Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02787591 2012-08-23
METHODS AND SYSTEMS FOR UPGRADING HYDROCARBON
This application claim priority to U.S. Provisional Patent Application No.
61/526,434,
filed August 23, 2012, the entirety of which is hereby incorporated by
reference.
BACKGROUND
Recovery of heavy oil from subsurface deposits is often carried out at remote
locations,
such as on offshore platforms located many miles from land and oil sands
deposits located in
generally uninhabited areas where extreme weather conditions are common. As
would be
expected, many issues arise due to the remoteness of these locations. One
example of such an
issue is the difficulty in transporting the recovered viscous heavy oil to
locations where
upgrading equipment is available. Additionally, in the case of offshore
platforms, there is a
market penalty for oil that arrives back to shore in a highly viscous state.
As discussed in co-pending U.S. Application No. 13/589,927, one possible
solution to
these problems is to subject the viscous heavy oil to upgrading at the remote
location and prior to
transporting the recovered material to refinery facilities located either
onshore or in more
populated areas. However, many materials needed to carry out upgrading
processes can be
scarce and/or expensive to produce at the remote locations where the heavy oil
is initially
recovered. For example, steam is used in several upgrading processes, but the
standard boiler
equipment typically available at remote locations and which can be used to
generate steam have
several shortcomings.
To begin with, steam generation by boilers can be very expensive. In some
instances,
almost 40% of the capital expenditure of upgrading equipment on an offshore
platform can be
attributed to boiler steam generation. The operating expenditure of boilers is
also very high, due
primarily to the need to pre-treat water used to create steam in a boiler. If
the water supplied to
the boiler for steam generation contains impurities (such as in the case of
seawater), it must be
pretreated in order to avoid scaling and sediment deposition on the inside of
the boiler. Scaling
build-up in the boiler decreases the boiler efficiency and can ultimately lead
to equipment
malfunction. Boilers also produce a flue gas that must be cleaned in order to
ensure compliance
with emissions standards. Additionally, roughly 10% of fuel heating value can
be lost in the
form of water vapor in the flue gas produced by boilers.
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CA 02787591 2012-08-23
Process integration that can allow scarce resources to be reused is also
difficult to
accomplish with standard boiler equipment available at most remote facilities.
For example, as
noted above, only water free of certain impurities can be used in boilers to
generate steam.
However, most produced water streams are not free of such impurities, meaning
that produced
water can not be directly supplied to a boiler as part of a process
integration scheme.
SUMMARY
The foregoing and other features, utilities and advantages of the invention
will be
apparent from the following more particular description of a preferred
embodiment of the
invention as illustrated in the accompanying drawings.
In some embodiments, a hydrocarbon upgrading system is disclosed. The system
includes a combustor and a nozzle reactor. The combustor includes an oxidant
inlet, a fuel inlet,
a combustion chamber, and an atomizer nozzle in fluid communication with the
combustion
chamber. The nozzle reactor includes a reactor body having a reactor body
passage with an
injection end and an ejection end, a first material injector having a first
material injection passage
and being mounted in the nozzle reactor in material injecting communication
with the injection
end of the reactor body passage, and a second material feed port penetrating
the reactor body.
The first material injection passage has (a) an enlarged volume injection
section, an enlarged
volume ejection section, and a reduced volume mid-section intermediate the
enlarged volume
injection section and enlarged volume ejection section, (b) a material
injection end in material
injecting communication with the combustion chamber, and (c) a material
ejection end in
material injecting communication with the reactor body passage. The second
material feed port
is (a) adjacent to the material ejection end of the first material injection
passage and (b)
transverse to a first material injection passage axis extending from the
material injection end to
the material ejection end in the first material injection passage in the first
material injector.
In some embodiments, a hydrocarbon recovery and upgrading system is disclosed.
The
system includes a combuster, a nozzle reactor, a steam assisted gravity
drainage system, and a
separation unit. The combustor includes an oxidant inlet, a fuel inlet, a
combustion chamber,
and an atomizer nozzle in fluid communication with the combustion chamber. The
nozzle
reactor includes a reactor body having a reactor body passage with an
injection end and an
ejection end, a first material injector having a first material injection
passage and being mounted
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in the nozzle reactor in material injecting communication with the injection
end of the reactor
body passage, and a second material feed port penetrating the reactor body.
The first material
injection passage has (a) an enlarged volume injection section, an enlarged
volume ejection
section, and a reduced volume mid-section intermediate the enlarged volume
injection section
and enlarged volume ejection section, (b) a material injection end in material
injecting
communication with the combustion chamber, and (c) a material ejection end in
material
injecting communication with the reactor body passage. The second material
feed port is (a)
adjacent to the material ejection end of the first material injection passage
and (b) transverse to a
first material injection passage axis extending from the material injection
end to the material
ejection end in the first material injection passage in the first material
injector. The steam
assisted gravity drainage system includes a steam assisted gravity drainage
injection well in
material injecting communication with the combustion chamber and a steam
assisted gravity
drainage production well. The separation unit includes an inlet in fluid
communication with the
steam assisted gravity drainage production well, a fuel outlet in fluid
communication with the
fuel inlet and a hydrocarbon outlet in fluid communication with the second
material feed port.
In some embodiments, a method of upgrading hydrocarbon material is disclosed.
The
method includes: injecting an oxidant stream and a fuel stream into a
combustor and producing a
combustion flame in a combustion chamber; injecting atomized pre-motive fluid
into the
combustion chamber and forming motive fluid; injecting the motive fluid into a
nozzle reactor;
and injecting a hydrocarbon material into the nozzle reactor.
In some embodiments, method of recovering and upgrading hydrocarbon is
disclosed.
The method includes: withdrawing a steam assisted gravity drainage product
from a steam
assisted gravity drainage production well; separating a fuel stream and a
hydrocarbon stream
from the steam assisted gravity drainage product; injecting an oxidant stream
and the fuel stream
into a combustor and producing a combustion flame in a combustion chamber;
atomizing a pre-
motive fluid stream, injecting the atomized pre-motive fluid into the
combustion chamber, and
forming motive fluid; injecting a first portion of the motive fluid into a
nozzle reactor; injecting
the hydrocarbon stream into the nozzle reactor; and injecting a second portion
of the motive fluid
into a steam assisted gravity drainage injection well.
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BRIEF DESCRIPTION OF THE DRAWINGS
The preferred and other embodiments are disclosed in association with the
accompanying
drawings in which:
Figure 1 is flow chart of embodiments of a hydrocarbon upgrading method
described
herein;
Figure 2 is a cross-sectional view of a combustor suitable for use in
embodiments
described herein;
Figure 3 is a cross-sectional view of a nozzle reactor suitable for use in
embodiments
described herein;
Figure 4 is a cross-sectional view of a nozzle reactor suitable for use in
embodiments
described herein;
Figure 5 is flow chart of embodiments of a hydrocarbon recovery and upgrading
method
described herein;
Figure 6 is a block diagram illustrating embodiments of a hydrocarbon recovery
and
upgrading system described herein;
Figure 7 shows a cross-sectional view of some embodiments of a nozzle reactor
described herein;
Figure 8 shows a cross-sectional view of the top portion of the nozzle reactor
shown in
Figure 7;
Figure 9 shows a cross-sectional perspective view of the mixing chamber in the
nozzle
reactor shown in Figure 7; and
Figure 10 shows a cross-sectional perspective view of the distributor from the
nozzle
reactor shown in Figure 7.
DETAILED DESCRIPTION
With reference to Figure 1, some embodiments of a method for upgrading
hydrocarbon
material include a step 1000 of injecting an oxidant stream and a fuel stream
into a combustor
and producing a combustion flame in a combustion chamber, a step 1100 of
injecting atomized
pre-motive fluid into the combustion chamber and forming motive fluid, a step
1200 of injecting
the motive fluid into a nozzle reactor, and a step 1300 of injecting
hydrocarbon material into the
nozzle reactor. The method beneficially provides an alternative to boilers for
motive fluid (e.g.,
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steam) generation. In addition to being less cost-intensive than boilers, the
method also allows
for the use of untreated water in motive fluid generation, which further makes
the method more
cost effective than motive fluid generated by boilers. Other benefits of the
method over the use
of boilers for motive fluid generation include the elimination of a flue gas
by-product and ability
to take advantage of produced streams from other processes for better process
integration.
In step 1000, an oxidant stream and a fuel stream are injected into a
combustor. The
reaction of the fuel stream and the oxidant stream creates a combustion flame
in the combustion
chamber of the combustor. An objective of step 1000 is to provide a heat from
the reaction
between the fuel stream and the oxidant stream to convert pre-motive fluid
injected into the
combustion chamber into motive fluid. The reaction between the oxidant stream
and the fuel
stream can also produce additional materials that can be used as motive fluids
in upgrading
processes such as cracking of hydrocarbon material in a nozzle reactor.
Any oxidant stream capable of being reacted with a fuel stream in a combustor
to
produce an exothermic reaction can be used in step 1000. In some embodiments,
the oxidant
stream is standard air from the surrounding environment. The oxidant stream
will typically
include a content of 02 and N2. In some embodiments, the oxidant stream
includes an 02 content
in the range of from 18 to 21 vol%. Industrial oxygen can also be used alone
or in combination
with air as the oxidant stream. Industrial oxygen can include from 90 to 99
vol% oxygen. The
use of industrial oxygen can advantageously reduce or eliminate nitrogen in
the process and
result in the production of a greater proportion of motive fluid.
Additionally, when motive fluid
produced using industrial oxygen is used in a nozzle reactor to produce
cracked hydrocarbon
products, the product leaving the nozzle reactor can be cleaner and more
combustible. Other
materials suitable for use as the oxidant stream include exhaust from a
turbine (which can have
depleted amounts of oxygen, such as less than 14 vol% 02) and enriched air
(which can include
from 22 to 28 vol% 02). Any combination of standard air, industrial oxygen,
turbine exhaust,
and enriched air can be used as the oxidant stream.
The oxidant stream injected into the combustor in step 1000 can be at a raised
temperature and pressure to facilitate the reaction in the combustor. In some
embodiments, the
oxidant stream has a temperature in the range of from 1250 to 1500 OF and the
oxidant stream
can have a pressure of from 100 to 550 psig. When the source of the oxidant
stream does not
provide oxidant at the desired temperature and/or pressure, steps can be taken
to adjust the
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temperature and/or pressure to within the desired ranges. Any suitable
techniques for heating
and/or pressurizing the oxidant stream can be used. For example, the oxidant
stream can be run
through a compressor to raise the pressure to within a suitable range.
In instances where a turbine, such as a gas turbine, is present at the remote
location, the
exhaust from the turbine can be used as the oxidant stream in step 1000. Use
of the turbine
exhaust as the oxidant stream can be useful because turbine exhaust typically
has a raised
temperature and pressure and has a desirable 02 content. Accordingly, use of
turbine exhaust
can eliminate or reduce the need to heat and pressurize the oxidant stream
prior to injecting the
oxidant stream into the combustor. In one example, turbine exhaust having an
02 of 14% is
provided at a temperature of 1,400 F and a pressure of 450 prig, meaning that
the exhaust from
the turbine can be directly injected into the combustor without the need for
any pre-treatment.
Such process integration lowers the overall cost of generating motive fluid.
The turbine integrated into the process can include the turbine used to
generate power for
the entire remote facility, such as the power needed for all rotating
machines, powered electrical
units, and accommodations (lights, air conditioning, etc.). Such turbines can
be natural gas or
fuel gas powered turbines. The motive fluid generation capacity can be
calculated based on the
exhaust gas temperature and flow rate from the turbine designed to power the
remote facility,
which in turn can be used to calculate the capacity of the nozzle reactor. An
example of a
commercially available gas turbine that can be used at the remote facility and
integrated into the
process is the Centaur 50 manufactured by Solar Turbines of California, USA.
The Centaur 50 is
a natural gas fired turbine that generates roughly 5 MW of electrical power.
In some embodiments, the exhaust from a custom engine can be used as the
oxidant
stream. The custom engine can include only an air compressor and a combustor
section. The
exhaust from such a custom engine can be used in the combustor to generate
motive fluid in the
same manner as described above when exhaust from a turbine is used in the
combustor.
Any fuel stream capable of being reacted with an oxidant stream in a combustor
to
produce an exothermic reaction can be used in step 1000. Exemplary fuel
streams include
natural gas, methane, or any other low carbon-producing hydrocarbon. The fuel
stream can also
include hydrogen. The fuel stream does not require any pretreatment as long as
the concentration
of high molecular weight hydrocarbons is kept below 0.4 vol%.
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The source of the fuel stream is generally not limited, and can include both
fuel provided
independently of any other processes being performed at the remote facility
and fuel produced by
other processes being performed at the remote facility. As described in
greater detail below, in
some embodiments the fuel stream is obtained in whole or in part from material
recovered via a
SAGD process being carried out at the remote location. Such material is
typically subjected to
various separation processes, one of which provides fuel suitable for use as a
fuel stream in step
1000.
The oxidant stream and the fuel stream are injected into a combustor to react
and provide
an exothermic reaction. Any combustor suitable for reacting the oxidant stream
and fuel stream
to provide an exothermic reaction can be used. With reference to Figure 2, a
typical combustor
200 suitable for use in the methods described herein will include a fuel
injector 210, an oxidant
stream injector 220, an igniter 230, a combustion chamber 240 where the
exothermic reaction
takes place and where the combustion flame is produced, and a casing 250
housing all of the
components of the combustor. The oxidant and fuel streams are injected into
the combustor,
where the two materials react, produce heat, and, with the aid of the igniter,
provide a
combustion flame. A basic example of the reaction that can take place inside
the combustion
zone when the fuel stream is methane is shown below:
CH4 + 0.502 4 CO + 2H2, h = -36kJ/mol
In addition to CO and H2, other reaction products that can be formed by the
reaction of
the fuel stream and the oxidant stream in the combustor include CO2, N2 and
H2O.
The amount of the fuel stream and oxidant stream injected into the combustor
can include
any rates suitable for reacting the two streams and that can be handled by the
combustor used. In
some embodiments, the stoichiometric ratio of fuel to oxidant is greater than
I (i.e., fuel rich).
Typical combustion products for the reaction of standard air and natural gas
(no additional steam
added) at various stoichiometric ratios of fuel to air (b) are provided in
Table 1.
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1.1 (D =1.3 (D =1.5
Wet Wet Wet
(%) (%) (%)
N2 69 N2 66 N2 63
C02 8 C02 5.5 C02 3.9
CO 2.5 CO 2.5 CO 9.0
H2 1.0 H2 4.0 H2 7.5
H2O 18.5 H2O 18.0 H2O 17.0
02 0.0 02 0.0 02 0.0
Table 1
Combustion of the fuel stream and standard air stream and sub-stoichiometric
ratios
lowers the adiabatic temperature of the combustion flame. Table 2 provides the
adiabatic flame
temperature at various D when the air stream is not pre-heated and when the
air stream is pre-
heated to 1,400 F.
(D Without Air With Air
Preheating ( F) Prc hcm t i n g ('I-,)
1.0 3500 4100
1.3 3400 4000
1.5 2800 3400
2.0 2400 3000
Table 2
Heat energy provided by the combustion flame is generally sufficient to
produce motive
fluid at a desired temperature and quench the products of combustion. For
example, some
cracking processes using nozzle reactors (discussed in greater detail below)
operate more
efficiently with motive fluid at 1,200 F. At many of the temperatures
provided in Table 2
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above, sufficient heat energy will be available to both produce motive fluid
at 1,200 F and
quench the combustion products.
In step 1100, atomized pre-motive fluid is injected into the combustion
chamber and
motive fluid is formed. When the atomized pre-motive fluid enters the
combustion chamber, the
heat energy provided by the combustion reaction between the oxidant stream and
the fuel stream
converts the atomized pre-motive fluid into motive fluid. Thus produced, the
motive fluid can be
used for various recovery and upgrading processing being carried out at the
remote facility.
The pre-motive fluid used in step 1100 can be selected from a variety of
suitable
materials. Generally speaking, the pre-motive fluid is a material that is
suitable for use as a
motive fluid in nozzle reactors Exemplary pre-motive fluids include, but are
not limited to,
water, natural gas, methanol, ethanol, ethane, propane, biodiesel, carbon
monoxide, nitrogen, and
combinations thereof.
When the pre-motive fluid injected into the combustion chamber is water, the
water can
be obtained from any suitable source available at the remote facility. The
water may not require
pretreatment, and therefore the source of the water is greatly expanded as
compared to water
sources that can be used when a boiler is used for steam generation. In some
embodiments (e.g.,
where the remote location is an offshore platform), seawater can be used as
the source of water.
In some embodiments where seawater is used, some pretreatment may be carried
out, such as
filtration to remove solids or desalination.
In some embodiments, the water is obtained from material recovered by a SAGD
process
being carried out at the remote facility. Such material is typically subjected
to various separation
processes, one of which provides water suitable for use as the atomized pre-
motive fluid in step
1100.
The pre-motive fluid injected into the combustion chamber is atomized.
Atomized pre-
motive fluid refers to small droplets of pre-motive fluid that are part of
fine spray injected into
the combustion chamber. Any technique capable of atomizing pre-motive fluid
can be used. In
some embodiments, atomization of the pre-motive fluid and injection of the
atomized pre-motive
fluid is performed by the same equipment.
In one example where the pre-motive fluid is water, high pressure atomizer
nozzles can
be used to both create an atomized water spray and inject the atomized water
spray into the
combustion chamber. Referring back to Figure 2, the combustor 200 can be
equipped with such
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a high pressure atomizer nozzle 260. The atomizer nozzle 260 is in fluid
communication with
the combustion chamber 240 such that the atomized water can be injected into
the combustion
chamber where heat energy is available to create steam from the atomized water
droplets. As
shown in Figure 2, in some embodiments the atomizer nozzle 260 is located near
the periphery
of the combustion chamber 240. In this manner, the atomized water can enter
the combustion
chamber 240 around the entire circumference of the combustion flame.
In some embodiments, the amount of atomized pre-motive fluid injected into the
combustion chamber is generally dependent on the amount of heat energy being
produced inside
the combustion chamber and available to convert the atomized pre-motive fluid
to motive fluid.
As noted above, some of the produced heat energy will be used to quench the
other combustion
products. In some embodiments, the atomized pre-motive fluid is injected into
the combustion
chamber to keep a pre-motive fluid to oil ratio in the range from 0.5 to 2Ø
Other reactions occur in the combustion chamber as a result of injecting the
atomized
pre-motive fluid into the combustion chamber and creating motive fluid. For
example, when the
pre-motive fluid is water, produced steam can react with unreacted fuel (e.g.,
methane) to
produce H2 and CO, which is an endothermic reaction. An exemplary reaction
between steam
and methane fuel is provided below:
CH4 + H2O -> CO + 3H2, h = +206 kJ/mol
Carbon monoxide produced from this reaction with react with steam to undergo
an
exothermic water gas shift reaction. For example:
CO + H2O - CO + H2, h = -41 kJ/mol
Taking into consideration all of these possible reactions, the final products
that can be
produced in the combustion chamber as a result of the introduction of the
oxidant stream, the
fuel stream, and atomized water into the combustion chamber include steam, H2,
CO, CO2, and
N2. Each of these products can be used as motive fluids in the nozzle reactor
cracking processes
described in greater detail below.
CA 02787591 2012-08-23
In embodiments where the fuel stream includes hydrogen and the oxidant stream
includes
industrial oxygen, it is theorized that an efficiency higher than 98% can be
obtained. This also
would advantageously provide a zero carbon dioxide emission process.
Natural gas can also serve as a pre-motive fluid that can be converted into a
motive fluid.
Use of natural gas as a pre-motive fluid may require some modification to the
processes
described above. For example, use of natural gas as a pre-motive fluid may
eliminate the need to
atomize the pre-motive fluid prior to its introduction into a combustor. In
some embodiments,
natural gas is added to the combustor as a pre-motive fluid to heat and
pressurize the pre-motive
fluid and thereby put it in a condition for use as a motive fluid in a nozzle
reactor. Accordingly,
in some embodiments, natural gas is introduced into the combustor where it
directly mixes with
the fuel stream (and optionally the oxidant stream) to heat the natural gas.
Atomized water can
also be provided as a means of controlling the mixing and preventing unwanted
reactions. For
example, atomized water introduced into the combustion chamber where natural
gas is mixing
with the fuel stream can moderate the mixed fluid temperature and prevent the
cracking of the
natural gas into soot. The result of this modified process is the creation of
heated and
pressurized natural gas suitable for use as a motive fluid in a nozzle
reactor. In some
embodiments, the natural gas leaving the combustor has a temperature in the
range of 1,200 F
and a pressure of 450 psig.
In some embodiments, the use of natural gas as a motive fluid can have a
beneficial
impact on upgrading performance in the nozzle reactor. For example, use of a
motive fluid
comprising 100% natural gas provide improved upgrading performance over motive
fluid
comprising mixture of natural gas and steam, or steam alone.
In alternative embodiments, natural gas is used as a pre-motive fluid to
produce syngas
for use as a motive fluid. This process can differ from the previously
described use of natural
gas as a pre-motive fluid in that reactions are allowed to take place within
the combustor to
thereby produce syngas. In some embodiments, natural gas is used as a pre-
motive fluid in
conjunction with using gas turbine exhaust as an oxidant. In such embodiments,
reactions
between gas turbine exhaust and the natural gas inside of the combustor
creates hot syngas (CH4,
H2, CO, H2O, N2, etc) suitable for use as a motive fluid. In carrying out this
reaction, it can be
important to ensure that all oxygen content from the gas turbine exhaust is
consumed in the
reforming reactions occurring inside the combustor.
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In some embodiments, the direct fired combustor in a gas turbine can be used
to create
motive fluids. Gas turbines typically include direct fired combustors similar
or identical to the
direct fired combustor described above and shown in FIG. 2. The direct fired
combustor in a gas
turbine can be used to make motive fluid by utilizing the exhaust generated by
the direct fired
combustor in the gas turbine. In some embodiments, the exhaust generated can
be directly
mixed with atomized water to make steam that is suitable for use as a motive
fluid. The exhaust
(which can be 02 depleted as described above) can have a temperature in the
range of 1,400 F.
Exhaust at this temperature can be capable direct mixing with atomized water
to produce steam.
Any manner of mixing the exhaust with atomized water can be used, and the
resulting steam can
have a sufficient temperature and pressure to be used as a motive fluid
(including when the steam
created is superheated steam).
Another manner in which exhaust generated by a direct fired combustor in a gas
turbine
can be used to make motive fluid is through indirect heating of water. For
example, the exhaust
having a sufficiently high temperature (e.g., 1,400 F) can be used in a shell
and tube heat
exchanger to transfer heat to water and thereby produce steam. The steam
produced in this
manner can be suitable for use as a motive fluid.
In steps 1200 and 1300, the motive fluid produced in the combustion chamber as
part of
step 1100 is injected into a nozzle reactor and a hydrocarbon material is
injected into the nozzle
reactor. An objective of injecting the two materials into the nozzle reactor
is to crack the
hydrocarbon material into lighter hydrocarbon compounds.
The nozzle reactor into which the motive fluid is injected can be any type of
nozzle
reactor capable of using motive fluid as a cracking material to upgrade
hydrocarbon material. In
some embodiments, the nozzle reactor into which the motive fluid is injected
is the nozzle
reactor described in U.S. Patent No. 7,618,597, the entirety of which is
hereby incorporated by
reference. The nozzle reactor described in the `597 patent generally receives
a motive fluid (also
referred to as cracking material and, in this case, the motive fluid derived
from the combustion
chamber) and accelerates it to a supersonic speed via a converging and
diverging injection
passage. Hydrocarbon material is injected into the nozzle reactor adjacent the
location the
cracking material exits the injection passage and at a direction transverse to
the direction of the
cracking material. The interaction between the cracking material and the
hydrocarbon material
results in the cracking of the hydrocarbon material into a lighter hydrocarbon
material.
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With reference to Figure 3, an exemplary nozzle reactor suitable for use in
the methods
and systems described herein is shown. The nozzle reactor, indicated generally
at 10, has an
injection end 12, a tubular reactor body 14 extending from the injection end
12, and an ejection
port 13 in the reactor body 14 opposite its injection end 12. The injection
end 12 includes an
injection passage 15 extending into the interior reactor chamber 16 of the
reactor body 14. The
central axis A of the injection passage 15 is coaxial with the central axis B
of the reactor
chamber.
With continuing reference to Figure 3, the injection passage 15 has a circular
diametric
cross-section and, as shown in the axially-extending cross-sectional view of
Figure 3, opposing
inwardly curved side wall portions 17, 19 (i.e., curved inwardly toward the
central axis A of the
injection passage 15) extending along the axial length of the injection
passage 15. In certain
embodiments, the axially inwardly curved side wall portions 17, 19 of the
injection passage 15
allow for a higher speed of injection when passing through the injection
passage 15 into the
reactor chamber 16.
In certain embodiments, the side wall of the injection passage 15 can provide
one or more
among: (i) uniform axial acceleration of material passing through the
injection nozzle passage;
(ii) minimal radial acceleration of such material; (iii) a smooth finish; (iv)
absence of sharp
edges; and (v) absence of sudden or sharp changes in direction. The side wall
configuration can
render the injection passage 15 substantially isentropic. These latter types
of side wall and
injection passage 15 features can be, among other things, particularly useful
for pilot plant nozzle
reactors of minimal size.
A material feed passage or channel 18 extends from the exterior of the
junction of the
injection end 12 and the tubular reactor body 14 toward the reaction chamber
16 transversely to
the axis B of the interior reactor chamber 16. The material feed passage 18
penetrates an annular
material feed port 20 adjacent the interior reactor chamber wall 22 at the end
24 of the interior
reactor chamber 16 abutting the injection end 12. The material feed port 20
includes an annular,
radially extending chamber feed slot 26 in material-injecting communication
with the interior
reactor chamber 16. The material feed port 20 is thus configured to inject
feed material: (i) at
about a 90 angle to the axis of travel of cracking material injected from the
injection nozzle
passage 15; (ii) around the entire circumference of a cracking material
injected through the
injection passage 15; and (iii) to impact the entire circumference of the free
cracking material
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stream virtually immediately upon its emission from the injection passage 15
into the reactor
chamber 16.
The annular material feed port 20 may have a U-shaped or C-shaped cross-
section among
others. In certain embodiments, the material feed port may be open to the
interior reactor
chamber 16, with no arms or barrier in the path of fluid flow from the
material feed passage 18
toward the interior reactor chamber 16. The junction of the material feed port
20 and material
feed passage 18 can have a radiused cross-section.
In alternative embodiments, the material feed passage 18, associated feed port
20, and/or
injection passage 15 may have differing orientations and configurations, and
there can be more
than one material feed port and associated structure. Similarly, in certain
embodiments the
injection passage 15 may be located on or in the side 23 of the reactor
chamber 16 (and if desired
may include an annular cracking material port) rather than at the injection
end 12 of the reactor
chamber 16; and the material feed port 20 may be non-annular and located at
the injection end 12
of the reactor chamber 16.
In the embodiment of Figure 3, the interior reactor chamber 16 can be bounded
by
stepped, telescoping tubular side walls 28, 30, 32 extending along the axial
length of the reactor
body 14. In certain embodiments, the stepped side walls 28, 30, 32 are
configured to: (i) allow a
free jet of injected cracking material, such as superheated steam, natural
gas, carbon dioxide, or
other material, to travel generally along and within the conical jet path C
generated by the
ejection nozzle passage 15 along the axis 13 of the reactor chamber 16, while
(ii) reducing the
size or involvement of back flow areas, e.g., 34, 36, outside the conical or
expanding jet path C,
thereby forcing increased contact between the high speed cracking material
stream within the
conical path C and feed material, such as heavy hydrocarbons, injected through
the feed port 20.
As indicated by the drawing gaps 38, 40 in the embodiment of Figure 3, the
tubular
reactor body 14 has an axial length (along axis B) that is much greater than
its width. In the
Figure 3 embodiment, exemplary length-to-width ratios are typically in the
range of 2 to 4 or
more.
With reference now to Figure 4 and the particular embodiment shown therein,
the reactor
body 44 includes a generally tubular central section 46 and a frustoconical
ejection end 48
extending from the central section 46 opposite an insert end 50 of the central
section 46, with the
insert end 50 in turn abutting the injection nozzle 52. The insert end 50 of
the central section 46
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CA 02787591 2012-08-23
consists of a generally tubular central body 51. The central body 51 has a
tubular material feed
passage 54 extending from the external periphery 56 of the insert end 50
radially inwardly to
injectingly communicate with the annular circumferential feed port depression
or channel 58 in
the otherwise planar, radially inwardly extending portion 59 of the axially
stepped face 61 of the
insert, end 50. The inwardly extending portion 59 abuts the planar radially
internally extending
portion 53 of a matingly stepped face 55 of the injection nozzle 52. The feed
port channel 58
and axially opposed radially internally extending portion 53 of the injection
nozzle 52
cooperatively provide an annular feed port 57 disposed transversely laterally,
or radially
outwardly, from the axis A of a preferably non-linear injection passage 60 in
the injection nozzle
52.
The tubular body 51 of the insert end SD is secured within and adjacent the
interior
periphery 64 of the reactor body 44. The mechanism for securing the insert end
50 in this
position may consist of an axially-extending nut-and-bolt arrangement (not
shown) penetrating
co-linearly mating passages (not shown) in: (i) an upper radially extending
lip 66 on the reactor
body 44; (ii) an abutting, radially outwardly extending thickened neck section
68 on the insert
end 50; and (iii) in turn, the abutting injector nozzle 52. Other mechanisms
for securing the
insert end 50 within the reactor body 44 may include a press fit (not shown)
or mating threads
(not shown) on the outer periphery 62 of the tubular body 51 and on the inner
periphery 64 of the
reactor body 44. Seals, e.g., 70, may be mounted as desired between, for
example, the radially
extending lip 66 and the abutting the neck section 68 and the neck section 68
and the abutting
injector nozzle 52.
The non-linear injection passage 60 has, from an axially-extending cross-
sectional
perspective, mating, radially inwardly curved opposing side wall sections 72,
74 extending along
the axial length of the non-linear injection passage 60. The entry end 76 of
injection passage 60
provides a rounded circumferential face abutting an injection feed tube 78,
which can be bolted
(not shown) to the mating planar, radially outwardly extending distal face 80
on the injection
nozzle 52.
In the embodiment of Figure 3, the nozzle passage 60 is a DeLaval type of
nozzle and has
an axially convergent section 82 abutting an intermediate relatively narrower
throat section 84,
which in turn abuts an axially divergent section 86. The nozzle passage 60
also has a circular
diametric cross-section (i.e., in cross-sectional view perpendicular to the
axis of the nozzle
CA 02787591 2012-08-23
passage) all along its axial length. In certain embodiments, the nozzle
passage 60 may also
present a somewhat roundly curved thick 82, less curved thicker 84, and
relatively even less
curved and more gently sloped relatively thin 86 axially extending cross-
sectional configuration
from the entry end 76 to the injection end 88 of the injection passage 60 in
the injection nozzle
52.
The nozzle passage 60 can thus be configured to present a substantially
isentropic or
frictionless configuration for the injection nozzle 52. This configuration may
vary, however,
depending on the application involved in order to yield a substantially
isentropic configuration
for the application.
The injection passage 60 is formed in a replaceable injection nozzle insert 90
press-fit or
threaded into a mating injection nozzle mounting passage 92 extending axially
through an
injection nozzle body 94 of the injection nozzle 52. The injection nozzle
insert 90 is preferably
made of hardened steel alloy, and the balance of the nozzle reactor 100
components other than
seals, if any, are preferably made of steel or stainless steel.
In the particular embodiment shown in Figure 3, the narrowest diameter D
within the
injection passage is 140 mm. The diameter E of the ejection passage opening 96
in the ejection
end 48 of the reactor body 44 is 2.2 meters. The axial length of the reactor
body 44, from the
injection end 88 of the injector passage 60 to the ejection passage opening
96, is 10 meters.
The interior peripheries 89, 91 of the insert end 50 and the tubular central
section 46,
respectively, cooperatively provide a stepped or telescoped structure
expanding radially
outwardly from the injection end 88 of the injection or injector passage 60
toward the
frustoconical end 48 of the reactor body 44. The particular dimensions of the
various
components, however, will vary based on the particular application for the
nozzle reactor,
generally 100. Factors taken into account in determining the particular
dimensions include the
physical properties of the cracking gas (density, enthalpy, entropy, heat
capacity, etc.) and the
pressure ratio from the entry end 76 to the injection end 88 of the injector
passage 60.
In certain embodiments having one or more non-linear cracking gas injection
passages,
e.g., 60, such as the convergent/divergent configuration of Figure 3, the
pressure differential can
yield a steady increase in the kinetic energy of the cracking material as it
moves along the axial
length of the cracking gas injection passage(s) 60. The cracking material may
thereby eject from
the ejection end 88 of the injection passage 60 into the interior of the
reactor body 44 at
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CA 02787591 2012-08-23
supersonic speed with a commensurately relatively high level of kinetic
energy. In these
embodiments, the level of kinetic energy of the supersonic discharge cracking
material is
therefore greater than can be achieved by certain prior art straight-through.
Feed stock is injected into the material feed passage 54 and then through the
mating
annular feed port 57. The feed stock thereby travels radially inwardly to
impact a transversely
(i. e., axially) traveling high speed cracking mateiral (for example, steam,
natural gas, carbon
dioxide or other gas not shown) virtually immediately upon its ejection from
the ejection end 88
of the injection passage 60. The collision of the radially injected feed stock
with the axially
traveling high speed steam jet delivers kinetic and thermal energy to the feed
stock. The
applicants believe that this process may continue, but with diminished
intensity and productivity,
through the length of the reactor body 44 as injected feed stock is forced
along the axis of the
reactor body 44 and yet constrained from avoiding contact with the jet stream
by the telescoping
interior walls, e.g., 89, 91 101, of the reactor body 44. Depending on the
nature of the feed stock
and its pre-feed treatment, differing results can be procured, such as
cracking of heavy
hydrocarbons, including bitumen, into lighter hydrocarbons.
Figures 7 and 8 show cross-sectional views of another embodiment of a nozzle
reactor
100 suitable for use in the methods described herein. The nozzle reactor 100
includes a head
portion 102 coupled to a body portion 104. A main passage 106 extends through
both the head
portion 102 and the body portion 104. The head and body portions 102, 104 are
coupled together
so that the central axes of the main passage 106 in each portion 102, 104 are
coaxial so that the
main passage 106 extends straight through the nozzle reactor 100.
It should be noted that for purposes of this disclosure, the term "coupled"
means the
joining of two members directly or indirectly to one another. Such joining may
be stationary in
nature or movable in nature. Such joining may be achieved with the two members
or the two
members and any additional intermediate members being integrally formed as a
single unitary
body with one another or with the two members or the two members and any
additional
intermediate member being attached to one another. Such joining may be
permanent in nature or
alternatively may be removable or releasable in nature.
The nozzle reactor 100 includes a feed passage 108 that is in fluid
communication with
the main passage 106. The feed passage 108 intersects the main passage 106 at
a location
between the portions 102, 104. The main passage 106 includes an entry opening
110 at the top of
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CA 02787591 2012-08-23
the head portion 102 and an exit opening 112 at the bottom of the body portion
104. The feed
passage 108 also includes an entry opening 114 on the side of the body portion
104 and an exit
opening 116 that is located where the feed passage 108 meets the main passage
106.
During operation, the nozzle reactor 100 includes a reacting fluid that flows
through the
main passage 106. The reacting fluid enters through the entry opening 110,
travels the length of
the main passage 106, and exits the nozzle reactor 100 out of the exit opening
112. A feed
material flows through the feed passage 108. The feed material enters through
the entry opening
114, travels through the feed passage 106, and exits into the main passage 108
at exit opening
116.
The main passage 106 is shaped to accelerate the reacting fluid. The main
passage 106
may have any suitable geometry that is capable of doing this. As shown in
Figures 7 and 8, the
main passage 106 includes a first region having a convergent section 120 (also
referred to herein
as a contraction section), a throat 122, and a divergent section 124 (also
referred to herein as an
expansion section). The first region is in the head portion 102 of the nozzle
reactor 100.
The convergent section 120 is where the main passage 106 narrows from a wide
diameter
to a smaller diameter, and the divergent section 124 is where the main passage
106 expands from
a smaller diameter to a larger diameter. The throat 122 is the narrowest point
of the main passage
106 between the convergent section 120 and the divergent section 124. When
viewed from the
side, the main passage 106 appears to be pinched in the middle, making a
carefully balanced,
asymmetric hourglass-like shape. This configuration is commonly referred to as
a convergent-
divergent nozzle or "con-di nozzle".
The convergent section of the main passage 106 accelerates subsonic fluids
since the
mass flow rate is constant and the material must accelerate to pass through
the smaller opening.
The flow will reach sonic velocity or Mach 1 at the throat 122 provided that
the pressure ratio is
high enough. In this situation, the main passage 106 is said to be in a choked
flow condition.
Increasing the pressure ratio further does not increase the Mach number at the
throat 122
beyond unity. However, the flow downstream from the throat 122 is free to
expand and can reach
supersonic velocities. It should be noted that Mach 1 can be a very high speed
for a hot fluid
since the speed of sound varies as the square root of absolute temperature.
Thus the speed
reached at the throat 122 can be far higher than the speed of sound at sea
level.
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CA 02787591 2012-08-23
The divergent section 124 of the main passage 106 slows subsonic fluids, but
accelerates
sonic or supersonic fluids. A convergent-divergent geometry can therefore
accelerate fluids in a
choked flow condition to supersonic speeds. The convergent-divergent geometry
can be used to
accelerate the hot, pressurized reacting fluid to supersonic speeds, and upon
expansion, to shape
the exhaust flow so that the heat energy propelling the flow is maximally
converted into kinetic
energy.
The flow rate of the reacting fluid through the convergent-divergent nozzle is
isentropic
(fluid entropy is nearly constant). At subsonic flow the fluid is compressible
so that sound, a
small pressure wave, can propagate through it. At the throat 122, where the
cross sectional area
is a minimum, the fluid velocity locally becomes sonic (Mach number = 1.0). As
the cross
sectional area increases the gas begins to expand and the gas flow increases
to supersonic
velocities where a sound wave cannot propagate backwards through the fluid as
viewed in the
frame of reference of the nozzle (Mach number > 1.0).
The main passage 106 only reaches a choked flow condition at the throat 122 if
the
pressure and mass flow rate is sufficient to reach sonic speeds, otherwise
supersonic flow is not
achieved and the main passage will act as a venturi tube. In order to achieve
supersonic flow, the
entry pressure to the nozzle reactor 100 should be significantly above ambient
pressure.
The pressure of the fluid at the exit of the divergent section 124 of the main
passage 106
can be low, but should not be too low. The exit pressure can be significantly
below ambient
pressure since pressure cannot travel upstream through the supersonic flow.
However, if the
pressure is too far below ambient, then the flow will cease to be supersonic
or the flow will
separate within the divergent section 124 of the main passage 106 forming an
unstable jet that
"flops" around and damages the main passage 106. In one embodiment, the
ambient pressure is
no higher than approximately 2-3 times the pressure in the supersonic gas at
the exit.
The supersonic reacting fluid collides and mixes with the feed material in the
nozzle
reactor 100 to produce the desired reaction. The high speeds involved and the
resulting collision
produces a significant amount of kinetic energy that helps facilitate the
desired reaction. The
reacting fluid and/or the feed material may also be pre-heated to provide
additional thermal
energy to react the materials.
The nozzle reactor 100 may be configured to accelerate the reacting fluid to
at least
approximately Mach 1, at least approximately Mach 1.5, or, desirably, at least
approximately
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CA 02787591 2012-08-23
Mach 2. The nozzle reactor may also be configured to accelerate the reacting
fluid to
approximately Mach I to approximately Mach 7, approximately Mach 1.5 to
approximately
Mach 6, or, desirably, approximately Mach 2 to approximately Mach 5.
As shown in Figure 8, the main passage 106 has a circular cross-section and
opposing
converging side walls 126, 128. The side walls 126, 128 curve inwardly toward
the central axis
of the main passage 106. The side walls 126, 128 form the convergent section
120 of the main
passage 106 and accelerate the reacting fluid as described above.
The main passage 106 also includes opposing diverging side walls 130, 132. The
side
walls 130, 132 curve outwardly (when viewed in the direction of flow) away
from the central
axis of the main passage 106. The side walls 130, 132 form the divergent
section 124 of the main
passage 106 that allows the sonic fluid to expand and reach supersonic
velocities.
The side walls 126, 128, 130, 132 of the main passage 106 provide uniform
axial
acceleration of the reacting fluid with minimal radial acceleration. The side
walls 126, 128, 130,
132 may also have a smooth surface or finish with an absence of sharp edges
that may disrupt the
flow. The configuration of the side walls 126, 128, 130, 132 renders the main
passage 106
substantially isentropic.
The feed passage 108 extends from the exterior of the body portion 104 to an
annular
chamber 134 formed by head and body portions 102, 104. The portions 102, 104
each have an
opposing cavity so that when they are coupled together the cavities combine to
form the annular
chamber 134. A seal 136 is positioned along the outer circumference of the
annular chamber 134
to prevent the feed material from leaking through the space between the head
and body portions
102, 104.
It should be appreciated that the head and body portions 102, 104 may be
coupled
together in any suitable manner. Regardless of the method or devices used, the
head and body
portions 102, 104 should be coupled together in a way that prevents the feed
material from
leaking and withstands the forces generated in the interior. In one
embodiment, the portions 102,
104 are coupled together using bolts that extend through holes in the outer
flanges of the portions
102, 104.
The nozzle reactor 100 includes a distributor 140 positioned between the head
and body
portions 102, 104. The distributor 140 prevents the feed material from flowing
directly from the
opening 141 of the feed passage 108 to the main passage 106. Instead, the
distributor 140
CA 02787591 2012-08-23
annularly and uniformly distributes the feed material into contact with the
reacting fluid flowing
in the main passage 106.
As shown in Figure 10, the distributor 140 includes an outer circular wall 148
that
extends between the head and body portions 102, 104 and forms the inner
boundary of the
annular chamber 134. A seal or gasket may be provided at the interface between
the distributor
140 and the head and body portions 102, 104 to prevent feed material from
leaking around the
edges.
The distributor 140 includes a plurality of holes 144 that extend through the
outer wall
148 and into an interior chamber 146. The holes 144 are evenly spaced around
the outside of the
distributor 140 to provide even flow into the interior chamber 146. The
interior chamber 146 is
where the main passage 106 and the feed passage 108 meet and the feed material
comes into
contact with the supersonic reacting fluid.
The distributor 140 is thus configured to inject the feed material at about a
90 angle to
the axis of travel of the reacting fluid in the main passage 106 around the
entire circumference of
the reacting fluid. The feed material thus forms an annulus of flow that
extends toward the main
passage 106. The number and size of the holes 144 are selected to provide a
pressure drop across
the distributor 140 that ensures that the flow through each hole 144 is
approximately the same. In
one embodiment, the pressure drop across the distributor is at least
approximately 2000 pascals,
at least approximately 3000 pascals, or at least approximately 5000 pascals.
Referring to Figure 9, holes 144 are shown having a circular cross-section.
Circular holes
144 are suitable for effective nozzle reactor operation when the nozzle
reactor is relatively small
and handling production capacities less than, e.g., 1,000 bbl/day. At such
production capacities,
the feed material passing through the circular holes will break up into the
smaller droplet size
necessary for efficient mixing or shearing with the reacting fluid.
The distributor 140 includes a wear ring 150 positioned immediately adjacent
to and
downstream of the location where the feed passage 108 meets the main passage
106. The
collision of the reacting fluid and the feed material causes a lot of wear in
this area. The wear
ring is a physically separate component that is capable of being periodically
removed and
replaced.
As shown in Figure 10, the distributor 140 includes an annular recess 152 that
is sized to
receive and support the wear ring 150. The wear ring 150 is coupled to the
distributor 140 to
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CA 02787591 2012-08-23
prevent it from moving during operation. The wear ring 150 may be coupled to
the distributor in
any suitable manner. For example, the wear ring 150 may be welded or bolted to
the distributor
140. If the wear ring 150 is welded to the distributor 140, as shown in Figure
9, the wear ring
150 can be removed by grinding the weld off. In some embodiments, the weld or
bolt need not
protrude upward into the interior chamber 146 to a significant degree.
The wear ring 150 can be removed by separating the head portion 102 from the
body
portion 104. With the head portion 102 removed, the distributor 140 and/or the
wear ring 150 are
readily accessible. The user can remove and/or replace the wear ring 150 or
the entire distributor
140, if necessary.
As shown in Figures 7 and 8, the main passage 106 expands after passing
through the
wear ring 150. This can be referred to as expansion area 160 (also referred to
herein as an
expansion chamber). The expansion area 160 is formed largely by the
distributor 140, but can
also be formed by the body portion 104.
Following the expansion area 160, the main passage 106 includes a second
region having
a converging-diverging shape. The second region is in the body portion 104 of
the nozzle reactor
100. In this region, the main passage includes a convergent section 170 (also
referred to herein as
a contraction section), a throat 172, and a divergent section 174 (also
referred to herein as an
expansion section). The converging-diverging shape of the second region
differs from that of the
first region in that it is much larger. In one embodiment, the throat 172 is
at least 2-5 times as
large as the throat 122.
The second region provides additional mixing and residence time to react the
reacting
fluid and the feed material. The main passage 106 is configured to allow a
portion of the reaction
mixture to flow backward from the exit opening 112 along the outer wall 176 to
the expansion
area 160. The backflow then mixes with the stream of material exiting the
distributor 140. This
mixing action also helps drive the reaction to completion.
The combustion chamber of the combustor can be in fluid communication with the
cracking material injection passage of the nozzle reactor such that the
produced motive fluid
passes directly into the nozzle reactor. The motive fluid exiting the
combustion chamber and
entering the nozzle reactor is passed through the cracking material injection
passage where, as
described above, the motive fluid is accelerated to a supersonic speed. Any
amount of motive
22
CA 02787591 2012-08-23
fluid necessary to crack hydrocarbon material injected into the nozzle reactor
can be supplied
into the nozzle reactor.
In some embodiments, supplemental motive fluid can be provided to the nozzle
reactor,
such as in the case where the combustor does not produce sufficient motive
fluid for cracking the
amount of hydrocarbon injected into the nozzle reactor. The supplemental
motive fluid can be
joined with the motive fluid produced by the combustor prior to injection into
the nozzle reactor.
Any suitable source of supplemental motive fluid can be used. In embodiments
where the
motive fluid is steam, traditional steam generation boilers can be used to
produce supplemental
motive fluid. In offshore contexts, steam generation boilers are a good source
of supplemental
motive fluid because the offshore platform already uses steam generation
boilers for other
processes carried out on the offshore platform.
In step 1300, the hydrocarbon material to be upgraded is injected into the
nozzle reactor.
When a nozzle reactor as described above is used, the hydrocarbon material is
injected into the
nozzle reactor at a location adjacent to where the motive fluid exits the
cracking material
injection passage and a direction transverse to the direction the motive fluid
enters the reactor
body passage.
Any hydrocarbon material capable of being upgraded in the nozzle reactor
through
interaction with motive fluid travelling at supersonic speeds can be used in
step 1300. In some
embodiments, the hydrocarbon material is a heavy hydrocarbon material, such as
a hydrocarbon
material having a molecular weight greater than 500. Such hydrocarbon
materials can include
bitumen and asphaltenes. In some embodiments, the hydrocarbon material is
hydrocarbon
material that is recovered from SAGD recovery processes being carried out at
the same remote
facility as the nozzle reactor upgrading. Such material when recovered via a
SAGD process is
typically subjected to one or more separation units, and one potential output
stream of the
separation units may be a heavy hydrocarbon stream.
In some embodiments, some deposits may appear within the nozzle reactor as a
result of
the upgrading process. Such scale build up should be monitored. In some
embodiments,
treatment of the water prior to injection into the nozzle reactor can be
provided in order to reduce
or avoid scale build up. Such treatments can include distillation, desalting,
and/or desalination
depending on the source.
23
CA 02787591 2012-08-23
Some embodiments of the method can include further process integration such
that the
upgrading processes are assisted by the recovery processes and vice versa.
With reference to
Figure 5, some embodiments of a method for recovering and upgrading
hydrocarbon material
include a step 500 of withdrawing a steam assisted gravity drainage product
from a steam
assisted gravity drainage production well, a step 510 of separating a fuel
stream and a
hydrocarbon stream from the steam assisted gravity drainage product, a step
520 of injecting a
combustion stream and the fuel stream into a combustor and producing a
combustion flame in a
combustion chamber, a step 530 of atomizing a water stream, injecting the
atomized water into
the combustion chamber, and forming steam, a step 540 of injecting a first
portion of the steam
into a nozzle reactor, a step 550 of injecting they hydrocarbon stream into
the nozzle reactor, and
a step 560 of injecting a second portion of the steam into a steam assisted
gravity drainage
injection well. In such a method, the SAGD recovery processing assists the
upgrading
processing by providing the fuel and hydrocarbon streams, and the upgrading
processing assists
the SAGD recovery processing by providing a portion of the necessary steam.
In step 500, a SAGD production well is provided through which SAGD product can
be
withdrawn. The SAGD production well can be any type of SAGD production well
known to
those of ordinary skill in the art and is part of any type of SAGD system to
known to those of
ordinary skill in the art. Generally speaking, the SAGD production well has a
first end that is
located within a deposit of hydrocarbon material. Typically, this end of the
production well will
be oriented in a horizontal direction and will be located under a SAGD
injection well that
introduces steam into the deposit of hydrocarbon material. The steam
introduced into the deposit
of hydrocarbon material will lower the viscosity of the hydrocarbon material
until it flows
downwardly under the influence of gravity to the SAGD production well located
under the
SAGD injection well. The SAGD production well receives this hydrocarbon
material and
provides a channel for the material to be pumped upwardly to the opposite end
of the production
well. The opposite end of the production well is located above ground.
The SAGD product brought to the surface by the SAGD production well can have a
variety of components. In some embodiments, the SAGD product includes
hydrocarbon
material, fuel, and water, as well as other components. The hydrocarbon
material component of
the SAGD product can be from 15 to 35% of the product and can include, e.g.,
bitumen,
asphaltenes and other heavy hydrocarbon material. The fuel component of the
SAGD product
24
CA 02787591 2012-08-23
can be from 0 to 0.5% of the product and can include, e.g., natural gas and
methane. The water
component of the SAGD product can be from 65 to 85% of the product.
The withdrawn SAGD product is subjected to separation processing in step 520.
An
objective of the separation processing is to separate a fuel stream and a
hydrocarbon stream from
the SAGD product. Once a fuel stream and a hydrocarbon stream are separated
from the SAGD
product, the streams can be used in steam generation and hydrocarbon upgrading
to provide for
beneficial process integration. Any equipment capable of separating these
streams from the
SAGD product can be used. In some embodiments, the separations are carried out
in multiple
separation apparatus. For example, a first separation can be carried out in an
emulsion breaker
tank, followed by a separation in a distillation unit.
The fuel stream separated in step 510 can be used in step 520, where an air
stream and
the fuel stream are injected into a combustor and a combustion flame is
produced in the
combustion chamber. Step 520 is similar or identical to step 100 described in
greater detail
above, with the condition that at least a portion of the fuel stream used in
step 520 is derived
from the SAGD product withdrawn in step 500 and separated in step 510.
Typically, make-up
fuel, such as imported natural gas, will be necessary to provide a sufficient
amount of fuel to
produce steam.
The water needed for 530 is typically provided by a source of water
independent from the
SAGD product. Any water source suitable for use in generating steam in a
combustor can be
used. The water is atomized, injected into the combustion chamber, and steam
is formed. Step
530 is similar or identical to step 110 described in greater detail above. In
some embodiments,
water from the SAGD product can be used in addition to or in place of the
independent water
source, although water from the SAGD produce will typically require
pretreatment prior to being
used in the combustor to generate steam. A typical required pretreatment
process for water
derived from SAGD product is a silica removing process. Without such a silica
removing
process, scaling of process equipment such as the nozzle reactor can occur.
When the upgrading process is integrated with the SAGD recovery process, the
steam
produced in step 530 can be used in both processes. In step 540, a first
portion of the steam is
injected into a nozzle reactor to carry out hydrocarbon cracking and upgrading
as described in
greater detail above. Step 540 is similar or identical to step 120 described
in greater detail
above, with the condition that only portion of the steam produced in the
combustion chamber is
CA 02787591 2012-08-23
injected into the nozzle reactor. The first portion of steam injected into the
nozzle reactor can be
any suitable amount needed to carry out the upgrading in the nozzle reactor.
Any mechanism
known to those of ordinary skill in the art can be used withdraw only a
portion of the steam
produced in the combustion chamber.
In step 550, the hydrocarbon stream separated from the SAGD product in step
510 is
injected into the nozzle reactor to interact with the steam injected into the
nozzle reactor in step
540 and crack and upgrade the hydrocarbon material. Step 550 can be similar or
identical to step
130 described in greater detail above, with the condition that at least a
portion of the
hydrocarbon material used in step 550 is derived from the SAGD product
withdrawn in step 500
and separated in step 510. To the extent necessary, additional make-up
hydrocarbon material
may be used.
In step 560, a second portion of the steam formed in the combustion chamber in
step 530
is injected into a SAGD injection well. An objective of injecting steam into
the SAGD injection
well is to assist with continued hydrocarbon recovery via the SAGD operation.
The SAGD
injection well can be any type of SAGD production well known to those of
ordinary skill in the
art for recovery hydrocarbon material from hydrocarbon deposits. Generally
speaking, the
SAGD injection well has a first end located within a deposit of hydrocarbon
material and a
second end above ground where steam is entered into the well. Typically, the
end of the
injection well within the deposit will be oriented in a horizontal direction
and will be located
above a SAGD production. Steam transported through the SAGD injection well is
injected into
the deposit of hydrocarbon material in order to lower the viscosity of the
hydrocarbon material
and cause it to flow downwardly under the force of gravity. Located beneath
the SAGD
injection well is the SAGD production well discussed above, which can receive
the flowing
hydrocarbon material and transport it above ground.
In some embodiments, the amount of steam required for the SAGD recovery
operation is
supplied by the second portion of steam generated in the combustion chamber
and allocated for
use in the SAGD process. However, in embodiments where an insufficient amount
of steam is
formed in the combustion chamber, make-sup steam can be provided to the SAGD
injection
well. Any suitable source of make-up steam can be used.
With reference to Figure 6, a system that can be used to carry out embodiments
of the
methods described above includes a combustor 610, a SAGD injector 620, a
nozzle reactor 630,
26
CA 02787591 2012-08-23
a SAGD producer 640, and a separation unit 650. As described in greater detail
above, fuel 611,
water 612, and air 613 are injected into the combustor 610 to produce steam
615. A portion of
the produced steam 615a can be transported to the SAGD injector 620 for use in
carrying out the
SAGD process. A portion of the produced steam 615b can be transported to the
nozzle reactor
630 for use in upgrading a stream of heavy hydrocarbon material 631 being
injected into the
nozzle reactor 630. The SAGD producer 640 produces a SAGD product 641 that can
include
hydrocarbon material, fuel, and water. The SAGD product 641 is therefore sent
to a separation
unit 650 capable of separating a fuel stream 652 and a hydrocarbon stream 653
from the SAGD
product 641. Leftover SAGD product, including water, can leave the separation
unit 650 via
leftover stream 651. Fuel stream 652 separated from the SAGD product 641 in
the separation
unit 650 can be sent to the combustor 610, while hydrocarbon stream 653 in
need of upgrading
can be sent to the nozzle reactor 630.
As described in greater detail above, the combustor 610 can be any type of
combustor
suitable for converting water into steam, and in some embodiments, includes an
atomizer for
receiving water 612 and injecting the water 612 in atomized form into the
combustion chamber
of the combustor 610. The source of the water is not limited, and can include,
for example, sea
water when the system is located on an off-shore platform. The air 613
injected into the
combustor can come from any suitable source, and in some embodiments if
provided by a
turbine. Gas turbine exhaust can be useful in the process described herein
because it is provided
at a high temperature and pressure. If the air 613 is not gas turbine exhaust,
additional
equipment to heat and compress the air prior to injection into the combustor
610 can be
provided. Gas turbine exhaust can also be used in conjunction with an air make-
up stream where
the gas turbine does not provide a sufficient amount of air for the combustor
610. The fuel 611
provided to the combustor can be any fuel for operating the combustor. In some
embodiments,
the fuel 611 is natural gas. As described in greater detail below, a portion
or all of the fuel 611
and the water 612 can be provided by a SAGD process integrated with combustor
610. To the
extent that the SAGD process does not provide a sufficient amount of water
and/or fuel, make-up
streams can be provided.
The steam 615 generated by the combustor can be divided into two streams, with
one
steam stream 615b being directed to a nozzle reactor 630 and the other steam
stream 615a being
directed to a SAGD injector 620. Any manner of separating the steam 615 into
the two streams
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CA 02787591 2012-08-23
615a, 615b can be provided and the amount of steam 615 diverted to each stream
can be
determined based on the amount of steam 615 produced by the combustor 610 and
the steam
demands of the SAGD injector 620 and the nozzle reactor 630.
The steam 615a directed to the SAGD injector 620 is injected into the ground
to soften
hydrocarbon material such as bitumen and cause the bitumen to flow down
towards a SAGD
producer. The SAGD injector 620 can include a plurality of SAGD injectors 620
such that the
steam 615a is distributed to each of the SAGD injectors 620 and a larger area
of the bituminous
deposit is subjected to steam injection. In instances where the steam 615a is
not sufficient to
supply one or more of the SAGD injectors 620, make up steam can be provided.
Steam 615b transported to the nozzle reactor 630 is injected into the nozzle
reactor 630 to
interact with a hydrocarbon stream 631 also injected into the nozzle reactor
630. The two
materials interact to crack and upgrade the hydrocarbon stream 631. In some
embodiments, the
nozzle reactor 630 is the nozzle reactor described above and illustrated in
Figure 3 and 4 such
that the steam 615b is injected into the nozzle reactor 630 in a direction
perpendicular to the
direction the hydrocarbon stream 631 is injected into the nozzle reactor. In
instances where
steam 615b does not provide a sufficient amount of steam for the nozzle
reactor 630, a make-up
steam stream can be provided to supplement steam 615b. The products leaving
the nozzle
reactor 630 can be re-used in the process, such as when the product stream
includes fuel gas,
water, and/or non-upgraded (or insufficiently upgraded) hydrocarbon. The fuel
gas and water
can be separated from the product stream and re-used in the combustor 610,
while the non-
upgraded hydrocarbon can be re-injected into the nozzle reactor 630.
As noted above, the SAGD injector 620 provides steam into a bituminous deposit
to
cause bitumen to flow down to a SAGD producer 640. The SAGD producer 640,
which may
actually be a plurality of SAGD producers, collects the softened bitumen and
transports it above
ground. The SAGD product 641 transported above ground by the SAGD producer can
include
heavy hydrocarbon material (such as bitumen), water, and fuel gas (such as
natural gas), along
with other components. Accordingly, a portion of the SAGD product 641 can be
transported to a
separation unit 650, where the components of the SAGD product 641 are
separated to be used in
the system.
Any separation unit 650 capable of separating a fuel stream 652 and a
hydrocarbon
stream 653 from the SAGD product 641 can be used, including various settling
and distillation
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CA 02787591 2012-08-23
apparatus. Once separated, the fuel stream 652 can be sent to the combustor
610 for use in steam
generation. The hydrocarbon stream 653 can be sent to the nozzle reactor 630
for upgrading.
Fuel stream make-up and/or hydrocarbon stream make-up can each be provided in
instances
where the separation unit 650 does not provide suitable amounts of either one
of these
components.
While the above described systems and methods generally reference use of a
single
nozzle reactor, multiple nozzle reactors can be used in the systems and
methods described herein.
The multiple nozzle reactors can be arranged in series, in parallel, or any
combination of the two.
Use of multiple nozzle reactors in series can generally help to increase the
conversion of heavy
hydrocarbon material into lighter hydrocarbon material, such as by separating
heavy
hydrocarbon exiting a first nozzle reactor and running it through a second
nozzle reactor located
downstream and whose operating conditions are adjusted to improve the
conversion of heavy
hydrocarbons. The use of multiple nozzle reactors in parallel can increase the
amount of
hydrocarbon material that can be processed and can mitigate issues relating to
scaling up nozzle
reactors to handle larger capacities.
In some embodiments of the systems and methods described herein, separation
processing is carried out on the products produced by the nozzle reactor. Such
separation
processing can be carried out on an offshore platform in embodiments where the
nozzle reactor
and/or combustor are located on an offshore platform. Any manner of separating
the
hydrocarbon product can be used. In some embodiments, cyclone separators are
used. Cyclone
separators can be useful due to their relatively small foot print. The
hydrocarbon products can be
separated into, for example, a lights, middle distillate, and residue stream.
The residue stream
may be recycled back into the nozzle reactor for further upgrading.
While the invention has been particularly shown and described with reference
to a
preferred embodiment thereof, it will be understood by those skilled in the
art that various other
changes in the form and details may be made without departing from the spirit
and scope of the
invention.
A presently preferred embodiment of the present invention and many of its
improvements
have been described with a degree of particularity. It should be understood
that this description
has been made by way of example, and that the invention is defined by the
scope of the
following claims.
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