Remote Steam Generation and Water Separation in SAGD Operations
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Solution Overview
Problem
In situ hydrocarbon recovery operations, particularly Steam-Assisted Gravity Drainage (SAGD), face inefficiencies and high costs due to steam generation and water treatment processes being centralized, leading to costly pipeline infrastructure and energy losses.
Innovation Solution
Implementing a SAGD method and system with remote steam generation using Direct-Fired Steam Generators (DFSGs) and on-site water-hydrocarbon separation, where steam and CO2 are generated and injected into wells, and produced fluids are separated and recycled, reducing the need for large pipelines and energy losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If steam generation and water treatment are performed in a central processing facility, then steam can be supplied to multiple remote hydrocarbon recovery areas, but pipeline infrastructure costs and energy losses increase
Solution Approach 1:
The centralized steam generation system is segmented into multiple distributed steam generators located at each remote hydrocarbon recovery area. This allows each area to generate its own steam locally, eliminating the need for long-distance steam pipelines and reducing energy losses during transportation while maintaining the ability to supply multiple areas through independent local generation units
2Length of moving object
If high pressure steam is transported over long distances, then steam can reach remote wells, but pipeline installation and maintenance costs increase
Solution Approach 1:
The steam generation function is extracted from the central processing facility and placed directly at the remote hydrocarbon recovery areas. This eliminates the need for long-distance high-pressure steam pipelines, reducing both installation and maintenance costs while still enabling steam delivery to remote wells through local generation
3Adaptability or versatility
If production fluids are pumped from remote areas to central facility, then fluids can be treated centrally, but large pipes and pumps are required
Solution Approach 1:
The centralized fluid treatment system is segmented into distributed separation units located at each remote hydrocarbon recovery area. These units perform initial separation of production fluids locally, reducing the volume and complexity of fluids that need to be transported to the central facility, thereby reducing pipeline sizes and pump capacities required
4Adaptability or versatility
If steam generators are located at central facility, then they can serve multiple well pads, but the generators become large and expensive
Solution Approach 1:
The large centralized steam generator is segmented into multiple smaller distributed steam generators located at each remote hydrocarbon recovery area. Each smaller generator serves its local area independently, reducing the size and cost of individual generators while collectively maintaining the ability to serve multiple well pads through distributed deployment
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 reduces heat loss, pipeline and pump sizes, and energy losses, while allowing for efficient recycling of produced water and hydrocarbons, maintaining oil recovery rates similar to CO2 injection scenarios.
Implementation Method 1
a steam generator for receiving feedwater and generating a steam-based mixture therefrom
Implementation Method 2
causing the heated hydrocarbons and condensed water to drain under the force of gravity into the underlying production well
Implementation Method 3
separating the produced fluids to obtain a produced gas and a produced emulsion; separating the produced emulsion to obtain a produced hydrocarbon-containing component and produced water
Data Source
AI summary
A Steam-Assisted Gravity Drainage (SAGD) method for recovering hydrocarbons from a reservoir can include generating steam and CO2 from feedwater, fuel and oxygen; transferring a steam-CO2 mixture comprising at least a portion of the steam and at least a portion of the CO2, to a proximate SAGD injection well; injecting the steam-CO2 mixture into the SAGD injection well; obtaining produced fluids from a SAGD production well underlying the SAGD injection well; transferring the produced fluids for separation proximate to the SAGD production well; separating the produced fluids into a produced gas and a produced emulsion; transferring the produced emulsion for separation proximate to the SAGD production well; separating the produced emulsion to obtain a produced hydrocarbon-containing component and produced water; supplying at least a portion of the produced water as at least part of the feedwater; and supplying the produced hydrocarbon-containing component to a central processing facility.