Plasma Fired Steam Generator for SAGD Well Pads
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Solution Overview
Problem
The existing steam generation processes for oil sands recovery, particularly in the SAGD method, face high capital costs, long installation and commissioning times, low process availability, and are not economically viable for smaller or isolated well pads due to the need for transporting high-pressure steam over long distances and the inefficiency in using dirty water.
Innovation Solution
A plasma fired steam generator system that combines submerged plasma arcs and resistive heating to generate high-pressure steam from dirty feed water, using either single or multiple electrodes and an electrode seal system, with an endless screw mechanism for precise control of electrode position and power input, allowing for efficient steam production directly at the well pad.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If steam is generated at a centralized boiler house and transported to oil wells, then steam can be provided to multiple wells, but capital costs increase and installation time lengthens
Solution Approach 1:
The centralized steam generation system is segmented into distributed modular units. Each oil well pad has its own compact steam generator, eliminating the need for long-distance steam transportation and reducing system complexity while maintaining steam supply capability
Solution Approach 2:
The solution transitions from a centralized spatial arrangement to a distributed spatial arrangement. By placing steam generation capacity at each well pad location rather than at a single central location, the system achieves both steam supply and reduced complexity
2Ease of manufacture
If once through steam generators are used, then steam generation is simple, but start-up and shutdown times are long and process availability is low
Solution Approach 1:
The steam generation system uses a heat exchanger design that allows dynamic operation. The heat exchanger can be quickly heated up and shut down, enabling rapid start-up and shutdown times while maintaining operational simplicity, thus improving process availability
Solution Approach 2:
The system changes operational parameters to achieve quick response. By using a heat exchanger with high thermal efficiency and appropriate heat transfer media, the system can rapidly adjust between different operational states, improving availability while keeping the design simple
3Length of moving object
If high pressure steam is transported over long distances, then steam can reach distant wells, but energy loss increases and economic viability decreases
Solution Approach 1:
The steam generation function is extracted from the centralized location and placed directly at each well pad. This eliminates the steam transportation infrastructure and associated energy losses, making the system economically viable for isolated well pads
Solution Approach 2:
Instead of transporting steam directly over long distances, the system uses local water resources at each well pad as an intermediary. Water is converted to steam in-situ, eliminating the need for long-distance steam transportation and reducing energy loss
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 solution reduces capital costs, shortens installation times, enhances process availability, and enables the use of brackish water, providing a cost-effective and efficient method for producing high-pressure steam directly at the well pad, eliminating the need for long-distance steam transportation and allowing for modular installation.
Implementation Method 1
The present system uses a combination of plasma arcs and resistive heating, generated either using alternating current or direct current and submerged under water, to produce steam from untreated (dirty) water. The energy needed to produce steam is provided by the plasma arcs struck between electrically conducting electrodes
Implementation Method 2
The present system uses a combination of plasma arcs and resistive heating, generated either using alternating current or direct current and submerged under water, to produce steam from untreated (dirty) water
Implementation Method 3
The energy needed to produce steam is provided by the plasma arcs struck between electrically conducting electrodes, as well as the water's electrical resistivity
Data Source
AI summary
A system for generating high pressure steam from dirty water uses a combination of sub-merged plasma arcs and electrical resistive heating. Dirty water from steam assisted gravity drainage, or other dirty water producing process, which needs to be converted into high pressure steam, is fed directly without any pre-treatment, into a plasma fired steam generator, powered by submerged electrodes. The combination of electric arc plasma and resistive heating is created between the submerged electrodes. The heat so generated will boil the water portion of the dirty water feed to generate steam that is collected in a steam space and then removed there from. The solids and other residues (residual sludge) present in the feed water settle down at the bottom of the steam generator and are removed via a blow-down stream. The plasma arcs are used to intermittently remove any scaling or solid deposits that can accumulate on the electrodes.