# Patent

## Title
Apparatus, system, and method for controlling combustion gas output in direct steam generation for oil recovery

## Abstract

An apparatus, system, and method for controlling combustion gas output in direct steam generation for oil recovery. A direct combustion steam generator burns a fuel and an oxygen-containing gas mixture to produce combustion products including steam, CO2 and N2. Supplemental oxygen is separately supplied to the combustion steam generator to adjust the oxygen content of the oxygen-containing gas mixture during the combustion process in order to adjust the ratio of CO2 to N2 produced in the combustion products.

## Background
CLAIM OF BENEFIT TO PRIOR APPLICATION
This application claims priority to Canadian Patent Application No. 2,853,115, filed May 29, 2014, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
Embodiments of the invention relate to apparatus, systems, and methods preferably for steam assisted oil recovery, but also for pre-cast concrete curing. In particular, the embodiments relate to methods and systems for generating an adjustably-variable gaseous stream containing steam and non-condensable gases in various proportions, for co-injection into a reservoir to enhance oil recovery, or to assist in concrete curing.
BACKGROUND OF THE INVENTION
Numerous steam assisted recovery processes are known for recovering bitumen from underground formation including Cyclic Steam Stimulation (CSS) and Steam Assisted Gravity Drainage (SAGD). Essentially, these steam-related processes involve the application of steam (i.e. heat) to a hydrocarbon-containing reservoir to reduce the viscosity of oil and/or bitumen therein and enhance its ability to flow. For example, during SAGD operations, steam introduced into a reservoir through a horizontal injector well transfers heat to the heavy oil upon condensation. The heavy oil with reduced viscosity due to this heating drains together with steam condensate and is recovered via a producer well disposed parallel and beneath the injector well.
Various techniques can provide for steam generation but the costs related to steam generation can often limit the economic feasibility of such techniques. Given the quantity of steam required for many of these steam-related processes, energy needed to generate the necessary heat for the steam generation represents a substantial cost. In addition, the associated environmental costs, including generation of greenhouse gases, can present severe limitations. In particular, the production of CO2 emissions that contribute to greenhouse gas as well consumption of fresh water for the steam generation are parameters in existing steam generation techniques that need to be reduced to the maximum extent possible.
Direct combustion steam generation may facilitate lowering these costs due to improvements in efficiency, inherent makeup water replacement, and reduced emissions. Direct steam generation operates by burning a fuel in a combustor and preferably injecting water into the combustor to produce a mixture of generated steam and the combustion products from the steam generator for injection into a hydrocarbon-containing reservoir.
U.S. Pat. No. 8,353,342 describes a direct steam generation method and apparatus that includes both generating steam for injection into a wellbore and capturing CO2 produced during steam generation in order to control CO2 emissions. Specifically, a method of steam assisted recovery of oil is described that includes first reforming natural gas to produce CO2 and hydrogen, followed by separating the CO2 from the hydrogen. Oxygen is also separated from other air components. Steam is then generated by introducing the separated hydrogen and oxygen into a combustion area where the hydrogen and the oxygen are ignited then contacted with water in the combustion area. The steam that is produced is injected into an injection well and includes products from combustion of the hydrogen and the oxygen as well as the water vaporized by heat from the combustion. According to the described method, therefore, produced CO2 is captured by sequestering the CO2 independent of injecting the steam into the injection well.
More recently, the benefit of co-injecting the produced CO2 with steam in direct steam generation techniques for oil recovery has been considered. In particular, the combustion gases, including CO2 which may be miscible in the oil and further serve to reduce its viscosity by swelling of the oil through gas solubility, introduce additional recovery mechanisms to the viscosity reduction associated with the injection of steam alone. Still further additional recovery mechanisms include: increased reservoir pressure, and movement of oil via reduced viscous drag. Furthermore, the injection of combustion gases downhole can address the emissions issues that arise with conventional surface steam generators.
Importantly, however, while co-injecting CO2 with steam may benefit steam-assisted oil recovery operations by lowering the steam to oil ratio, for example, the desired concentrations of the CO2 within the steam to achieve such benefits for any particular steam-related oil production process may not, however, coincide with output from the direct steam generation.
International Patent Publication No. WO2007/081816 describes a direct combustion steam generator in which water is introduced into a vortex sustaining container and flows through the container in a spiraling manner to create a liquid vortex. The swirling water surrounds the flame and combustion is carried out inside the rotating body of water. The combustion product is achieved by supplying fuel and tangentially supplying an oxygen containing gas to a burner to produce the flame. Combustion is carried out using air enriched with oxygen at varying concentrations (or even pure oxygen) in order to provide a vapor stream consisting of steam and the desired level of CO2. The hydrocyclone design of the generator is described as being capable of withstanding the flame temperatures encountered with combustion of fuel with oxygen or enriched air.
United States Patent Publication No. 2014/0060825 discloses the ability to control CO2 levels in the output mixture of steam and CO2, by controlling the temperature of the water fed to the steam generator. Specifically, a method of generating a mixture of steam and CO2 is described as including supplying fuel and oxygen into a direct steam generator in addition to water that is heated to above 200° C. Combusting the fuel and oxygen in the direct steam generator as the preheated water is introduced, produces a mixture of steam and combustion products that has a CO2 level in mass percent of steam below 11 percent.
A need continues to exist in the oil recovery industry for improved methods and systems for generating steam and non-condensable gases, such as CO2 mixtures, for best optimized recovery of heavy oil and bitumens from hydrocarbon-containing reservoirs which allows for optimal (and continuous) control of CO2, steam, and nitrogen by a reservoir engineer when same injected downhole to best produce oil from a particular well within a unique formation of specific viscosity, ambient temperature, porosity, permeability, and pressure, over time.
The above background information is provided for the purpose of making known information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present invention.
SUMMARY OF THE INVENTION
An object of the present disclosure is to provide an apparatus, system, and method for controlling combustion gas output in direct steam generation for oil recovery, or alternatively for steam concrete curing.
In accordance with one aspect, the invention relates to a direct combustion steam generator comprising: (a) a combustion container comprising an inner wall defining a combustion chamber, the combustion container having a first end comprising a burner for producing a flame within the combustion chamber for carrying out combustion of a fuel and an oxygen-containing gas mixture to produce combustion products comprising steam, CO2, and N2, and a second end comprising an outlet through which the combustion products exit from the combustion chamber; (b) at least one fuel inlet at the first end of the combustion container, the fuel inlet located proximate the burner and configured to deliver the fuel to the burner at a delivery pressure exceeding atmospheric pressure; (c) at least one air inlet at the first end of the combustion container, the air inlet located proximate the burner and configured to deliver air to the burner at a delivery pressure exceeding atmospheric pressure, wherein the air contributes to the oxygen-containing gas mixture; and (d) at least one oxygen inlet at the first end of the combustion container, the oxygen inlet located proximate the burner and configured to deliver a supply of supplemental oxygen to the burner at a delivery pressure exceeding atmospheric pressure, wherein the supplemental oxygen is supplied to the burner to adjust the oxygen content of the oxygen-containing gas mixture, whereby the composition of the combustion products produced in the combustion chamber will accordingly be adjusted to thereby provide various ratios and amounts of nitrogen relative to the amounts of CO2. Specifically the composition of exhaust gas adapted to be generated may advantageously range using the apparatus of the present invention from 0% nitrogen being produced and 88% of the exhaust from the generator being CO2 and 12% steam (where a stochiometric quantity of pure oxygen is provided), to a situation where only air is provided but in quantities of air to supply a stochiometric supply of oxygen, and an exhaust gases being generated in such circumstances which are then 71.8% nitrogen, 18% CO2, and 9.9% steam.
In another broad aspect of the invention the invention comprises direct combustion steam generator adapted to burn a hydrocarbon fuel therein in which a byproduct of such combustion is water in the form of steam, comprising:

    
    
        (a) a combustion container comprising an inner wall defining a combustion chamber, the combustion container having a first end comprising a burner for producing a flame within the combustion chamber for carrying out combustion of a fuel and an oxygen-containing gas mixture to produce combustion products comprising at least steam, CO2, and at desired times N2, and a second end comprising an effluent outlet through which the combustion products exit from the combustion chamber in an effluent stream;
        (b) at least one fuel inlet at the first end of the combustion container, the fuel inlet located proximate the burner and configured to deliver the fuel to the burner at a delivery pressure exceeding atmospheric pressure;
        (c) at least one air inlet at the first end of the combustion container, the air inlet located proximate the burner and configured to deliver air to the burner at a delivery pressure exceeding atmospheric pressure; (d) at least one supplemental oxygen inlet at the first end of the combustion container, the supplemental oxygen inlet located proximate the burner and configured to deliver a supply of supplemental oxygen having a percentage of nitrogen therein less than air and comprising up to 100% pure oxygen to the burner, wherein the supplemental oxygen contributes to or comprises the oxygen-containing mixture;
        (e) a flow regulator means for adjusting a rate of flow of air through the at least one air inlet relative to a rate of flow of said supplemental oxygen through said at least one oxygen inlet, to thereby adjust an amount of oxygen in said oxygen-containing gas mixture being supplied to said burner; an air flow control valve which regulates flow and quantum of air supplied to said combustion container via said at least one air inlet;
        wherein a proportion or amount of said one or more combustion products produced in the combustion chamber which form said effluent stream is adjustable by use of said flow regulator means.
    
    


Advantageously, a well operator who is controlling a well that is using gases generated by the steam generator of the present invention may adjust the ratio to provide up to 88% CO2 and 18% steam to reduce viscosity of oil in the formation. Also advantageously, where less CO2 but greater amounts of inert pressurizing gas are required, by using the steam generator device of the present invention allows altering the exhaust gas make-up, by providing only air to the steam generator device which in such circumstances will then allow the provision of exhaust gases comprising up to 71.8% N2 when pressurization of the formation for a time is required for a time to optimize output as opposed to reducing viscosity of oil in such formation.
Likewise advantageously, where the exhaust gases of the steam generator of the present invention are alternatively desired for steam curing of concrete (which is useful in cold climates), the generator of the present invention can be used to promote carbon dioxide (CO2) and steam concrete curing.
In this regard, concrete strength increases with age as long as moisture (saturated steam), CO2, and heat are present for hydration of cement. Two distinct types of concrete carbonation are used:
(a) natural weathering carbonation, which is relevant to mature concrete over an extended period of time when it is exposed to the atmosphere, and
(b) steam and carbon dioxide (CO2) carbonation, which increases carbon dioxide (CO2) by Oxygen (O2) addition, promotes early age carbonation, which involves fresh concrete at very early ages (starting as early as immediately after mixing and ending prior to, or in line with, the conclusion of accelerated curing, as much as 48 hours later).
Accordingly, using a steam generator of the present type allows adjustment of the exhaust gases to maximize CO2 production thereof by injecting pure O2 without injecting air, so as to with the approximately 88% CO2 and high carbonization thereby:

    
    
        (1) increase in masonry plant productivity, thereby saving time and total cost of concrete blocks;
        (2) reduction of dimensional movement and water absorption,
        (3) reduction in the release of combustion emissions,
        (4) improve compressive strength of the concrete; and
        (5) obtain an energy savings, where the exhaust gas generating device of the present invention utilizes natural gas or propane as a fuel source.
    
    


In accordance with another aspect of the present invention, the present invention relates to a direct combustion steam generator comprising: (a) a combustion container comprising an inner wall defining a combustion chamber, the combustion container having a first end comprising a burner for producing a flame within the combustion chamber for carrying out combustion of a fuel and an oxygen-containing gas mixture to produce combustion products comprising steam, CO2, and N2, and a second end comprising an outlet through which the combustion products exit from the combustion chamber; (b) at least one fuel inlet at the first end of the combustion container, the fuel inlet located proximate the burner and configured to deliver the fuel to the burner at a delivery pressure exceeding atmospheric pressure; (c) at least one air inlet at the first end of the combustion container, the air inlet located proximate the burner and configured to deliver air to the burner at a delivery pressure exceeding atmospheric pressure, wherein the air contributes to the oxygen-containing gas mixture; (d) at least one oxygen inlet at the first end of the combustion container, the oxygen inlet located proximate the burner and configured to deliver a supply of supplemental oxygen to the burner at a delivery pressure exceeding atmospheric pressure, wherein the supplemental oxygen is supplied to the burner to adjust the oxygen content of the oxygen-containing gas mixture, whereby the composition of the combustion products produced in the combustion chamber can be adjusted; and (e) at least one water inlet operatively connected to the combustion chamber and configured to deliver a supply of water onto the inner wall of the combustion chamber to cool the temperature of the combustion chamber and to adjust the quality of the steam generated by the combustion.
In accordance with a further aspect, there is described a system for steam assisted oil recovery in a hydrocarbon-containing reservoir, comprising the direct combustion steam generator according to embodiments of the present disclosure, the steam generator configured to produce combustion products from a supply of fuel, air, supplemental oxygen, and water, wherein the steam generator is coupled to convey the combustion products into an injection well in the reservoir, and wherein the composition of the combustion products is controllably adjusted in response to the conditions of the reservoir by altering the supply of the supplemental oxygen.
In accordance with another aspect, there is described a method of steam assisted oil recovery from a hydrocarbon-containing reservoir, comprising: (a) providing the direct combustion steam generator according to embodiments of the present disclosure; (b) delivering a fuel and an oxygen-containing gas mixture to the combustion steam generator at a pressure exceeding atmospheric pressure, wherein the oxygen-containing gas mixture can be provided by a supply of air delivered to the combustion steam generator; (c) delivering a supply of supplemental oxygen to the combustion steam generator at a delivery pressure exceeding atmospheric pressure, wherein the supplemental oxygen is supplied to the combustion steam generator to adjust the oxygen content of the oxygen-containing gas mixture; (d) burning the fuel and the oxygen-containing gas mixture in the direct combustion steam generator to generate combustion products comprising steam, CO2, and N2; and (e) injecting the combustion products into an injection well; wherein the ratio of CO2 to N2 produced in the combustion products can be adjusted by adjusting the supply of supplemental oxygen delivered to the combustion steam generator.
Advantages of an above combustor and method for enhanced oil recovery include, but are not limited to:

    
    
        1) Because the burner can operate on oxygen or air or any ratio of the two, it gives the petroleum engineer a new set of tools to control and optimize recovery from oil field formations using SAGD-type recovery processes;
        2) Because all products of combustion go down the SAGD well in accordance with the method of the present invention, the burner produces no atmospheric CO2,
        3) No heat is lost to the atmosphere as with a normal boiler where heat goes up the stack;
        4) No atmospheric NOx's are produced because all components go down the SAGD well; and
        5) Should heavy oil be used as a fuel no SO2 will go into the atmosphere because all exhaust components go into the SAGD well.
    
    





BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the invention will become more apparent in the following detailed description in which reference is made to the appended drawings.
FIG. 1 is a schematic representation of a direct combustion steam generator for controlling combustion gas output in direct steam generation, according to embodiments of the present disclosure;
FIG. 2 is a cross-sectional view of the direct combustion steam generator represented in FIG. 1, according to embodiments of the present disclosure;
FIG. 3 is a schematic of the direct combustion steam generator illustrated in FIG. 1, applied to vertical well steam flood type enhanced oil recovery (EOR), according to embodiments of the present disclosure;
FIG. 4 is a schematic of the direct combustion steam generator illustrated in FIG. 1, applied to horizontal well SAGD enhanced oil recovery (EOR), according to embodiments of the present disclosure; and
FIG. 5 shows, in terms of control of the supply of air relative to the supply of pure or substantially pure oxygen, the relationship necessary to maintain stoichiometric (complete) combustion, and in particular the relationship between such two parameters followed in the Examples.



DETAILED DESCRIPTION OF THE INVENTION
Definitions
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
As used herein, the term “hydrocarbon-containing reservoir”, refers to subterranean formations that are explored and exploited for hydrocarbon resources through drilling and extraction techniques.
As used herein, the term “about” refers to an approximately +/−10% variation from a given value. It is to be understood that such a variation is always included in any given value provided herein, whether or not it is specifically referred to.
Steam injected into a hydrocarbon-containing reservoir facilitates heavy oil and bitumen flow in two ways—reducing its viscosity by heating it, and increasing the pressure in the reservoir to help it flow. As the steam cools, however, it condenses back to a liquid state which results in a decline in pressure and inefficiency in production. Co-injection of a non-condensable gas with the steam can further enhance the oil recovery and compensate for this decline. For example, injected nitrogen (N2) gas can expand in the reservoir to create increased pressure that pushes or drives oil to a production wellbore. Other gases, such as CO2, are miscible in the oil i.e., dissolve in the oil, to further lower the viscosity of the oil and improve its flow rate.
The combustion products derived from direct steam generation techniques can include N2 and/or CO2 depending on the burner oxidant used with the fuel. When fuels are burned with air, N2 forms part of the combustion product mixture, as illustrated by the exemplary equation using methane as the example fuel:

CH4+2O2+8N2→CO2+2H2O+8N2 

When combustion is carried out in pure oxygen (i.e. no air and thus absence of nitrogen), only CO2 and H2O are produced and provided to the effluent combustion stream, as illustrated by the below formula:

CH4+2O2→CO2+2H2O.

The ratio of CO2 to N2 in the combustion products is controlled in the present invention by controlling the amount of pure oxygen in relation to the air input into the direct steam generator for combustion with the fuel. Typically, the required level of oxygen is provided as air, pure oxygen, or air with a pre-determined level of oxygen enrichment.
In the prior art, there was little ability to adjust the ratio of CO2 to N2 within the produced combustion products, as the ratio of N2 to O2 in air is typically a fixed ratio of about 3.25:1, with normal air comprising 75.5% nitrogen gas (by weight) and 23.2% oxygen gas (by weight), namely a ratio of 3.25:1. Thus to maintain complete combustion (ie supply oxygen gas to the fuel in required stoichiometric relation) associated quantity of nitrogen was supplied to the steam generator in a fixed ratio. Thus any steam generation units having only air supply were not amenable to allow adjustment of the ratio of produced CO2 to N2 during enhanced oil recovery (EOR), and thus had no ability to optimize and vary, for a given well and given formation conditions, the amount of viscosity reduction (via CO2 injection) in relation to the amount of pressure increase provided by the injection of N2.
More particularly, the phase behavior of the combustion gas mixtures and the heavy oil are strongly dependent on reservoir conditions such as temperature, pressure, and heavy oil composition. For example, in high pressure applications with lighter oils, CO2 is miscible with the oil, with resultant swelling of the oil, and reduction in viscosity, and possibly also with a reduction in the surface tension with the reservoir rock. In the case of low pressure reservoirs or heavy oils, CO2 will form an immiscible fluid, or will only partially mix with the oil. Some oil swelling may occur, and oil viscosity can still be significantly reduced. The ability to adjust the ratio of CO2 to N2 in response to the changing conditions of the reservoir can, therefore, be beneficial to the efficiency of EOR (enhanced oil recovery).
In prior art methods, the manner of regulating the amount of CO2 to N2 injected in a formation has typically been through injection of either through a separate injector well. Drilling of a separate feeder well for injection of either of such gases was and is an expensive proposition, and an inexpensive and inefficient method to alter the proportion of CO2 to N2 being supplied to a formation.
The embodiments of the present disclosure provide a system and method for controlling the combustion gas output in combination with steam generation and combined injection, which control simultaneously allows for not only injection of steam and CO2 to reduce viscosity of the oil but further allows for real-time adjustment of the ratio of CO2 to N2 ratio in response to the unique and sometimes changing pressure, temperature, viscosity, permeability, and porosity conditions of the reservoir.
An embodiment of the present disclosure will now be described by reference to FIGS. 1 and 2, which show a schematic representation of a direct combustion steam generator of the present disclosure.
Referring to FIGS. 1 and 2, a steam generator 1 of the present disclosure comprises a combustion container 10 having an inner wall defining a combustion chamber 15. The combustion container 10 includes a burner (not shown) for producing a flame 270 within the combustion chamber 15 for carrying out combustion of a fuel and an oxygen-containing gas mixture to produce combustion products that comprise steam, CO2, and N2. The combustion products exit the combustion chamber 15 through an outlet 50 at the opposite end of the combustion container 10 for injection into a hydrocarbon-containing reservoir, for example.
Controlling Combustion Gas Output in Direct Steam Generation—Real-Time Oxygen Enrichment
As discussed, when fuels are burned with air, only about 21% of the air, that is oxygen, is consumed in the combustion reaction, leaving about 79% of the air to remain as mostly inert N2 (by volume). When combustion is carried out in pure oxygen, on the other hand, only CO2 and H2O is the resulting combustion product. The ratio of CO2 to N2 in the combustion products can thus be controlled by the amount of oxygen input in relation to air which is input into the combustor for combustion with the fuel, which when water is further injected produces an effluent stream containing saturated or superheated steam and CO2, with the amount of N2 gas being variable for optimized control of pressurization of the formation in relation to CO2 being injected.
As illustrated in FIGS. 1 and 2, the fuel and oxygen-containing gas enter the combustion container 10 and mix in a combustion area of the burner for the steam generator 1 and are ignited. Fuel is supplied through at least one fuel inlet 90 proximate the burner and configured to deliver the fuel to the burner at a delivery pressure exceeding atmospheric pressure. According to embodiments of the present disclosure, the fuel can be any hydrocarbon-containing mixture, for example heavy oil, methane, propane, natural gas liquids, and/or naphtha. In certain embodiments, the fuel supply is pressurized through a compressor.
The composition of the oxygen-containing gas that combusts with the fuel will depend on the particular reservoir conditions and the desired levels of CO2 and N2 required for EOR. According to embodiments of the present disclosure, the steam generator 1 comprises at least one air inlet 100 proximate the burner and configured to deliver air to the burner at a delivery pressure exceeding atmospheric pressure. In certain embodiments, the air supply is pressurized through a compressor. According to embodiments of the present disclosure, as shown in FIG. 1, the fuel inlet 90 is fluidly connected to the air inlet 100 to deliver a mixture of fuel and air to the burner.
The steam generator 1 further comprises at least one oxygen inlet 80 located proximate the burner and configured to separately deliver a supply of supplemental oxygen to the burner at a delivery pressure exceeding atmospheric pressure. As shown in FIGS. 1 and 2, the supplemental oxygen inlet 80 is configured to supply supplemental O2 to the burner after the fuel and air is injected into the burner. In this way, the supplemental oxygen can be controllably added throughout any particular combustion process to adjust the oxygen content of the oxygen-containing gas mixture as needed. Moreover, the supplemental O2 can be added in response to the changing conditions of the reservoir. The addition of supplemental O2 can, therefore, be controlled and added to a combustion process in real-time to adjust the composition of the combustion products produced.
The O2 delivered through the oxygen inlet 80 can be supplied from commercial containers, or by pipeline, or in situations where feasible, can be prepared by a physically adjacent air separation unit. According to such embodiments, air enters an air separation unit to separate out O2 from other components of the air and to provide a compressed supply of O2 for delivery through the supplemental oxygen inlet 80. Air separation can be carried out by any number of techniques known in the art, for example, by cryogenic fractional distillation or by O2 pressure swing adsorption (PSA).
According to embodiments of the present disclosure, as shown in FIG. 1, the air inlet 100, fuel inlet 90, and oxygen inlet 80 each comprise a control means to control the fluid flow into the burner. The control means can include, for example, any combination of a control valve 110, 140, 170, a flow meter 120, 150, 180, and/or a check valve 130, 160, 190. According to certain embodiments, each control means can be controlled by a programmable controller.
By offering the ability to control the combustion gas output, the steam generator 1 of the present disclosure allows supplemental O2 to be added to the fuel at various concentrations. In certain embodiments, it may be desirable to input air as the oxygen-containing gas. In such embodiments, supplemental O2 is not input into the steam generator 1. In further embodiments, it may be desirable to input pure O2 as the oxygen-containing gas. In such embodiments, air is not input into the steam generator 1. The desired O2 content of the oxygen-containing gas can be determined at the discretion of the operator of any given EOR operation.
In certain embodiments, supplemental O2 can be added in relation to the quantum of air supplied to increase the CO2 content in the effluent stream, under stoichiometric conditions (where no supplemental H2O is added for steam generation) from a minimum of  ̃20% (by weight) with no supplemental oxygen added and only air being supplied, to a maximum of  ̃65% (by weight) with substantially pure oxygen and no air being supplied, where for example propane is used as the fuel.
Similarly and correspondingly, the ratio of air to supplemental O2 added to the fuel can be controlled to reduce the N2 content of the combustion gas output to anywhere from  ̃72% N2 (by weight, using a weight ratio of 75.47 nitrogen/23.2 oxygen, with no supplemental O2 being supplied) to 0% N2. For example, by supplying 33.3% (by weight) pure oxygen and 66.6% (by weight) air to the combustor, the N2 content of the resultant combustion gas (where for example propane is the fuel utilized) can be reduced from 72% to 63% (by weight) while the CO2 quantum in the effluent is correspondingly increased from 18% to about 24% (by weight) (when no water is added to the combustor to produce additional steam.
Direct Steam Generation—Steam Quality Adjustment
As shown in FIGS. 1 and 2, the direct combustion steam generator 1, further comprises at least one water inlet 60 operatively connected to the combustion chamber 15 and configured to deliver a supply of water 70. According to certain embodiments, the water inlet 60 is configured to deliver the water through an inner annulus 5 formed with the inner wall about the circumference of the combustion container 10. The water enters the bottom end of the annulus to cool the inner wall of the combustion chamber 15 and spray over the top of the inner annulus 5 in direct contact and fluid communication with the combustion area of the flame. In this way, the temperature of the combustion chamber 15 as well as the steam output temperature can be managed.
Transfer of heat from the flame to the water introduced through the water supply 70 into the steam generator 1 vaporizes the water into steam. Further, combustion of the fuel and the oxygen-containing gas also generates vaporized water. Thus, quantity of the steam made exceeds quantity of water input into the steam generator 1 since the steam includes vaporized water resulting from combustion of the fuel and the oxygen-containing gas mixed with the water inputted and heated. The quantity of the steam made and output through the outlet 50, therefore, exceeds the quantity of water input into the steam generator 1 from the water supply 70. For example, flow rate of water (steam) output may be between about 20% and 25% greater than flow rate of water input through the water supply 70. According to some embodiments, this increase in water may be sufficient to enable net water production within the steam generator 1 such that the steam generator 1 is self contained for water needs.
According to certain embodiments, the water inlet 60 includes control means to control the water flow into the combustion chamber 15. The control means can include, for example, any combination of a control valve 200, a flow meter 210, and/or a check valve 220. According to certain embodiments, each control means can be controlled by a programmable controller.
Steam production, therefore, can be subjected to quality adjustment. For example, the amount of water input into the combustion process can be controlled according to the embodiments described. In other embodiments, for example, the water may be preheated. In this way, the properties of the generated steam can be adjusted to the particular requirements of a given hydrocarbon-containing reservoir.
Direct Combustion Steam Generation Process for Enhanced Oil Recovery
As illustrated in FIGS. 3 and 4, in a steam assisted enhanced oil recovery (EOR) operation, the outlet 50 directs steam and combustion product output from the steam generator 1 at a pressure greater than about 450 psig, for example, into an injection well 400 to fluidize the hydrocarbon-containing reservoir 360. The steam from the output eventually condenses to create an oil/water mixture that migrates through the reservoir 360. The oil/water mixture is gathered at the production well 410 through which the oil/water mixture is recovered to surface via production line 320. In embodiments applied to SAGD operations (FIG. 4), the injection well 400 includes a horizontal borehole portion that is disposed above (e.g., 4 to 6 meters above) and parallel to a horizontal borehole portion of the production well 410. A separator 330 separates the oil/water mixture within the production line 320 and provides an oil product 340 and recovered water 350, which according to some embodiments can be recycled.
In the embodiments shown in FIGS. 3 & 4, and similar to the numerical references earlier referred to in FIGS. 1-2, air flow inlet 100 communicates with steam generator 1, having air control valve 280 thereon for regulating flow and quantum of air entering steam generator 1. Similarly, line 90 designates the fuel flow inlet to steam generator 1, having fuel control valve 290 thereon for regulating flow and quantum of fuel entering steam generator 1. Likewise, line 80 is the supplemental oxygen flow inlet to steam generator 1, having oxygen control valve 300 thereon for regulating flow and quantum of oxygen entering steam generator 1. Lastly, line 310 is a water supply line for providing water to steam generator 1, for purposes previously described, namely for changing the quality and/or amount of superheated steam being supplied by steam generator 1 in effluent stream 50 and/or cooling the combustion container 10 of steam generator 1 as shown in FIG. 2.
As discussed, the co-injection of combustion gases, CO2 and/or N2, with steam can increase oil production rates significantly. The effective ratio of CO2 and/or N2 for oil recovery of a given hydrocarbon-containing reservoir will depend on the reservoir conditions which can change during the oil recovery operation. According to embodiments of the present disclosure, this ratio of CO2 to N2 produced in the combustion products can be adjusted by adjusting the level of supplemental oxygen supplied to the combustion steam generator 1 to adjust the oxygen content of the oxygen-containing gas mixture burned with the fuel to generate the combustion products comprising steam, CO2, and N2.
According to certain embodiments, the conditions of the reservoir are monitored during the oil recovery operation to determine the amount of supplemental oxygen to deliver to the combustion steam generator throughout the process. In this way, adjustments to the ratio of steam and combustion products (i.e., ratio of CO2 and N2) can be made in real-time during the oil recovery process in response to the changing conditions of the reservoir in order to maximize oil production.
Direct Combustion Steam Generator and Process for Enhanced Oil Recovery Using Control of Each of Fuel, Air, Supplemental Oxygen, and Water Supplied by Steam Generator to Control Amounts of CO2, N2, and Amount and Degree of Superheated Steam Produced
In a further refinement, it is often desirable to further be able to control not only the ratio of CO2 to N2 produced by the resultant combustion gas, but to further control the quality of steam within such combustion gases and also the degree of superheating, if desired, of such steam within such combustion gases. This can be done by further controlling the rate of fuel input, as well as the rate of water input which is converted to steam. Some H2O may also appear in the combustion byproduct, due to humidity of air if air is used instead of pure oxygen.
For example, for a given hydrocarbon fuel CxHy, burning of such fuel will liberate a quantity of heat ΔH(heat of combustion), as per the below formula:

CxHy+a(O2+3.25N2)→xCO2+(y/2)H2O+3.25aN2+ΔH(heat of combustion), where a=x+y/4

For a situation where a percentage P of oxygen supplied and (1−P) is the corresponding percentage of air supplied, such equation becomes:

CxHy+PO2+(1−P)a(O2+3.25N2)→xCO2+(y/2)H2O+3.25(1−P)aN2+ΔH(heat of combustion), where a=x+y/4

Conversely, addition of water to the combustor, which vaporizes due to the presence of heat in the combustor, will absorb heat due to the latent heat of vaporization ΔH(heat of vaporization).
In controlling the rate of fuel supplied to the combustor, the net heat balance need always be exothermic [and thus a specific amount of fuel, oxygen (in the form of a specific desired ratio of air to supplemental oxygen), as well as the rate of input of the water Q] must all be adjusted relative to each other to allow stoichiometric combustion requirements for optimum combustion and so that the resultant heat is ultimately positive so that all water supplied is turned to steam in at least a saturated state, as shown below:

CxHy+PO2+(1−P)a(O2+3.25N2)+QH2O(liquid)xCO2+(y/2)H2O+3.25aN2+QH2O(gas)+ΔH(heat of combustion)−ΔH(heat of vapourization)≧0

where ΔH(heat of vapourization)=Q(unit of volume/time)×Latent heat of vaporization(unit of heat/unit time)×Time(unit of time) 

To the extent that the heat balance is positive for the above equation, assuming all supplied components are supplied at 100° C., is greater than zero, such will provide a degree of superheating to the steam.
Accordingly, in a preferred embodiment as shown in FIG. 1, the steam generator 1 of the present invention and the method of the present invention utilize control valves 140, 110, 170, and 200 situated respectively on each of the supply of the fuel, air, supplemental oxygen, and water which are each separately supplied to the steam generator 10, to further allow such additional control capability of each of such constituents to allow the degree of superheating, quality of steam in the effluent, and the ratio of CO2 to N2 in the resultant produced gaseous effluent stream.
Thus in a preferred embodiment (see FIG. 2) the present invention comprises a combustor 10, having a separate fuel supply inlet 90, an air supply inlet 100, a substantially pure oxygen supply inlet 80, and a water supply inlet 70, each controlled by valves 140, 110, 170, and 200 respectively to allow variation of the rate of supply of each of the foregoing to the combustor 1. In a further preferred embodiment, such valves 140, 110, 170, and 200 are automated valves which may be individually electrically, hydraulically, or pneumatically controlled to allow individual variation of the rate of supply of each of the fuel, air, supplemental oxygen, and water to the combustor unit 10.
Thus in a further embodiment the present invention comprises a process 1 for supplying steam and carbon dioxide to a formation using a combustor 10 for creating and supplying an effluent gas stream containing steam and carbon dioxide to an underground formation 360, the process comprising adjusting the rate, via valves 140, 110, 170, and 200 on the respective lines of supply of each of fuel 90, air 100, supplemental oxygen 80, and water 70 to said combustor 10, during injection of said effluent gas stream into an underground formation 360 to heat and reduce the viscosity of oil and/or bitumen in such underground formation 360.
To gain a better understanding of the invention described herein, the following examples are set forth. It will be understood that these examples are intended to describe illustrative embodiments of the invention and are not intended to limit the scope of the invention in any way.
EXAMPLES
Example 1
Controllable Combustion Gas Output
The combustion products generated by the steam generator of the present disclosure were determined over a range of O2 and air feeds that were combusted with a hydrocarbon-containing fuel, in this case being propane as the model fuel, although clearly any alternative readily available fuel may be used, such as methane or natural gas. The steam generator was operated at a pressure of 45 psig. and 292° F. Stoichiometric ratios of the feeds were maintained. The results are presented in Table 1.







TABLE 1







Controllable Production of Combustion Product









Output Flow Rate


Input Flow Rate (grams per minute)
(grams per minute)













Oxygen
Propane
Air
Water
CO2
Steam
Nitrogen
















 916
252
—
4640
755
5052
—


—
252
 3931
4600
755
5000
3015


4581
1260
—
23200
3775
25262
—


—
1260
19655
23000
3775
25062
15074 


3023
1260
 8036
23135
3775
25197
5024


1527
1260
16073
23067
3775
25129
10,049  









No CO or water was detected in the output, therefore total combustion was assumed and conversion of all injected water to steam

(a) Propane Fuel with Substantially Pure Oxygen

C3H8+5O2→3CO2+4H2O

On the first run 252 gm/min of propane and 916 gm/min of oxygen and were fed to the burner along with 4640 gm/min of water. This resulted in 5052 gm/min of saturated steam and 755 gm/min of CO2. The mass ratio of CO2/steam was 0.149, meaning that for every gram of water input into the steam generator 0.149 grams of CO2 and no nitrogen is produced. The percent composition of the CO2 in the effluent stream was (755/5052+755)=13% (by weight), with no N2.
On the second run for the above reaction, 4581 gm/min of oxygen and 1260 gm/min of propane along with 23200 gm/min of water was fed to the burner. (The 4581 gm/min of oxygen is the stoichiometric mass of oxygen required for 1260 gm/min of propane). This resulted in 3775 gm/min of CO2 and 25262 gm/min of saturated steam. The mass ratio of CO2/steam was 0.149, and the percent composition of the CO2 in the effluent stream was again 13% [ie 3755/(25262+3755)=13% (by weight)], with no N2, the remainder being steam. This is a relatively high content of CO2 in the effluent would be expected to significantly reduce the viscosity of heavy oil in EOR.
(b) Propane Fuel with Air

C3H8+5(O2+3.25N2)→3CO2+4H2O+5(3.25N2)

On the first run 252 gm/min of propane and 3931 gm/min of air (ie slightly in excess of the stoichiometric requirement of air required of 3895 gm/min) were fed to the burner along with 4600 gm/min of water. This resulted in 5000 gm/min of saturated steam, 755 gm/min CO2, and 3015 gm/min of nitrogen. The mass ratio of CO2/steam was 0.151 and the mass ratio of nitrogen/steam was 0.603, indicating that with the use of air for combustion 4.0 (four) times as much N2 as CO2 is produced. This may be beneficial in EOR particularly if the hydrocarbon-containing formation needs pressure, however the percentage of CO2 in the effluent stream dropped to 8.6% [755/(755+5000+3015)]=8.6% (by weight). Even if only a stoichiometric amount of air been supplied (3895 gm/min) for 252 gm/min propane, this would have stoichiometrically produced 2798 g/min N and 755 gm/min CO2, such still would have resulted in nearly 3.7 times the amount of N2 per amount of CO2 produced (by weight) (2798/756=3.7)
On the second run 1260 gm/min of propane and 19655 gm/min of air (ie containing oxygen in the amount of 19655/3.25=6042 gm/min substantially in excess of the stoichiometric requirement of oxygen required of 4581 gm/min) were fed to the burner along with 23000 gm/min of water. This resulted in 25062 gm/min of saturated steam, 3755 gm/min CO2, and 15074 gm/min of nitrogen. The mass ratio of CO2/steam was 0.151 and the mass ratio of nitrogen/steam was 0.603, again indicating that with this proportion of air in relation the propane supplied four (4) times as much N2 than CO2 is produced in the effluent stream. This may be beneficial in EOR particularly if the hydrocarbon-containing formation needs pressure, however the percentage of CO2 in the effluent stream dropped to 8.6% [755/(755+5000+3015)]=8.6% (by weight) as compared to 13% when pure oxygen was used. Even if only a stoichiometric amount of air been supplied (4581 gm/min) for 1260 gm/min propane, this would have stoichiometrically produced 14,888 g/min N (ie 3.25×4581 gm/min) and 3779 gm/min CO2, such still would have resulted in nearly 3.9 times the amount of nitrogen per amount of CO2 produced (by weight). (ie 14,888/3779=3.9)
(c) Propane Fuel with 1/3 Oxygen and 2/3 Air

C3H8+(1/3)5O2+(2/3)*5(O2+3.25N2)→3CO2+4H2O+2*(5)/3(3.25N2)

1527 gm/min of oxygen and 16073 gm/min of air (ie a total of 5255 gm/min oxygen which is in substantial excess of the stoichiometric amount of oxygen of 4582 g/min required for 1260 gm/min of propane) were fed to the burner along with 1260 gm/min of propane and 23067 gm/min of water. This resulted in 3775 gm/min of CO2, 25129 gm/min of saturated steam, and 10,049 gm/min of nitrogen exhausting from the burner system. This gives a CO2/steam ratio of 0.150 and a nitrogen/steam ratio of 0.518, with thus 3.45 times the mass of nitrogen being produced relative to the mass of produced CO2. Even if only the amount of air to provide the stoichiometric total amount of oxygen required had been supplied (i.e. 4582 gm/min oxygen), this would have produced 9927 gm/min of N (and 3780 gm/min of CO2), this would have resulted in 2.63 times the amount of N2 to CO2 (by weight). It is expected that this supplied mixture of 1/3 pure oxygen and 2/3 air would nonetheless pressurize a hydrocarbon-containing formation, but more slowly than using only air alone as shown above.
(d) Propane Fuel with 2/3 Oxygen and 1/3 Air

C3H8+(2/3)5O2+(1/3)5(O2+3.25N2)→3CO2+4H2O+5/3(3.25N2)

3023 gm/min of oxygen and 8036 gm/min of air (i.e. 3023+8036/3.25=5497 gm/min of oxygen) substantially in excess of the stoichiometric amount of oxygen required (4582 gm/min) for 1260 gm/min of propane, were fed to the burner along with 1260 gm/min of propane and 23135 gm/min of water. This resulted in 3775 gm/min CO2, 25197 gm/min of saturated steam, and 5024 gm/min of N2 exhausting from the system. This gave a CO2/steam ratio of 0.150 and a N2/steam ratio of 0.200, indicating that if 1/3 air to 2/3 pure oxygen is input into the system, only 1.33 times more N2 as compared to CO2 is produced. It is thus the situation that the formation in this instance would be pressurized with nitrogen less readily than in above example (c), but whose viscosity would be lessened more than in above example (c) due to the substantially higher percentage of end product CO2 being injected into the formation.

## Claims

1. A direct combustion steam generator adapted to burn a hydrocarbon fuel therein in which a byproduct of such combustion is water in the form of steam, comprising:
(a) a combustion container comprising an inner wall defining a combustion chamber, the combustion container having a first end comprising a burner for producing a flame within the combustion chamber for carrying out combustion of a fuel and an oxygen-containing gas to produce combustion products comprising at least steam, CO2, and at desired times N2, and a second end comprising an effluent outlet through which the combustion products exit from the combustion chamber in an effluent stream;
(b) at least one fuel inlet at the first end of the combustion container, the fuel inlet located proximate the burner and configured to deliver the fuel to the burner at a delivery pressure exceeding atmospheric pressure;
(c) at least one air inlet at the first end of the combustion container, the air inlet located proximate the burner and configured to deliver air to the burner at a delivery pressure exceeding atmospheric pressure;
(d) at least one supplemental oxygen inlet at the first end of the combustion container, the supplemental oxygen inlet located proximate the burner and configured to deliver a supply of supplemental oxygen having a percentage of nitrogen therein less than air and comprising up to 100% pure oxygen to the burner, wherein the supplemental oxygen contributes to or comprises the oxygen-containing mixture;
(e) a flow regulator means for adjusting a rate of flow of air through the at least one air inlet relative to a rate of flow of said supplemental oxygen through said at least one supplemental oxygen inlet, to thereby adjust an amount of oxygen in said oxygen-containing gas being supplied to said burner;
wherein a proportion or amount of said one or more combustion products produced in the combustion chamber which form said effluent stream is adjustable by use of said flow regulator means.

2. The direct combustion steam generator according to claim 1, wherein said flow regulator means regulates said amount or proportion of said supplemental oxygen supplied to the burner to thereby adjust the amount or proportion of CO2 and/or N2 contained in the effluent stream.

3. The direct combustion steam generator according to claim 1, wherein the at least one fuel inlet is fluidly connected to the at least one air inlet to deliver a mixture of fuel and air to the burner at a delivery pressure exceeding atmospheric pressure.

4. The direct combustion steam generator according to claim 1, wherein the air inlet, fuel inlet, and supplemental oxygen inlet each comprise flow regulator means to control the flow thereof into the combustion chamber.

5. The direct combustion steam generator according to claim 4, wherein each flow regulator means is controlled by an automated controller.

6. The direct combustion steam generator according to claim 1, further comprising at least one water inlet operatively connected to the combustion chamber and configured to deliver a supply of water to the combustion chamber.

7. The direct combustion steam generator according to claim 6, wherein said water inlet is configured to deliver a supply of water onto the inner wall of the combustion chamber to cool the temperature of the combustion chamber.

8. The direct combustion steam generator according to claim 6, wherein said water inlet is configured to deliver a supply of water to the steam generator and provide additional steam in the effluent stream.

9. The direct combustion steam generator according to claim 8, wherein the water inlet further comprises a flow regulator means to control flow of water into the combustion chamber via said water inlet.

10. The direct combustion steam generator according to claim 9, wherein the flow regulator is controlled by an automated controller.

11. The direct combustion steam generator according to claim 1, wherein the effluent outlet further comprises a flow regulator to control flow of the combustion products exiting the combustion chamber.

12. The direct combustion steam generator according to claim 11, wherein said flow regulator to control flow of the combustion products exiting the combustion chamber further provides a backpressure in the combustion chamber.

13. A system for steam assisted oil recovery in a hydrocarbon-containing reservoir, comprising the direct combustion steam generator according to claim 1, wherein the steam generator is configured to produce said combustion products from a supply of said fuel, said air, said supplemental oxygen, and said water, wherein the steam generator is coupled to convey the combustion products into an injection well in the reservoir, and wherein the composition of the combustion products is controllably adjusted in response to the conditions of the reservoir by altering the rate of supply of the supplemental oxygen relative to the supply of said air to said combustion chamber.

14. The system according to claim 13, wherein the supply of said supplemental oxygen includes an air separation unit to extract oxygen from air.

15. The system according to claim 14, wherein the air separation unit is a pressure swing adsorption unit (PSA).

16. The system according to claim 13, further comprising an automated controller for controllably adjusting the flow regulators in response to the conditions of the reservoir.

17. The direct combustion steam generator as claimed in claim 1, further having sensing means for determining said amount or proportion of CO2 and N2 in said effluent stream exiting said combustion chamber.

18. The direct combustion steam generator according to claim 17, wherein said sensing means senses proportion or amount of CO2 and/or N2 in the effluent stream and said flow regulator means regulates said rate of flow of said supplemental oxygen through said at least one supplemental oxygen inlet to adjust said sensed amount or proportion of CO2 and/or N2 in the effluent stream to a desired value.

19. The direct combustion steam generator according to claim 18, wherein said flow regulator means in addition regulates said rate of flow of air through the at least one air inlet.

20. A direct combustion steam generator comprising:
(a) a combustion container comprising an inner wall defining a combustion chamber, the combustion container having a first end comprising a burner for producing a flame within the combustion chamber for carrying out combustion of a fuel and an oxygen-containing gas mixture to produce combustion products comprising steam, CO2, and at times N2, and a second end comprising an effluent outlet through which the combustion products exit from the combustion chamber in an effluent stream;
(b) at least one fuel inlet at the first end of the combustion container, the fuel inlet located proximate the burner and configured to deliver the fuel to the burner at a delivery pressure exceeding atmospheric pressure;
(c) at least one air inlet at the first end of the combustion container, the air inlet located proximate the burner and configured to deliver air to the burner at a delivery pressure exceeding atmospheric pressure, wherein the air contributes to or comprises the oxygen-containing gas mixture, said air inlet having a flow regulator thereon to adjust quantum and rate of air supplied to said burner via said at least one air inlet;
(d) at least one supplemental oxygen inlet at the first end of the combustion container, the supplemental oxygen inlet located proximate the burner and configured to deliver a supply of supplemental oxygen having a percentage of nitrogen therein less than air and comprising up to 100% pure oxygen to the burner, said supplemental oxygen inlet having a flow regulator thereon to adjust quantum and rate of said supplemental oxygen supplied to said burner via said at least one supplemental oxygen inlet, wherein said supplemental oxygen contributes to or forms the oxygen-containing gas mixture produced in the combustion chamber can be adjusted; and
(e) at least one water inlet operatively connected to the combustion chamber and configured to deliver a supply of water onto the inner wall of the combustion chamber to cool the temperature of the combustion chamber
whereby a proportion or amount of said one or more combustion products produced in the combustion chamber which form said effluent stream is adjustable by use of one or both of said flow regulators.

21. The direct combustion steam generator according to claim 20, further comprising sensing means, wherein the quantum or proportion of CO2 and/or N2 contained in the combustion products as sensed by said sensing means is used to control said flow regulator on said supplemental oxygen inlet.

22. The direct combustion steam generator according to claim 20, wherein the at least one fuel inlet is fluidly connected to the at least one air inlet to deliver a mixture of fuel and air to the burner at a delivery pressure exceeding atmospheric pressure.

23. The direct combustion steam generator according to claim 20, wherein the air inlet, fuel inlet, oxygen inlet, and water inlet each comprise a flow regulator to control flow thereof into the combustion chamber.

24. The direct combustion steam generator according to claim 23, wherein each flow regulator is controlled by an automated controller.

25. The direct combustion steam generator according to claim 20, wherein the effluent outlet further comprises a flow regulator to control flow of the combustion products including steam exiting the combustion chamber.