Vapor Generator Combustion Gas Quenching
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Solution Overview
Problem
Conventional hydrocarbon recovery methods from heavy oil or bitumen formations are energy and cost intensive, and generate significant carbon dioxide emissions, with inefficiencies in steam injection processes and challenges in capturing CO2.
Innovation Solution
A method involving a vapor generator that combusts fuel and oxidant to produce combustion gas, which is then cooled with water to produce steam, and a solvent is introduced to transfer heat, creating a mixture of combustion gas, steam, and heated solvent vapor for injection into reservoirs to enhance hydrocarbon recovery, using a direct quenching process to reduce thermal inefficiencies and flue gas emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional steam injection is used for hydrocarbon recovery, then hydrocarbon mobility is improved, but energy consumption and CO2 emissions increase
Solution Approach 1:
The patent combines steam generation and solvent vaporization into a single direct-contact heat transfer process. Combustion gases from fuel oxidation directly contact both water and hydrocarbon solvent in the vapor generator, simultaneously producing steam and solvent vapor. This merged process eliminates separate heating systems and reduces overall energy consumption while maintaining effective hydrocarbon recovery.
Solution Approach 2:
The patent converts harmful CO2-rich combustion gases into a useful heating medium. Instead of flaring or venting these gases, the system utilizes their thermal energy to generate steam and solvent vapor directly. The CO2 emissions are thus converted into a beneficial heat source that drives the hydrocarbon recovery process.
2Productivity
If conventional steam injection is used for hydrocarbon recovery, then hydrocarbon mobility is improved, but CO2 emissions increase
Solution Approach 1:
The patent converts harmful CO2-rich combustion gases into a useful heating medium. Instead of flaring or venting these gases, the system utilizes their thermal energy to generate steam and solvent vapor directly. The CO2 emissions are thus converted into a beneficial heat source that drives the hydrocarbon recovery process.
Solution Approach 2:
The patent changes the physical state and composition parameters of the injection fluid. Instead of injecting pure steam, the system produces a mixed vapor phase containing both water vapor and hydrocarbon solvent vapor. This compositional parameter change allows the injection fluid to serve dual purposes: thermal heating and chemical dissolution of heavy hydrocarbons.
3Productivity
If direct contact of water with combustion gas is used, then steam is produced efficiently, but thermal energy loss occurs
Solution Approach 1:
The patent combines steam generation and solvent vaporization into a single direct-contact heat transfer process. Combustion gases from fuel oxidation directly contact both water and hydrocarbon solvent in the vapor generator, simultaneously producing steam and solvent vapor. This merged process eliminates separate heating systems and reduces overall energy consumption while maintaining effective hydrocarbon recovery.
Solution Approach 2:
The patent ensures continuous utilization of thermal energy through a staged direct-contact process. Combustion gases first transfer heat to water for steam generation, then the remaining thermal energy continuously vaporizes the hydrocarbon solvent. This continuous action sequence maximizes energy utilization and minimizes thermal 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 approach improves the efficiency of hydrocarbon recovery by reducing thermal energy input and minimizing CO2 emissions, allowing for effective mobilization and extraction of hydrocarbons while maintaining a balanced solvent-to-water ratio, thereby optimizing the recovery process.
Implementation Method 1
combusting a combination of fuel and oxidant in a flow path through a vapor generator to produce combustion gas
Implementation Method 2
supplying water into the flow path of the vapor generator and in contact with the combustion gas to cool the combustion gas and produce steam
Implementation Method 3
supplying a solvent for hydrocarbons into the flow path of the vapor generator to transfer heat to the solvent from the combustion gas already cooled by vaporization of the water
Data Source
AI summary
Methods and apparatus relate to recovering petroleum products from underground reservoirs. The recovering of the petroleum products relies on introduction of heat and solvent into the reservoirs. Supplying water and then solvent for hydrocarbons in direct contact with combustion of fuel and oxidant generates a stream suitable for injection into the reservoir in order to achieve such thermal and solvent based recovery.