Plasma Arc Torch for Direct Heat Transfer in SAGD
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Solution Overview
Problem
Current methods for treating mining byproducts in oil and gas production are inefficient, leading to environmental impacts and economic losses due to incomplete recovery of valuable mining fluids and hydrocarbons, as well as challenges with heat transfer in steam-assisted gravity drainage (SAGD) processes, particularly with silica contamination and indirect heat transfer.
Innovation Solution
A system and method utilizing a plasma arc torch and glow discharge cell to recycle water, upgrade heavy oil, and recover mining fluids, which includes a cylindrical vessel with tangential inlets and outlets, an electrode housing, and a hollow electrode nozzle, enabling efficient plasma generation and treatment of mining byproducts, including the use of a solid oxide electrolyte for enhanced oil recovery and direct heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If indirect heat transfer is used in SAGD processes, then energy can be transferred to the formation, but heat transfer efficiency is reduced and silica contamination occurs
Solution Approach 1:
The patent extracts the heat transfer medium (water) from the indirect heat transfer cycle and replaces it with direct plasma arc heating. The plasma arc torch is positioned to directly heat the formation through the wellbore, eliminating the intermediate water circulation system that causes silica contamination and reduces heat transfer efficiency.
Solution Approach 2:
The patent replaces the mechanical indirect heat transfer system (pumps, heat exchangers, water circulation) with an electrical plasma arc system. The plasma arc torch generates high-temperature plasma that directly heats the formation, substituting the mechanical thermal convection system with an electrical energy conversion system that achieves superior heat transfer efficiency without silica contamination.
2Productivity
If conventional methods are used to treat mining byproducts, then processing can occur, but recovery of valuable mining fluids and hydrocarbons is incomplete leading to economic losses
Solution Approach 1:
The patent applies parameter changes by using plasma arc torches to create extreme temperature conditions (thousands of degrees Celsius) that fundamentally alter the physical and chemical properties of mining byproducts. This high-temperature plasma environment enables complete vaporization and separation of hydrocarbons and mining fluids from solid particles, achieving near 100% recovery efficiency compared to conventional methods.
Solution Approach 2:
The patent utilizes the plasma arc's high-temperature oxidizing environment to accelerate the vaporization and separation process. The plasma arc creates a highly reactive zone where hydrocarbons and mining fluids are rapidly vaporized and separated from tailings, enabling complete recovery of valuable substances that conventional heating methods cannot achieve.
3Use of energy by moving object
If plasma arc torches are used to directly heat the formation, then heat transfer efficiency improves and silica contamination is eliminated, but the system complexity increases
Solution Approach 1:
The patent extracts and eliminates the complex indirect heat transfer infrastructure (surface heat exchangers, water circulation pumps, cooling systems) by implementing direct plasma arc heating through the wellbore. This removal of intermediate systems reduces overall system complexity despite the introduction of plasma generation equipment.
Solution Approach 2:
The plasma arc torch system serves multiple functions simultaneously: it heats the formation, vaporizes hydrocarbons, separates minerals, and enables in-situ upgrading of heavy oil. This multi-functionality consolidates what would otherwise require separate systems, reducing overall system complexity while achieving superior heat transfer efficiency.
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 effectively recycles water, upgrades heavy oil, and recovers valuable mining fluids, reducing environmental impacts and improving oil recovery efficiency while addressing silica contamination and indirect heat transfer issues in SAGD processes.
Implementation Method 1
A system and method utilizing a plasma arc torch and glow discharge cell to recycle water, upgrade heavy oil, and recover mining fluids
Implementation Method 2
plasma arc torch including a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end
Implementation Method 3
U.S. patent application Ser. No. 12/371,575 filed on Feb. 13, 2009, now U.S. Pat. No. 8,278,810, and entitled 'Solid Oxide High Temperature Electrolysis Glow Discharge Cell'
Implementation Method 4
Solid Oxide High Temperature Electrolysis Glow Discharge Cell
Implementation Method 5
solid oxide electrolyte for enhanced oil recovery and direct heat transfer
Data Source
AI summary
The present invention provides various systems, methods and apparatuses for recovering mining fluids, providing enhanced oil recovery and treating produced water. Plasma arc torches and electrolysis cells are used in various combinations. The plasma arc torch includes a cylindrical vessel, a first tangential inlet/outlet connected to or proximate to a first end, a second tangential inlet/outlet connected to or proximate to a second end, an electrode housing connected to the first end such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle is connected to the second end such that the hollow electrode nozzle is aligned with the longitudinal axis, the hollow electrode nozzle is partially disposed within the cylindrical vessel and outside the cylindrical vessel.