Separators and mixers for delivering controlled-quality solar-generated steam over long distances, and associated systems and methods are disclosed. In particular embodiments, wet steam steam is separated into a vapor fraction flow (e.g., a dry steam flow) and a liquid fraction flow, each of which is directed to a target user (e.g., an enhanced oil recovery operation), where the flows can be re-combined prior to use.
As fossil fuels become more scarce, the energy industry has developed more sophisticated techniques for extracting fuels that were previously too difficult or expensive to extract. One such technique is to inject steam into an oil-bearing formation to free up and reduce the viscosity of the oil. Several techniques for steam injection presently exist, and are often referred to collectively as “Thermal Enhanced Oil Recovery,” or “Thermal EOR.” Representative steam injection techniques include cyclic, steamflood, steam-assisted gravity drainage (SAGD), and other strategies using vertical and/or horizontal injection wells, or a combination of such wells, along with continuous, variable-rate, and/or intermittent steam injection in each well.
One representative system for generating steam for steam injection is a fuel-fired boiler, having a once-through configuration or a recirculating configuration. Other steam generating systems include heat recovery steam generators, operating in a continuous mode. Thermal EOR operations often produce steam 24 hours per day, over a period ranging from many days to many years, which consumes a significant amount of fuel. Accordingly, another representative steam generator is a solar steam generator, which can augment or replace fuel-fired boilers. Solar steam generators can reduce fuel use, reduce operations costs, reduce air emissions, and/or increase oil production in thermal recovery projects. Solar steam generators, due to the necessarily large land area required for solar collectors, may be located at some distance from the point of use of the steam; as a result long interconnecting lines may be required. Solar steam generators necessarily deliver steam at varying flow rates as incoming sunshine varies. A challenge with such systems is that it can be difficult to maintain proper steam conditions in steam distribution lines in light of the varying output provided by the solar steam generator. Accordingly, there remains a need in the industry for systems and methods that reliably maintain steam conditions despite such variations.
The present technology is directed generally to separators and mixers for delivering controlled-quality solar-generated steam over long distances, and associated systems and methods. By definition, steam at less than 100% quality has a gas or vapor component and a liquid component. As used herein, “gas” and “vapor” are synonymous, and refer to the gaseous phase of a substance (e.g., water). At some (relatively higher) flow velocities, the liquid component is entrained as droplets within the flowing gas or vapor. At some (relatively lower) flow velocities, separation of the liquid and vapor fractions may occur. Separated liquid fractions are undesirable, as problems arise, including but not limited to, incorrect instrument readings and/or damage to the steam distribution system from “water hammer” as liquid fractions may flow as “slugs”. These problems may be particularly significant in conduits carrying steam over long distances, as pressure drop rises linearly with conduit length for a given conduit diameter and flow rate. To mitigate excessive pressure drop, a common design practice is to use steam lines of larger diameter, reducing flow velocity and associated pressure drop. Thus, for the same mass of steam, flow velocities are lower than they would be in a smaller diameter conduit. The lower flow velocity at low mass flow rates further increases the propensity for liquid-vapor separation.
In particular embodiments of the present technology, representative systems and methods include separating steam having a quality of less than 100% into a gas or vapor component (e.g., dry, non-superheated steam) and a liquid component. The vapor and liquid components are then separately directed to a target user, e.g., a power generation facility, an enhanced oil recovery facility, a process heat user and/or another suitable industrial facility. In one embodiment, the two flows are re-mixed or re-combined to obtain the proper steam quality, prior to use at the facility. The steam is then used for enhanced oil recovery, generating electrical power and/or other industrial processes. Because the separated vapor fraction contains few or no entrained liquid droplets, it is less likely to separate at low flow velocities. Low flow velocities often occur during solar steam generation, e.g., at the beginning and end of the day when the sun is low, and during periods of cloud cover. Accordingly, as will be described in further detail below, separating and re-mixing the vapor and liquid components can prevent damage to the steam distribution network and provide for a more reliable level of steam quality, despite the variations in the amount of steam produced by the solar steam generator.
Particular embodiments are described below in the context of steam generated for enhanced oil recovery operations. In other embodiments, the steam may be used for electrical power generation, process heat, and/or other uses. Many embodiments of the technology described below may take the form of computer- or controller-executable instructions, including routines executed by a programmable computer or controller. Those skilled in the relevant art will appreciate that the technology can be practiced on computer/controller systems other than those shown and described below. The technology can be embodied in a special-purpose computer, controller or data processor that is specifically programmed, configured or constructed to perform one or more of the computer-executable instructions described below. Accordingly, the terms “computer” and “controller” as generally used herein refer to any data processor and can include Internet appliances and hand-held devices (including palm-top computers, wearable computers, cellular or mobile phones, multi-processor systems, processor-based or programmable consumer electronics, network computers, mini computers and the like). Information handled by these computers can be presented at any suitable display medium, including a CRT display or LCD.
The technology can also be practiced in distributed environments, where tasks or modules are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules or subroutines may be located in local and remote memory storage devices. Aspects of the technology described below may be stored or distributed on computer-readable media, including magnetic or optically readable or removable computer disks, as well as distributed electronically over networks. Data structures and transmissions of data particular to aspects of the technology are also encompassed within the scope of the embodiments of the present technology.
The rate at which steam is produced by the solar field 110 is variable, e.g., due to variations in solar insolation that occur naturally over the course of a 24 hour period. Solar insolation is typically measured as Direct Normal Irradiance (DNI) and varies from zero (at night) to a peak value (typically at or around noon). Solar insolation also varies as a function of cloud cover, weather patterns, and season (e.g., due to the changing angle of inclination of the earth's axis relative to the sun). As a result of the foregoing variations, the system 100a can include an additional steam source 171 to supplement the steam provided by the solar field 110. In a representative embodiment, the additional steam source 171 can include a fuel-fired steam generator that burns hydrocarbon fuel (e.g., natural gas) to supplement the steam provided by the solar field 110. A header 161 allows steam from the solar field 110 and/or the additional steam source 171 to be directed to the target user 170.
In at least some embodiments, the solar field 110 can be positioned a significant distance L from the target user 170. For example, in some embodiments, L can range from hundreds of meters to multiple kilometers. In particular embodiments, L can have values of 100 meters, 200 meters, 500 meters, 1000 meters, 2000 meters, or more, depending, for example on the nature of the target user. For example, when the target user includes an oil field, L can have values toward the higher end of those listed above, so that the solar field does not interfere with the ability to place oil extraction wells and/or steam injection wells where they are expected to produce significant oil output. These long distances can present challenges to transporting steam without excessive loss of pressure or heat while maintaining mixed gas-liquid flow. In particular, the steam conduit 118 may require insulation to prevent the steam from cooling significantly over the distance L. Also, the steam conduit 118 may be required to be of a relatively larger diameter (to reduce the flow velocity and accompanying pressure drop per unit distance), than would be used for a shorter steam transport distance. Maintaining proper steam characteristics—mixed gas/liquid flow—within the steam line becomes challenging due to variations in the steam flow rate. For example, the diameter of the steam conduit 118 may be selected to carry the peak flow rate of steam at a target steam quality level (e.g., 80%) at a low enough velocity to reduce pressure drop in the conduit. However, when the steam flow rate is below the peak value (e.g., as the solar field is starting up after sunrise, shutting down toward sunset and/or when cloud cover reduces solar insolation), the velocity of the steam within the steam conduit 118 drops. As the velocity drops, moisture in the steam is more likely to condense and precipitate, creating a two-phase flow. The two-phase flow will typically include slowly moving liquid phase and more rapidly moving gas phase passing over the liquid water. Waves and liquid slugs commonly form at the interface between the gas phase and the liquid phase, and, as such waves build in amplitude, can produce hammer shocks and/or other effects that not only further reduce the uniformity of the flow, but can also cause significant damage to the steam conduit 118 and/or associated equipment.
An additional drawback associated with sizing the steam conduit 118 to handle the maximum flow rate of steam at the target steam quality is that, in at least some embodiments, the conduit can become quite large. For example, in some embodiments, the conduit can exceed 16 inches in diameter. At such diameters, the cost of the conduit itself, and the cost of welding sections of the conduit together can increase dramatically, thereby reducing the cost effectiveness of solar generated steam.
One approach to addressing the foregoing potential drawbacks is illustrated in
One potential drawback with the arrangement described above with reference to
In other embodiments, the two flows are not mixed. For example, only the vapor fraction may be put to a revenue-generating use (e.g., power generation or enhanced oil recovery) at the target user 170, while the liquid fraction is disposed of. It may nevertheless be advantageous to transport the liquid fraction to the target user 170 for disposal because the user may have other steam generation sources that also produce a liquid fraction that is to be disposed of. For example, the target user 170 may have a fossil-fuel-fired boiler that produces a vapor flow and a liquid flow. By transporting the liquid fraction produced by solar energy to the target user 170, the two liquid flows can be consolidated for disposal, thereby avoiding the need for two separate liquid disposal processes (one at the solar field and another at the user).
An advantage of the arrangement shown in
Beginning with
An outlet header 116 collects steam (e.g., wet steam) from each solar field 110 and delivers the steam to the separator 130, as indicated by arrow B. A vapor fraction (e.g., dry steam is directed from the separator to the vapor fraction conduit 131, as indicated by arrow C, and a liquid fraction (removed from the wet steam at the separator 130) is delivered to the liquid fraction conduit 132, as indicated by arrow D. A first valve 241a controls the flow of steam into the separator 130, a second valve 241b controls the return of water to the working fluid supply 119, a third valve 241c controls the flow of vapor in the vapor fraction conduit 131, a fourth valve 241d controls the flow of liquid in the liquid fraction conduit 132, and a fifth valve 241e controls the return of the liquid from the liquid fraction conduit 132 to the working fluid supply 119 or to a system exit. Further details of the operation of the foregoing valves are described later.
The system 200 can also include one or more sensors 250 distributed at various points throughout the fluid flow network. Representative sensors include a temperature sensor 251, a pressure sensor 252, and a flow rate sensor 253. In other embodiments, the sensors 250 can be of other suitable types to perform other suitable functions. In any of these embodiments, the sensors 250 (and/or other data sources) provide inputs 181 to a controller 180. The controller 180 processes the inputs 181 and issues outputs 182 for controlling any of a variety of suitable aspects of the operation of the system 200. Such aspects can include instructions for controlling the valves described above.
One feature of an embodiment shown in
Two related parameters that can be important for maintaining the target steam characteristics (including the mixing of phases) are steam flow velocity and turbulence level. In particular, directing the wet steam to flow at a high velocity, and a high turbulence level can improve steam uniformity characteristics. To facilitate this approach, the system 200 can include a second header 162 and a third header 163 disposed between the mixer 160 and a first header 161. Multiple parallel lines 165 (identified as lines 165(1), 165(2), . . . 165(n)) extend between the second header 162 and the third header 163, with each line individually controlled by a corresponding line valve 145(1), 145(2) . . . 145(n). An additional line 166 can remain open at all times. The individual lines 165 can be selectively opened or closed by actuating the corresponding valves 145 as the wet steam flow increases or decreases. This approach can be used to maintain a high flow velocity and high level of turbulence between the mixer 160 and the first header 161, so as to prevent or at least restrict the likelihood for the flow to separate into a two-phase flow. Because the lines 165 are short and are generally co-located near the target user 170, the problem of heat loss associated with long parallel lines (described above with reference to
The vapor fraction conduit 131 and/or the liquid fraction conduit 132 can include a bypass line and corresponding valves. For example, the vapor fraction conduit 131 can include a main vapor fraction valve 242a, a vapor fraction bypass line 234, and an associated vapor fraction bypass valve 242b. The liquid fraction conduit 132 can include a main liquid fraction valve 243a, a liquid fraction bypass line 235, and an associated conduit bypass valve 243b. During overall system startup operations, the bypass valves 242b, 243b are opened and the bypass lines 234, 235 route flow around the main valves 242a, 243a. During normal day and nighttime operation, described further below, the main valves 242a, 243a remain open.
The typically daily operation of the overall system 200 is described further below with reference to
At the end of the day, the liquid fraction conduit 132 can be drained so as to avoid starting up the next morning with a large mass of cold water. In particular, the water in the liquid fraction line 132 can be directed from the liquid fraction conduit 132 through the fifth valve 241e where it is either dumped, or directed through the second valve 241b into the working fluid supply 119. Removing the water from the liquid fraction conduit 132 eliminates the need to keep the water warm overnight. Instead, steam from the additional steam source 171 can be directed backward through the liquid fraction conduit 132 at night to keep it warm, e.g., in generally the same manner discussed above for the vapor fraction line 131.
As operation begins the following morning, water is initially directed from the working fluid supply 119 through the solar fields 110, and back to the solar fields 110 via the first and second valves 241a, 241b until the target steam quality is achieved. As the solar fields 110 increase in temperature, the controller 180 can fill the liquid fraction conduit 132 with hot water so that an ample supply of hot water is available for remixing at the mixer 160 when vapor begins flowing through the vapor fraction conduit 131. Accordingly, the liquid fraction conduit 132 can have a relatively small diameter to reduce the amount of time required to fill it with hot water during the daily startup process. Another approach, which can be used in addition to or in lieu of the small diameter liquid fraction line, is to begin directing wet steam to the separator 130 well before the target steam quality to be delivered to the target user 170 is achieved. For example, if the target steam quality for the target user 170 is 80%, the process can include directing steam to the separator when the quality is only 50%. The resulting high liquid fraction flow (due to the low quality of steam entering the separator 130) will quickly fill the liquid fraction line 132. As the quality of the steam produced at the solar fields increases, the first valve 241a directs (or continues to direct) steam to the separator 130. The separator 130 directs vapor through the vapor fraction conduit 131, and liquid fraction through the liquid fraction conduit 132. The mixer 160 then re-mixes the separate phases for delivery to the target user 170.
One feature of at least some of the embodiments described above with reference to
From the foregoing, it will be appreciated that specific embodiments of the disclosed technology have been described herein for purposes of illustration, but that various modifications may be made without deviating from the technology. For example, the solar fields described above are illustrated schematically as including trough-shaped, mirror-based solar concentrators. In other embodiments, the solar collection systems can include other types of solar collectors, including, but not limited to, point-source collectors, power-tower arrangements, dish-shaped collectors, and/or linear Fresnel collectors. Particular embodiments of the systems described above were described in the context of water as a working fluid. In other embodiments, the systems can operate in a generally similar manner using a different working fluid (e.g., a molten salt) that exchanges heat with water to create steam.
Certain aspects of the technology described in the context of particular embodiments may be combined or eliminated in other embodiments. For example, the degree to which the overall operation of the systems described above as automated can vary from one embodiment to another. Furthermore, particular embodiments of the disclosed technology were described in the context of solar EOR operations. In other embodiments, the same or generally similar technology can be applied to other types of operations that use solar-generated steam. Representative operations include electrical power generation and facility heating.
Still further, while advantages associated with certain embodiments of the disclosed technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the present technology. Accordingly, the present disclosure and associated technology can encompass other embodiments not expressly shown or described herein.
To the extent any materials incorporated herein by reference conflict with the present disclosure, the present disclosure controls.
The present application claims priority to U.S. Provisional Application No. 62/289,644, filed on Feb. 1, 2016 and incorporated herein by reference in its entirety.
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20170219203 A1 | Aug 2017 | US |
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