Pump system for gas entrainment
11131173 · 2021-09-28
Assignee
Inventors
- Shane Broussard (Youngsville, LA, US)
- Bruce M. Schertz (Weston, WI, US)
- Chad L. Felch (Kronenwetter, WI)
Cpc classification
F04D1/006
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
E21B43/166
FIXED CONSTRUCTIONS
E21B43/255
FIXED CONSTRUCTIONS
E21B43/40
FIXED CONSTRUCTIONS
F04D31/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
E21B43/12
FIXED CONSTRUCTIONS
E21B43/40
FIXED CONSTRUCTIONS
Abstract
A pump system includes a centrifugal pump having an impeller, a first inlet arranged to receive a first flow of liquid, a second inlet arranged to receive a flow of gas at a first pressure, the gas being soluble in the liquid, and an outlet arranged to discharge a second flow of liquid that contains the flow of gas solubilized therein. An injection pump has an inlet arranged to receive the second flow of liquid. The injection pump is operable to increase the pressure of the second flow of liquid to produce a high-pressure flow of liquid, and includes a discharge arranged to discharge the high-pressure flow of liquid.
Claims
1. A pump system comprising: a centrifugal pump including: an impeller; a first inlet arranged to receive a first flow of liquid; a second inlet arranged to receive a flow of gas at a first pressure, the gas being soluble in the liquid, the impeller operable to combine the first flow of liquid and the flow of gas into a second flow of liquid; and an outlet arranged to discharge the second flow of liquid that contains the flow of gas solubilized therein; and an injection pump having a discharge and an inlet arranged to receive the second flow of liquid, the injection pump operable to increase the pressure of the second flow of liquid to produce a third flow of liquid, and to discharge the third flow of liquid through the discharge.
2. The pump system of claim 1, further comprising a holding tank that contains a liquid and a gas that has de-solubilized from the liquid.
3. The pump system of claim 2, further comprising a three-phase separator positioned to receive a produced fluid mixture including a hydrocarbon liquid, the gas, and the liquid, the three-phase separator including a gas outlet, a separate hydrocarbon outlet, and a third outlet that directs liquid to the holding tank, the liquid including the gas solubilized in the liquid.
4. The pump system of claim 1, wherein the impeller includes a dual-sided impeller having a first side arranged to receive the first flow of liquid from the first inlet and a second side arranged to receive the flow of gas from the second inlet, the impeller operable to solubilize the flow of gas into the first flow of liquid to define the second flow of liquid.
5. The pump system of claim 1, wherein the first pressure is between 1 psig and 20 psig.
6. The pump system of claim 1, wherein the liquid in the first flow of liquid includes water and the gas in the flow of gas contains carbon dioxide.
7. The pump system of claim 6, wherein the carbon dioxide is at least 95 percent solubilized in the second flow of liquid.
8. A method of operating a pump system, the method comprising: directing a first flow of liquid to a centrifugal pump; directing a flow of gas at a first pressure to the centrifugal pump, the flow of gas being soluble in the liquid; rotating an impeller in the centrifugal pump to increase the pressure of the first flow of liquid and the flow of gas and to combine the first flow of liquid and the flow of gas into a second flow of fluid; discharging the second flow of liquid that contains the flow of gas solubilized therein; directing the second flow of liquid to an injection pump; and operating the injection pump to inject the second flow of liquid into an oil well to enhance oil production.
9. The method of claim 8, further comprising collecting a liquid and a gas that has de-solubilized from the liquid in a holding tank, and directing the gas to the centrifugal pump as a portion of the flow of gas and directing the liquid to the centrifugal pump as a portion of the first flow of liquid.
10. The method of claim 9, further comprising receiving a produced mixture in a three-phase separator from the oil well, the produced liquid including a hydrocarbon liquid, the gas, and the liquid, wherein the three-phase separator includes a gas outlet, a separate hydro-carbon outlet, and a third outlet for directing liquid to the holding tank, the liquid including the gas solubilized in the liquid.
11. The method of claim 8, wherein the impeller includes a dual-sided impeller, and wherein the first flow of liquid is directed to a first side of the impeller and the flow of gas is directed to a second side of the impeller.
12. The method of claim 11, further comprising rotating the impeller to solubilize the flow of gas into the first flow of liquid to define the second flow of liquid.
13. The method of claim 8, wherein the first pressure is between 1 psig and 20 psig.
14. The method of claim 8, wherein the liquid in the first flow of liquid includes water and the gas in the flow of gas contains carbon dioxide.
15. The method of claim 14, wherein the carbon dioxide is at least 95 percent solubilized in the second flow of liquid.
16. A pump system comprising: a three-phase separator positioned to receive a produced fluid mixture from an oil well, the fluid mixture including a hydrocarbon liquid, a gas, and water, the three-phase separator including a gas outlet, a separate hydrocarbon outlet, and a water outlet; a holding tank positioned to receive the water from the water outlet, the water including a quantity of solubilized gas that de-solubilizes in the holding tank such that the holding tank contains separated water and gas; a centrifugal pump including: a dual sided impeller including a first side impeller and a second side impeller coupled to one another for co-rotation; a first inlet arranged to receive a first flow of water from the holding tank and to direct the first flow of water to the first side impeller; a second inlet arranged to receive a flow of gas from the holding tank at a first pressure and to direct the flow of gas to the second side impeller, the dual sided impeller operable to combine the first flow of water and the flow of gas into a second flow of liquid; and an outlet arranged to discharge the second flow of liquid that contains the flow of gas solubilized therein; and an injection pump having an inlet arranged to receive the second flow of liquid, a working member operable to increase the pressure of the second flow of liquid to produce a third flow of liquid, and an outlet arranged to discharge the third flow of liquid to the oil well.
17. The pump system of claim 16, wherein the first pressure is between 1 psig and 20 psig, and wherein the flow of gas contains carbon dioxide.
18. The pump system of claim 17, wherein the carbon dioxide is at least 95 percent solubilized in the second flow of liquid.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.
(2) The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:
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DETAILED DESCRIPTION
(9) Aspects and embodiments are not limited in their application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. Aspects and embodiments disclosed herein are capable of other embodiments and of being practiced or of being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” “having,” “containing,” “involving,” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
(10) Embodiments, principles, and features are described herein with reference to implementation in illustrative embodiments. In particular, certain embodiments disclosed herein are described in the context of being an entrainment system. Certain embodiments disclosed herein are described in the context of being an oil recovery system. Aspects and embodiments, however, are not limited to use in the described exemplary systems. The components and materials described herein as making up the various embodiments are intended to be illustrative and not restrictive. Many suitable components and materials that would perform the same or a similar function as the materials described herein are intended to be embraced within the scope of the disclosure.
(11) In some embodiments, the devices, systems, and methods disclosed herein provide advantages with regard to, for example, capital costs, operational costs, system footprint and environmental-friendliness as compared to conventional gas entrainment systems. In particular, the devices, systems, and methods disclosed herein provide such advantages as compared to conventional gas injection enhanced oil recovery systems.
(12) Unless otherwise explicitly stated, all pressures are gauge pressures.
(13) Injecting a gas into oil formations is one method of performing enhanced oil recovery.
(14) With reference to
(15) The produced liquid is directed from the oil well 502 to a separator 504 in the form of a three-phase separator 504. The separator 504 includes a hydrocarbon outlet that discharges oil separated from the produced liquid. A gas outlet is provided to discharge any separated gas, including the carbon dioxide that separates from the produced liquid. A third outlet directs the remaining liquid, typically water with some quantity of solubilized carbon dioxide to a holding tank 506.
(16) The holding tank 506 illustrated in
(17) Vapor recovery units 508 (VRUs) are used to gather the released gas from the head space 516 and send it to other areas for safe handling or reuse.
(18) In conventional arrangements, the vapor recovery units 508 are periodically taken out of service for maintenance. During maintenance, a temporary vapor recovery unit 508 is installed to continue operation. Bringing the temporary vapor recovery unit 508 to the field and installing it can be very costly and time consuming.
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(21) From the collection manifold 518, the fluid (e.g., water with solubilized carbon dioxide) is directed to one or more injection pumps 514. The injection pumps 514 operate to inject the fluid into the oil well 502 at high pressure to complete the cycle.
(22) Embodiments disclosed herein generally relate to devices, systems, and methods that may replace conventional compressing and storage steps of gas, and instead provide immediate solubilization of the gas. For example, embodiments disclosed herein may provide solubilization of a gas into a single-phase aqueous stream that can be processed for further use. In some embodiments, the further use may include re-injecting the gas into an oil recovery well.
(23) In certain embodiments, there is provided a method of producing a single-phase gas entrained aqueous solution. The method may comprise pumping an aqueous solution and a gas through a dual-sided impeller pump (e.g., the dual phase pump 510). The dual phase pump 510 may be capable of dissolving a greater volume of gas in the fluid than conventional pumps used for gas entrainment. The systems and methods may comprise or be capable of solubilizing a gas to at least about 90% dissolution in water. For example, the systems and methods may comprise or be capable of solubilizing the gas to at least about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, or about 99%. Systems and methods disclosed herein may comprise or be capable of solubilizing the gas to at least about 99.9%, about 99.99%, or about 99.999% in water. In certain embodiments, the systems and methods may be capable of solubilizing a gas to more than its saturation.
(24) Gases which may be solubilized by the systems and methods disclosed herein generally include gases with a higher solubility in water than air. The solubility of a gas in water may vary by temperature and gauge pressure.
(25) TABLE-US-00001 TABLE 1 solubility of exemplary gases in water. The solubility in Table 1 has units of grams of gas dissolved in 100 g of water, when the total pressure above the solution is 1 atm. Gas Solubility Acetylene 0.117 Ammonia 52.9 Bromine 14.9 Carbon dioxide 0.169 Carbon monoxide 0.0028 Chlorine 0.729 Ethane 0.0062 Ethylene 0.0149 Hydrogen 0.00016 Hydrogen sulfide 0.385 Methane 0.0023 Nitrogen 0.0019 Oxygen 0.0043 Sulfur Dioxide 11.28
(26) In accordance with certain aspects, there is provided the dual phase pump 510 for producing a single-phase gas entrained aqueous solution. As disclosed herein, single-phase refers to a fluid having no visible gas. The dual phase pump 510 may be configured to dissolve gas in water. In general, the dual phase pump 510 may be configured to pressurize the gas to at least 90% dissolution, for example at least 95% dissolution, as previously described herein. The dual phase pump 510 may pressurize the gas to produce a single-phase gas entrained aqueous solution.
(27) In certain embodiments, the dual phase pump 510 may have a dual-sided impeller 600 shown in
(28) Before proceeding, it should be noted that the aforementioned pump could include two inlets as described or alternatively, the liquid and the gas could be pre-mixed prior to entry into the impellers 602, 604.
(29) The dual phase pump 510 may have an inlet fluidly connectable to a source of water and a source of gas. In certain embodiments, the source of water and the source of gas may be a gas entrained liquid, for example, produced water. In an exemplary embodiment, the dual phase pump 510 may be configured to pressurize CO.sub.2 in produced water to at least 95% dissolution in the water. Thus, the dual phase pump 510 may receive a multi-phase solution and produce a single-phase fluid of gas dissolved in water, for example, of CO.sub.2 dissolved in water. In other embodiments, the source of gas and the source of liquid may be separate. In such embodiments, the dual phase pump 510 may receive a liquid and a gas and produce a single-phase fluid of the gas dissolved in the liquid.
(30) The dual phase pumps 510 disclosed herein may be operated by varying the gas pressure. In some embodiments, the gas may be pressurized between about less than 1 psig (0.07 Bar) and about 20 psig (1.38 Bar). For instance, the gas may be pressurized at about less than 1 psi (0.07 Bar), about 1 psi (0.07 Bar), about 5 psi (0.34 Bar), about 10 psi (0.69 Bar), about 15 psi (1.03 Bar), or about 20 psi (1.38 Bar). As described in the examples, in accordance with certain embodiments, increasing gas pressure may increase gas flow while still providing a single-phase fluid. Thus, in accordance with certain embodiments, the methods disclosed herein may provide gas at a faster rate while maintaining a single-phase fluid. Similarly, the pumps may be operated by varying flow rate of the water and/or gas into the pump.
(31) In certain embodiments, varying gas discharge pressure and/or water or gas flow rate may enable an increased gas flow rate downstream from the dual phase pump 510. The pressurized dual phase pumps 510 disclosed herein may provide a greater single-phase gas flow rate than conventional pumps. In accordance with certain embodiments, a single-phase gas flow rate of at least about 20 gpm (75.7 liters/minute), for example, of at least about 25 gpm (94.6 liters/minute), may be achieved by increasing gas discharge pressure into the dual phase pump 510. The systems and methods may be operated to produce a single-phase gas having a flow rate of at least about 15 gpm (56.8 liters/minute), at least about 20 gpm (75.7 liters/minute), at least about 25 gpm (94.6 liters/minute), or at least about 30 gpm (113.6 liters/minute).
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(33) In one exemplary embodiment, the pump 202 and the dual phase pump 510 may be or may include a Brise™ 2.0 pump system (distributed by Siemens Water Solutions, Rothschild, Wis.).
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(35) The pump 302 may be employed as part of a system for gas entrainment. In accordance with certain aspects, there is provided a system for producing a single-phase gas entrained aqueous solution. The system may comprise the pump 302, as described herein, having the inlet 306 fluidly connected to a source of multi-phase water and gas 304. The system may comprise the pump 302 with the outlet 208 fluidly connected to a point of use. The point of use may be a device or system capable of receiving a single-phase gas entrained fluid. The system may comprise a flow meter configured to measure or control flow rate of one or more fluids in the system. In some embodiments, the system may comprise a valve configured or capable of controlling backpressure of a fluid within the system.
(36) In one exemplary embodiment, the pump 302 may be or may include a Brise™ 2.0 pump system (distributed by Siemens Water Solutions, Rothschild, Wis.).
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(38) In accordance with an exemplary aspect, the system may be a system for enhanced oil recovery from an oil recovery well. The system disclosed herein may provide increased efficiency in oil production when compared to systems employing conventional pumps. The enhanced oil recovery system may comprise a holding tank 506 having an inlet fluidly connectable, or in practice fluidly connected, to a source of produced water comprising CO.sub.2.
(39) The system may comprise the pump 402 as previously described herein (or other pumps described herein), having an inlet 306 fluidly connected to an outlet of the holding tank 506. The pump 402 may be configured to pressurize the CO.sub.2 to produce a single-phase gas entrained aqueous solution. The system may further comprise a fluid injection pump 514 having an inlet fluidly connected to an outlet 208 of the pump 402. The fluid injection pump 514 may be configured to re-inject the single-phase gas entrained aqueous solution into the oil well 502.
(40) Typically, fluid injection pumps 514 cannot handle a multi-phase stream or the fluid injection pumps 514 may cavitate and fail. Thus, the discharge from the pumps 202, 302, 402, 510 disclosed herein may generally be solubilized in an amount sufficient to avoid cavitation or failure of a downstream fluid injection pump 514. In some embodiments, the discharge may be a single-phase dissolved CO.sub.2 aqueous solution.
(41) An exemplary system for enhanced oil recovery from an oil well 500 is shown in
(42) Thus, certain embodiments disclosed herein comprise employing a dual phase pump 510 in an oil recovery system to entrain CO.sub.2 in water and deliver a single-phase stream directly to re-injection pumps 514 during maintenance interruptions. The result is a cost-effective option, compared to bringing in temporary vapor recovery units 508. The dual phase pump 510 can entrain, pressurize, and solubilize the CO.sub.2 into a single-phase stream that can be sent directly to the re-injection pumps 514 to be then be injected into the oil well 502.
(43) The pumps 202, 302, 402, 510 disclosed herein may improve maintenance operations by replacing offline vapor recovery units 508 with a single pressurizing pump 202, 302, 402, 510. If few enough pumps 202, 302, 402, 510 can be used to replace the offline vapor recovery units 508, there may be substantial cost savings, reduced footprint, and reduced energy demand.
(44) In accordance with another aspect, there is provided a method of facilitating gas re-injection during enhanced oil recovery. The method may comprise providing a pump 202, 302, 402, 510 as disclosed herein. The method may comprise fluidly connecting the pump 202, 302, 402, 510 to an enhanced oil recovery system, as described herein. For example, the method may comprise fluidly connecting the pump 202, 302, 402, 510 to a source of produced water comprising CO.sub.2 and/or to a fluid injection pump 514 configured to reinject the single-phase gas entrained solution into an oil recovery well. The method may comprise instructing a user to fluidly connect the pump 202, 302, 402, 510, as disclosed herein.
(45) In certain embodiments, the method may comprise instructing a user on how to operate the pump 202, 302, 402, 510. For example, the methods may comprise instructing a user to operate the pump 202, 302, 402, 510 at a certain flow rate and/or with a certain backpressure.
(46) In accordance with yet another aspect, there is provided a method of retrofitting a gas injection enhanced oil recovery system comprising a fluid injection pump 514. The method may comprise providing a pump 202, 302, 402, 510, fluidly connecting the pump 202, 302, 402, 510, and/or instructing a user, as previously described.
(47) In certain embodiments, the systems and methods disclosed herein may be applied to any application where CO.sub.2 needs to be recovered or disposed. In enhanced oil recovery processes, CO.sub.2 recovery and discharge are regulated by state agency. It is noted that the methods disclosed herein could be used to solubilize any gas up to its solubility limit, for example, for recovery or discharge.
(48) Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only.
EXAMPLES
(49) An experimental system was prepared and operated to test gas entrainment performance of a pressurizing pump. The experimental system tested dissolution of CO.sub.2 in water. It was not known if the CO.sub.2 would dissolve quickly enough to meet the needs of an enhanced oil recovery system.
(50) The system included a water source and a CO.sub.2 bank fluidly connected to a pressurizing pump. The pump was a Brise™ 2.0 pump. The fluid conduit downstream of the pump was clear, to allow observation of the entrained fluid. A valve was positioned downstream from the pump to control backpressure. The valve provided fluid connection to a downstream booster pump. The entrained fluid was recycled or sent to a drain.
(51) The system was tested with CO.sub.2 at varying pressures of 1 psig (0.069 Bar) and 15 psig (1.03 Bar). The control gas was air. The fluid used for testing was water at a temperature of 60° F. (15.6 degrees Celsius), specific gravity of 1, and viscosity of 1 cP. The pump was operated at a speed of 3600 rpm.
(52) The results are presented in Table 2 and the graphs of
(53) TABLE-US-00002 TABLE 2 Test Run Results Suction Discharge Water Pressure Pressure Flow Gas Flow Gas Flow Run (psig) (psig) (gpm) (SCFH) (gpm) 1 −3.4 60 78.8 47.0 5.9 2 −3.4 60 78.2 145.8 18.2 3 −3.9 60 78.1 194.4 24.2 4 −3.4 80 53.0 22.0 2.7 5 −1 80 54.2 121.5 15.1 6 −1 80 54.4 170.1 21.2 7 0 100 33.0 15.0 1.9 8 0 100 31.7 109.4 13.6 9 0.5 100 32.5 145.8 18.2 Gas/ Water SCFH Gas Flow Differential Run % Gas Comparison Comments Pressure (psi) 1 7.4 Air 2 phase 63.4 2 23.2 CO.sub.2 1 psi 3.1 × air draw 1 phase 63.4 3 31.0 CO.sub.2 15 psi 4.1 × air draw 1 phase 63.9 4 5.2 Air 2 phase 83.4 5 27.9 CO.sub.2 1 psi 5.5 × air draw 1 phase 81.0 6 39.0 CO.sub.2 15 psi 7.7 × air draw 1 phase 81.0 7 5.7 Air 2 phase 100.0 8 43.0 CO.sub.2 1 psi 7.3 × air draw 1 phase 100.0 9 55.9 CO.sub.2 15 psi 9.7 × air draw 1 phase 99.5
(54) Briefly, it was determined that not only was the CO.sub.2 and water discharge fluid always single-phase, but also the gas flow significantly increased when using CO.sub.2 as compared to air, which was not anticipated prior to testing. The increase in gas flow ranged between three to seven times greater than that of air, varying with discharge pressure. The increase was even greater, between four to ten times greater, when the CO.sub.2 source was maintained at about 15 psig (1.03 Bar) pressure.
(55) The increase in CO.sub.2 gas flow obtained with the Brise™ 2.0 pump enables fewer pumps to replace the temporary VRU, making the application more economical, reducing footprint of the system, and reducing an energy demand of the system. Due to the Brise™ 2.0 impeller design, and the mixing action it creates in the pump, the high CO.sub.2 gas flow is possible while still maintaining the single-phase discharge.
(56) Thus, CO.sub.2 may be entrained in water to form a single-phase fluid with the systems and methods disclosed herein. It is expected that systems entraining other gases having a greater solubility than air will have similar results. In particular, it is expected that systems entraining other gases having a greater solubility than CO.sub.2 will have similar results.
(57) While specific embodiments have been discussed, the above specification is illustrative and not restrictive. Many variations will become apparent to those skilled in the art upon review of this specification and the claims below. The full scope should be determined by reference to the claims, along with their full scope of equivalents, and the specification, along with such variations.
(58) Certain embodiments are within the scope of the following claims.