WELL FLUID TREATMENT AND STEAM GENERATION USING CAVITATION
20170241218 · 2017-08-24
Inventors
Cpc classification
F22B1/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01D1/0017
PERFORMING OPERATIONS; TRANSPORTING
International classification
E21B21/06
FIXED CONSTRUCTIONS
E21B43/34
FIXED CONSTRUCTIONS
Abstract
A well fluid treatment system includes a cavitation reactor causing cavitation-induced heating of a flow sufficient to convert at least a portion of water in the well fluid to steam a single pass of the well fluid through the cavitation reactor, a steam-liquid phase separator receives the heated well fluid and separates the flow into steam and a condensed contaminated fluid. One or more auxiliary systems are coupled to the steam outlet and receive the flow of steam in order to transfer thermal energy from the flow of steam to one or more of the following: (a) a well fluid treatment process before the cavitation reactor, and (b) a condensed contaminated fluid treatment process after the cavitation reactor.
Claims
1. A well fluid treatment system, the system comprising: a cavitation reactor comprising a reaction chamber housing, a rotor and a stator mounted in the reaction chamber housing, a well fluid inlet into the reaction chamber housing and a heated fluid outlet from the reaction chamber housing, the cavitation reactor configured to cause cavitation of a flow of well fluid received through the well fluid inlet and transfer sufficient thermal energy to the flow of well fluid to convert at least a portion of water in the well fluid to steam in a single pass of the well fluid through the cavitation reactor; a steam-liquid phase separator comprising a separator housing, a heated well fluid inlet into the separator housing, a steam outlet from the separator housing, and a residual outlet from the separator housing, the heated well fluid inlet coupled to the heated fluid outlet to receive the flow of heated well fluid from the cavitation reactor, the steam-liquid phase separator configured to separate the flow of heated fluid into steam and a condensed contaminated fluid; and an auxiliary system coupled to the steam outlet to receive a flow of steam, the auxiliary system adapted to transfer thermal energy from the flow of steam to one or more of the following: (a) a well fluid treatment process before the cavitation reactor, or (b) a condensed contaminated fluid treatment process after the cavitation reactor.
2. The system of claim 1, wherein the cavitation reaction is a continuous cavitation reactor, the continuous cavitation reactor adapted to heat an uninterrupted flow of the well fluid to an uninterrupted flow of steam.
3. The system of claim 1, wherein the auxiliary system comprises a steam tracing system comprising a plurality of steam conduits adapted to variably transfer thermal energy from the flow of steam to adjacent fluid conduits of the well fluid treatment system, the steam tracing system enabling temperature regulation of a fluid in the adjacent fluid conduits.
4. The system of claim 1, wherein the auxiliary system comprises a heating system of the phase separator, the heating system adapted to regulate the temperature of fluids in the phase separator using thermal energy from the flow of steam.
5. The system of claim 1, wherein the auxiliary system comprises a heat exchanger adapted to heat the flow of well fluid prior to the cavitation reactor.
6. The system of claim 1, wherein the well fluid contains oil, and wherein the phase separator is further adapted to separate the oil from the condensed contaminated fluid.
7. The system of claim 6, wherein the auxiliary system comprises a heating system adapted to dry the condensed contaminated fluid and separate remaining water from the oil.
8. The system of claim 1, wherein the well fluid contains salt.
9. The system of claim 1, further including a condenser for receiving the flow of steam, the condenser adapted to generate a liquid water from the received flow of steam.
10. The system of claim 1, wherein the thermal energy transferred to the flow of well fluid in a single pass is sufficient to convert at least a 50% of the water in the well fluid to steam at atmospheric pressure.
11. The system of claim 1, wherein the auxiliary system is an absorption chiller adapted to convert the thermal energy from the flow of steam to chill a fluid.
12. A method of treating well fluid, the method comprising: causing cavitation in a flow of well fluid through a cavitation reactor, the cavitation heating the flow of well fluid to a temperature sufficient to convert at least a portion of water in the well fluid to steam in a single pass of the well fluid through the cavitation reactor; separating the flow of heated fluid into steam and a condensed contaminated fluid; and transferring thermal energy from the flow of steam to an auxiliary process doing one or more of the following: (a) treating the well fluid before the cavitation reactor, or (b) treating the condensed contaminated fluid after the cavitation reactor.
13. The method of claim 11, where causing cavitation in a flow of well fluid comprises continuously causing cavitation in an uninterrupted flow of well fluid.
14. The method of claim 11, wherein the auxiliary process flows the steam through a plurality of steam conduits adjacent to fluid conduits of the well fluid treatment system, the axillary process regulating the temperature of a fluid in the adjacent fluid conduits.
15. The method of claim 11, wherein the auxiliary process comprises regulating the temperature of one or more fluids in a phase separator receiving the flow of heated fluid.
16. The method of claim 12, comprising: converting thermal energy from the flow of steam into mechanical energy; and partially causing the cavitation with the mechanical energy.
17. The method of claim 12, wherein the auxiliary process comprises heating the flow of well fluid prior to the cavitation reactor.
18. The method of claim 12, wherein the well fluid contains oil, and wherein separating comprises separating the oil from the condensed contaminated fluid.
19. The method of claim 18, wherein the auxiliary process comprises agitating the well fluid prior to the cavitation reactor, the agitating separating at least some of the oil from of well fluid prior to the cavitation reactor.
20. The method of claim 12, comprising heating the flow of well fluid with the cavitation reactor in a single pass to a temperature sufficient to convert at least 50% of water in the well fluid to steam at atmospheric pressure.
21. The method of claim 12, wherein the auxiliary process comprises flowing the steam into an absorption chiller, the absorption chiller generating chilled water.
22. A well fluid treatment system, the system comprising: a cavitation reactor adapted to cause cavitation of a flow of well fluid received through the well fluid inlet and to heat the flow of well fluid to a temperature sufficient to convert at least a portion of water in the well fluid to steam in a single pass of the well fluid through the cavitation reactor; a steam-liquid phase separator adapted to separate the flow of heated fluid into steam and a condensed contaminated fluid; and an auxiliary system coupled to the steam outlet to receive a flow of steam, the auxiliary system adapted to transfer thermal energy from the flow of steam to one or more of the following: (a) a well fluid treatment process before the cavitation reactor, or (b) a condensed contaminated fluid treatment process after the cavitation reactor.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0023]
[0024]
[0025]
[0026]
[0027]
DETAILED DESCRIPTION
[0028]
[0029] In operation, a feed pump 120 is coupled to the source conduit 10 to draw the fluid feedstock 10 through a dirt separator 110 to remove any large particulate matter in the fluid feedstock, for example, rocks larger than the passageways of the cavitation reactor, and provide the strained fluid feedstock, via conduit 11, to the cavitation reactor 130. In certain instances, the dirt separator 110 is a screen or other coarse filter arranged to filter particular larger than the spacing between the rotor and external casing/ring from the fluid feedstock. The feed pump 120 is driven by a pump motor 121, which is powered by a source of electric power 20, which in certain instances is a generator, solar cells, battery, or a connection to a local power grid. The cavitation reactor 130 is powered by a cavitation drive motor 131, which is also powered by the source of electric power 20 or another source. The cavitation reactor 130 causes cavitation-induced heating to take place in the strained fluid feedstock, which generates a flow of heated feedstock at a temperature and pressure sufficient to vaporize at least a portion of the water content of the heated feedstock in a single pass through the cavitation reactor 131. In some instances, the cavitation reactor 130 raises the heated feedstock to a temperature sufficient to convert 100% of the water content of the heated feedstock to steam at atmospheric pressure. In other instances, the cavitation reactor raises the temperature of the heated feedstock to a temperature sufficient to convert at least 50% of the water content of the heated feedstock to steam at atmospheric pressure. In some instances, the cavitation reactor accepts a continuous uninterrupted flow of well fluid and continuously heats the well fluid to generate an uninterrupted flow of heated feedstock in conduit 30. The heated feedstock in conduit 30 is delivered from the cavitation reactor 130 to the separator 140, where it is able to expand and form steam that exits the separator 140 through conduit 50. Non-water fluids that survive the cavitation process and possibly a portion of the water are separated from the steam as condensate fluids in conduit 40. Additionally, any particulate matter remaining (or created by the heat of cavitation) in the condensate fluid are able to settle in the separator 140 and are removed as solids through conduit 60. As noted above, in some instances, the separator 140 is a three-phase separator that is able to separate oils or other petroleum products from the heated feedstock.
[0030] The auxiliary steam systems 150 accepts the steam from conduit 50 to recoup the thermal energy of the steam and generate purified water from the steam's condensate. The condensate reprocessing system 141 accepts the flow of condensate fluid in conduit 40 from the separator, and, in some instances, provides (i) further processing of the condensate fluid to remove petroleum byproducts, (ii) drying of the condensate fluid, or (iii) storage of the condensate fluid 40 for removal. Similarly, the solids processing system 160 accepts the solids from conduit 60 from the separator 140 and in some instances provides, for example, further processing or storage of the solids. The entire cavitation fluid treatment system 100 in some instances is packaged as single system on a skid 102 or frame with interconnecting piping and fittings as described above.
[0031] The auxiliary systems 150 in some instances utilize the steam for many applications. For example, a low pressure steam generator to produce electrical power 20, which, in some instances, is sent back to the treatment facility to supplement the cavitation reactor 130 or any others machines. Other examples of auxiliary systems 150 include treatment processes using thermal energy from the steam 50 to prevent freezing of fluids or to improve flow, steam powered pumps that may supplement the cavitation drive motor 131 or any other mechanically driven process, HVAC heating and cooling, process heating or preheating the fluid feedstock to improve cavitation reactor efficiency.
[0032] Example applications for the cavitation fluid treatment system 100 include salt water disposal, desalinization, HVAC heating and cooling, marine, oil and gas, power generation, beverage processing, industrial/process, waste water treatment, and disaster clean up. Desalinization is a similar same process as salt-water disposal, but with seawater as opposed to process fluids. The feed source is typically the ocean or other salt-water body of water. In HVAC application, steam can be used to heat a separate loop through heat exchangers, a closed loop system where the water never leaves/flashes. Cooling with cavitation fluid treatment system 100 can be done through using the generated steam to power an absorption chiller. In some instances, the cavitation fluid treatment system 100 is used to refine oil. In some instances, the cavitation fluid treatment system 100 is used in the food and beverage industry to heat fluids where scaling is a concern, for example, chocolate. With respect to disaster clean up, the cavitation fluid treatment system 100 skid 102 is powered remote via solar, wind, or generator power 20. In some instances, the skid 102 is drop shipped into a disaster area to provide clean fresh water, hot water, steam, and or treat contaminated water sources.
[0033]
[0034]
[0035] In operation, a flow of fluid, for example, fluid feedstock 10, is provided to the cavitation reactor 330 at the inlet 313 and the flow of fluid passes around the flow cone 323 and into the passage 302 between the surface of the rotor 320 and the adjustable diameter sleeve 312. As the fluid passes from the inlet 313, through the passageway 302, and to the outlet 313, rotation of the rotor 320 and the cavitation-inducing features 324 creates localized regions of extremely low pressure, which momentarily causes cavitation bubbles to form in the fluid. The subsequent and violent collapse of the cavitation bubbles generates heat within the fluid from the mechanical energy of the spinning rotor 320. The intense heat and pressure of the act of cavitation is able to destroy organics that may be present in the fluid along with other compounds. Through the act of hydrodynamic cavitation, and/or secondary acoustic cavitation, the fluid is heated/pressurized to its point of vaporization. This varies depending on the fluid and other conditions such as temperature, humidity and pressure. The phase separator 140 will then remove the clean steam and separate out remaining solids (i.e. salt, metals, etc.). Solids present in the flow small enough to pass through the passageway 302 may pass unchanged.
[0036] The adjustable diameter sleeve 312 in some instances is a sleeve type insert into the external casing 310. This allows for simple modification of the device with change in fluid as opposed to completely new device or machining.
[0037]
[0038] In operation, flowback or produced fluid 80 is trucked or piped to a loading and unloading facility 480. From the unload facility 480, the produced water 80 is stored in a holding tank or settling pond 443 where the produced water 80 settles and oil 70 in some instances is skimmed from the surface and stored in the skim oil storage tank 470. From the settling pond 443, a contaminated feedstock 65 is delivered to the gun barrel separation device 442. The gun barrel separator 442 removes oils 70 from the produced fluid 80. In the gun barrel separator 442, contaminated salt-water 19 and oil 70 are separated, with oil 70 flowing to the top and contaminated salt-water 19 resting on bottom, which also enables solids 60 to be extracted. Once separated, the oil 70 in some instances is removed to the skim oil storage tank 470 for site removal at the loading and unloading facility 480. The remaining salt-water 19 is then transferred to the salt-water holding tank 401 and delivered to the preheated cavitation fluid treatment system 200 by the feed pump 120 as a fluid feedstock 10. Optionally, the fluid feedstock 10 can be delivered to a disposal well 499 for disposing of produced water and flowback. Disposal wells 499 typically return produced water back to the original well site and, in some instances, are old oil or gas well that are no longer producing. The use of the cavitation fluid treatment system 200 enables the volume of the produced water being disposed of and changes the concentration of the produced water by removing fresh water to be reused elsewhere.
[0039] The feedstock in conduit 10 is delivered to the preheated cavitation fluid treatment system 200 and is preheated by the heat exchanger 170 and subsequently heated by the cavitation reactor 130 to a temperature sufficient to vaporize at least a portion of the water content in the feedstock, for example 230° F. The heated feedstock in conduit 30 is delivered to the separator 140, where the steam is separated from the condensate fluid and solids. The steam exits the separator 140 in conduit 50, the condensate fluid exists in conduit 40, and the solids exit in conduit 60. The condensate fluid in conduit 40, in some instances, is returned to the salt water holding tank 401, delivered directly to the disposal well 499, or further processed to remove any remaining water content. A portion of the steam in conduit 50, in some instances, and as detailed above in
[0040] Generally, placing the preheated cavitation fluid treatment system 200 at an existing salt-water disposal facility 400 (i.e., settling pond 443, gun barrel separator 442, and disposal well 499), is optimal for installation of the preheated cavitation fluid treatment system 200 to utilize existing equipment to reduce operating costs. In some aspects, installing a secondary branch of the discharge of the saltwater holding tanks 401 will provide the required feedstock for the system while still allowing normal salt-water disposal operation. This configuration provides a constant flow of feedstock we need, without interference with the standard salt-water disposal operations, but reduces the amount of salt-water that is disposed into the well 499. Alternately, if the discharge from the gun barrel 442 separator 442 is sufficient the cavitation fluid treatment system 200 can replace the storage tanks and pull feedstock directly from the gun barrel separator 442. In addition, depending on system capacities and salt-water disposal facility 400 throughput, the cavitation system, in some instances, is also piped in parallel to increase capacity.
[0041]
[0042]
[0043] Continuing to refer to
[0044]
[0045] Continuing to refer to the auxiliary steam devices in
[0046] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. Accordingly, other implementations are within the scope of the following claims.