrating renewable energy sources for steam generation, while maintaining silica in solution at lower pH to prevent scaling.
Implementation Method 1
using induced-gas flotation units and a high-pressure evaporator with a bubble generator to remove scales and solids
Implementation Method 2
generates steam directly from de-oiled produced water in a single step
Implementation Method 3
heating the produced water to a temperature sufficient to generate steam
Implementation Method 4
incorporating solar power for heating
Data Source
AI summary
A system of generating steam from an emulsion stream produced from a reservoir via thermal recovery has a heat exchanger for adjusting the emulsion to a first temperature; at least one separation device for separating water from the emulsion at the first temperature to obtain produced water; an optional produced water preheater, and a high pressure evaporator for receiving the produced water and generating steam using the produced water. The evaporator has a vapor drum; a heating element receiving the water stream, and in fluid communication with the vapor drum via a pressure letdown device; a heating source for imparting sensible heat to the water stream for generating steam. The evaporator also includes a recirculation pump for circulation of blowdown concentrate, and a bubble generator for generating bubbles and injecting generated bubbles into the heating element to enable self-removal of scales and other solid deposits in the evaporator.