Produced water steam generation process using produced water boiler with gas turbine

Abstract

A method and system for producing steam for use in heavy hydrocarbon recovery operations. Water, containing impurities, produced from the well is separated from hydrocarbons and other materials, and subsequently directly passed to a produced water boiler with online pigging. The boiler is indirectly heated by means of a hot flue gas, such as a gas turbine exhaust, which produces electricity (for powering a central processing facility, or alternatively a burner to heat the boiler) and exhaust heat for heating the boiler.

What is claimed is: 
     
         1 . A method for generating steam for use in a thermal hydrocarbon recovery operation, the operation comprising at least one hydrocarbon recovery well, the method comprising the steps of:
 producing produced materials from the at least one hydrocarbon recovery well;   treating the produced materials to separate water from the produced materials;   feeding the water into steam generation means;   providing a heat source;   providing heat exchange means between the heat source and the steam generation means;   transferring heat from the heat source to the steam generation means via the heat exchange means;   allowing the heat to increase the temperature of the steam generation means; and   heating at least a portion of the water in the steam generation means to or above the water's boiling point to generate steam.   
     
     
         2 . The method of  claim 1  further comprising the step of treating the produced materials to separate gas and/or solids and/or hydrocarbon from the produced materials. 
     
     
         3 . The method of  claim 2 , wherein the gas is separated, further comprising the step of treating the gas by using gas treating means. 
     
     
         4 . The method of  claim 3  wherein treating the gas comprises reducing sulphur content of the gas. 
     
     
         5 . The method of  claim 2 , wherein the hydrocarbon is separated, further comprising the step of diluting the hydrocarbon with a diluent for transport of the hydrocarbon. 
     
     
         6 . The method of  claim 1  further comprising the step of injecting the steam into the at least one hydrocarbon recovery well. 
     
     
         7 . The method of  claim 2 , wherein the gas is separated, further comprising the steps of feeding the gas to the heat source and using the gas to at least partially fuel the heat source. 
     
     
         8 . The method of  claim 1  further comprising the step of injecting the steam into the at least one hydrocarbon recovery well. 
     
     
         9 . The method of  claim 1  wherein the heat source is waste heat from a machine. 
     
     
         10 . The method of  claim 9  wherein the machine is an electricity generator. 
     
     
         11 . The method of  claim 1  wherein the steam generation means are a produced water boiler. 
     
     
         12 . The method of  claim 1  further comprising the step of cleaning build-up from the steam generation means via mechanical cleaning means. 
     
     
         13 . The method of  claim 10  wherein gas is separated from the produced materials, the electricity generator is a gas turbine unit, and the gas is used to at least partially fuel the gas turbine unit, the waste heat comprising heated exhaust produced by the gas turbine unit. 
     
     
         14 . The method of  claim 12  wherein the mechanical cleaning means comprise on-line pigging. 
     
     
         15 . The method of  claim 2 , wherein the hydrocarbon is separated, further comprising the step of partially upgrading the hydrocarbon. 
     
     
         16 . A steam generation system for use in thermal hydrocarbon recovery operations wherein the operations comprise at least one hydrocarbon recovery well, the system comprising:
 produced materials treatment means configured to separate water from produced materials produced from the at least one hydrocarbon recovery well;   feeding means for feeding the water to steam generation means;   a heat source; and   heat exchange means between the heat source and the steam generation means for transferring heat from the heat source to the steam generation means, allowing heat to increase the temperature of the steam generation means and heating at least a portion of the water in the steam generation means to or above the water's boiling point to generate steam from the water.   
     
     
         17 . The system of  claim 16  wherein the produced materials treatment means are configured to separate gas and/or solids and/or hydrocarbon from the produced materials. 
     
     
         18 . The system of  claim 17  wherein the produced materials treatment means are configured to separate the gas from the produced materials, further comprising gas treating means for treating the gas. 
     
     
         19 . The system of  claim 18  wherein the gas treating means are for reducing sulphur content of the gas. 
     
     
         20 . The system of  claim 17  wherein the produced materials treatment means are configured to separate the hydrocarbon from the produced materials, further comprising a diluent source for diluting the hydrocarbon with a diluent for transport of the hydrocarbon. 
     
     
         21 . The system of  claim 16  further comprising steam injection means for injecting the steam into the at least one hydrocarbon recovery well. 
     
     
         22 . The system of  claim 16  wherein the heat source is waste heat from a machine. 
     
     
         23 . The system of  claim 22  wherein the machine is an electricity generator. 
     
     
         24 . The system of  claim 16  wherein the steam generation means are a produced water boiler. 
     
     
         25 . The system of  claim 16  further comprising mechanical cleaning means for cleaning build-up inside the steam generation means. 
     
     
         26 . The system of  claim 23  wherein the produced materials treatment means are configured to separate the gas from the produced materials, the electricity generator is a gas turbine unit, and the gas is used to at least partially fuel the gas turbine unit, the waste heat comprising heated exhaust produced by the gas turbine unit. 
     
     
         27 . The system of  claim 25  wherein the mechanical cleaning means comprise on-line pigging. 
     
     
         28 . The system of  claim 17  wherein the produced materials treatment means are configured to separate the hydrocarbon from the produced materials, further comprising partial upgrading means for partially upgrading the hydrocarbon.