Liquid indirect steam boiler

Abstract

Systems and methods generate steam in hydrocarbon recovery operations and may further enable emulsion separation and product upgrading. The methods rely on indirect boiling of water by contact with a thermal transfer liquid heated to a temperature sufficient to vaporize the water. Examples of the liquid include oils, recovered hydrocarbons, liquid metals and brine. Heating of the liquid may utilize circulation of the liquid across or through a furnace, heat exchangers, or a gas-liquid contactor supplied with hot gas. Further, a solvent for bitumen introduced into the water may also vaporize upon contact with the thermal transfer liquid.

1 . A method of generating steam in a hydrocarbon recovery operation, comprising:
 recovering a mixture of produced water and hydrocarbons from an underground formation;   introducing the water into a vessel;   contacting the water within the vessel with a liquid heated to above a boiling point of the water for vaporization of the water into steam within the vessel;   separating the steam in an overhead of the vessel from the liquid; and   injecting the steam into the formation to facilitate additional hydrocarbon recovery.   
     
     
         2 . The method according to  claim 1 , wherein the liquid is petroleum based. 
     
     
         3 . The method according to  claim 1 , wherein the liquid includes brine. 
     
     
         4 . The method according to  claim 1 , wherein the liquid is heated by heating coils disposed in the liquid within the vessel. 
     
     
         5 . The method according to  claim 1 , wherein the liquid is heated by molten sodium circulated through heating coils disposed in the liquid within the vessel. 
     
     
         6 . The method according to  claim 1 , wherein the liquid is heated in a circulation loop from the vessel by gas contact heat exchange before being returned to the vessel. 
     
     
         7 . The method according to  claim 1 , wherein the liquid is heated in a circulation loop from the vessel by a furnace before being returned to the vessel. 
     
     
         8 . The method according to  claim 1 , wherein the water is pressurized to at least 10,000 kilopascals prior to being introduced into the vessel. 
     
     
         9 . The method according to  claim 1 , wherein the water is separated from the hydrocarbons prior to being introduced into the vessel. 
     
     
         10 . The method according to  claim 1 , further comprising preheating the water prior to being introduced into the vessel. 
     
     
         11 . The method according to  claim 1 , further comprising adding a solvent to the water for vaporization of the solvent with the water. 
     
     
         12 . The method according to  claim 1 , wherein the water is separated from the hydrocarbons at a facility separate and remote from location of the vessel at a well pad where the steam is injected. 
     
     
         13 . A system for generating steam in a hydrocarbon recovery operation, comprising:
 a production well for recovering a mixture of produced water and hydrocarbons from an underground formation;   a vessel coupled to the production well for receiving the water;   a liquid disposed within the vessel in contact with the water and heated to above a boiling point of the water for vaporization of the water into steam within the vessel; and   an injection well in fluid communication with the steam separated in an overhead of the vessel from the liquid and for conveying the steam into the formation to facilitate additional hydrocarbon recovery.   
     
     
         14 . The system according to  claim 13 , further comprising a nozzle to introduce the water as droplets into the vessel. 
     
     
         15 . The system according to  claim 13 , wherein the liquid is petroleum based. 
     
     
         16 . The system according to  claim 13 , wherein the liquid includes brine. 
     
     
         17 . The system according to  claim 13 , further comprising heating coils disposed in the liquid within the vessel for transfer of heat to the liquid. 
     
     
         18 . The system according to  claim 13 , further comprising heating coils disposed in the liquid within the vessel for transfer of heat to the liquid from molten sodium circulated within the coils. 
     
     
         19 . The system according to  claim 13 , further comprising a circulation loop from the vessel for heating the liquid by heat exchange in a gas-liquid contactor. 
     
     
         20 . The system according to  claim 13 , further comprising a circulation loop from the vessel for heating the liquid by a furnace before being returned to the vessel.