Temperature Configurable Sample Holder for Heavy Oil Extraction Testing
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Solution Overview
Problem
Current methods for heavy oil and tar sand extraction, particularly insitu thermal recovery using steam, face challenges such as high heat losses, clay swelling, and significant greenhouse gas emissions, while solvent extraction processes lack understanding of physical mechanisms and accurate modeling due to coarse spatial resolution, leading to inefficient and inaccurate data collection.
Innovation Solution
A temperature configurable sample holder with individually controllable heaters and sensors is used to simulate insitu temperature profiles, minimizing parasitic heat losses and allowing for real-time testing of solvent extraction processes, enabling accurate measurement of bitumen yield and extraction rate without lengthy experimental times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steam extraction is used for insitu recovery of bitumen, then the bitumen viscosity is reduced and flow is improved, but heat losses increase and greenhouse gas emissions are significant
Solution Approach 1:
The patent changes the thermal fluid parameter from steam to liquid solvents, fundamentally altering the extraction mechanism from thermal to solvent-based gravity drainage, thereby eliminating the heat loss problem while maintaining bitumen recovery capability
Solution Approach 2:
The patent replaces the thermal field (steam heating) with a chemical field (solvent extraction), substituting the mechanism of thermal energy transfer with solvent-bitumen interaction and gravity-driven flow
2Productivity
If computer models with coarse grid block sizes are used for reservoir simulation, then model run time is reduced, but concentration gradient accuracy decreases significantly
Solution Approach 1:
The patent segments the reservoir into fine grid blocks (100-200 microns) to accurately capture concentration gradients, accepting the computational cost as necessary for process understanding and model validation
Solution Approach 2:
The patent performs preliminary laboratory experiments and fine-grid simulations to establish accurate concentration gradient data and physical mechanisms before developing simplified empirical models for field-scale applications
3Device complexity
If experimental testing of solvent extraction is conducted without temperature control, then device complexity is reduced, but parasitic heat losses increase and experimental accuracy decreases
Solution Approach 1:
The patent applies localized heating elements at specific positions within the experimental apparatus to maintain precise temperature profiles, allowing different zones to have different thermal characteristics as required by the extraction process
Solution Approach 2:
The patent implements temperature sensing and control systems that continuously monitor and adjust heating to maintain desired temperature profiles, using feedback from temperature measurements to regulate heat input and minimize parasitic losses
4Measurement precision
If solvent extraction processes are tested with fine spatial resolution, then concentration gradient measurement accuracy is improved, but the number of calculations and model run time increase by a factor of 5000
Solution Approach 1:
The patent divides the computational domain into fine grid blocks to accurately resolve concentration gradients, using segmentation to capture the physics at the appropriate scale despite the increased computational burden
Solution Approach 2:
The patent uses laboratory-scale physical models and fine-grid numerical models as copies of the field system to study concentration gradients, then uses the insights gained to develop simplified empirical models for field-scale prediction
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 allows for quick and accurate simulation of insitu conditions, reducing experimental time and parasitic heat losses, thereby providing reliable data for developing empirical models of solvent extraction processes, enhancing the understanding and efficiency of heavy oil and tar sand extraction.
Implementation Method 1
The sample holder may be provided with an outer shell that incorporates individually controllable and localized heaters
Implementation Method 2
Each of the heaters can be in the form of an electrical resistor, which is periodically energized to supply heat
Implementation Method 3
a temperature sensor to measure the heater temperature
Implementation Method 4
increasing the pressure in the pressure vessel to simulate an overburden pressure
Implementation Method 5
the solvent concentration gradient provides the primary driving force for solvent penetration and extraction
Implementation Method 6
solvent gravity drainage processes
Data Source
AI summary
There is disclosed a method of testing oil extraction processes including the steps of: 1) placing a sample to be tested in a sample holder which has a configurable temperature profile; 2) placing the sample holder in a pressure vessel; 3) increasing the pressure in the pressure vessel to simulate an over burden pressure; 4) configuring the temperature profile of the sample holder to match a desired temperature profile; 5) applying an oil extraction process to the sample; 6) measuring one or more parameters of the oil extraction process; 7) measuring the temperature of the sample to which the process is being applied; and 8) configuring the sample holder to match the measured temperature profile. A device to test oil extraction processes on samples is also disclosed. The device has a temperature configurable sample holder having sufficient temperature control to provide a desired heat profile to the sample.