Hydrogen peroxide steam generator for oilfield applications

Abstract

Exemplary apparatuses, systems, and methods are provided to produce steam for use in oil field applications. In some embodiments, a catalyst is provided that includes a plurality of ceramic bodies impregnated with an alkaline-promoted manganese oxide. In other embodiments, the catalyst includes a plurality of bodies formed of an active ceramic oxide in a consolidated state without an underlying ceramic body. The bodies are contacted with a liquid hydrogen peroxide having a strength, in one embodiment, between about 30 and about 70 weight percent to produce steam. The steam is directed to an oil field application, such as, but not limited to, a geologic formation to increase oil production from the geologic formation, an applicator to clean oilfield equipment, a heat exchanger to heat hydrogen peroxide, or a heat exchanger to heat living quarters.

What is claimed is: 
     
         1 . A method of manufacturing an apparatus for producing steam generated primarily by decomposition of a liquid hydrogen peroxide solution, the method comprising:
 providing a catalyst for decomposing the liquid hydrogen peroxide solution to produce the steam, wherein the steam is produced primarily by the decomposition of the liquid hydrogen peroxide solution, wherein providing a catalyst comprises:
 providing one or more ceramic bodies in a catalytic solution, 
 drying the one or more ceramic bodies, and 
 calcining the one or more ceramic bodies; 
   providing a liquid hydrogen peroxide source;   providing a first fluid communication pathway between the liquid hydrogen peroxide source and the catalyst; and   providing a second fluid communication pathway to conduct generated steam away from the catalyst.   
     
     
         2 . The method of  claim 1 , wherein drying the one or more ceramic bodies comprises placing the one or more ceramic bodies in an oven above about 150 degrees Celsius. 
     
     
         3 . The method of  claim 1 , wherein calcining the one or more ceramic bodies comprises heating the one or more ceramic bodies in an oven at between about 200 degrees Celsius and about 500 degrees Celsius. 
     
     
         4 . The method of  claim 1 , wherein the liquid hydrogen peroxide source is configured to contain the liquid hydrogen peroxide solution, the liquid hydrogen peroxide solution having a concentration:
 a) between about 30 weight percent and about 70 weight percent; or   b) between about 50 weight percent and about 65 weight percent.   
     
     
         5 . The method of  claim 1 , further comprising impregnating one or more of the one or more ceramic bodies in the catalytic solution. 
     
     
         6 . The method of  claim 5 , wherein impregnating the one or more of the one or more ceramic bodies in the catalytic solution comprises soaking the ceramic bodies for less than about one hour. 
     
     
         7 . The method of  claim 1 , wherein one or more of the one or more ceramic bodies have a shape that includes one or more selected from a group consisting of: spherical, square, rectangular, and triangular. 
     
     
         8 . The method of  claim 1 , wherein one or more of the one or more ceramic bodies have a shape that includes closely packed chunks, extrudate, pieces, pellets, or a combination thereof. 
     
     
         9 . The method of  claim 1 , wherein the liquid hydrogen peroxide solution further comprises a stabilizer. 
     
     
         10 . The method of  claim 9 , wherein the stabilizer is selected from a group consisting of one or more phosphoric acids, phosphonic acids, or inorganic stannates. 
     
     
         11 . The method of  claim 1 , wherein the one or more ceramic bodies includes a monolith body. 
     
     
         12 . The method of  claim 1 , wherein the one or more ceramic bodies are formed in a consolidated state. 
     
     
         13 . A method of manufacturing an apparatus for producing steam generated primarily by decomposition of a liquid hydrogen peroxide solution, the method comprising:
 providing a manganese dioxide catalyst for decomposing the liquid hydrogen peroxide solution into oxygen and steam primarily in response to contact with the manganese dioxide catalyst to produce the steam at the catalyst, wherein the steam is produced primarily by the decomposition of the liquid hydrogen peroxide solution into oxygen and steam in response to contact with manganese dioxide of the manganese dioxide catalyst and not primarily by combustion;   providing a liquid hydrogen peroxide source configured to contain the liquid hydrogen peroxide solution, the liquid hydrogen peroxide solution having a concentration below a self-heat concentration of the liquid hydrogen peroxide solution and less than about 64.7 weight percent;   providing a first coupling configured to provide a first fluid communication pathway between the liquid hydrogen peroxide source and the manganese dioxide catalyst; and   providing a second coupling configured to provide a second fluid communication pathway from the catalyst, wherein the second fluid communication pathway communicates steam from the catalyst.   
     
     
         14 . The method of  claim 13 , wherein providing the second coupling further comprises providing the second coupling configured to provide the second fluid communication pathway from the catalyst and to at least one of production tubing, pipelines, and tanks, wherein the steam at least one of cleans and clears the at least one of production tubing, pipelines, and tanks. 
     
     
         15 . The method of  claim 13 , wherein the apparatus is further provided for producing steam for cleaning at least one of production tubing, pipelines, and tanks. 
     
     
         16 . The method of  claim 13 , wherein the second fluid communication pathway is provided connecting between the catalyst and a geologic formation for injecting the steam and not the liquid hydrogen peroxide solution into the geologic formation. 
     
     
         17 . The method of  claim 9 , wherein the liquid hydrogen peroxide solution is provided with a concentration greater than 30 weight percent. 
     
     
         18 . A method of manufacturing an apparatus for producing steam generated primarily by decomposition of a liquid hydrogen peroxide solution, the method comprising:
 providing a chamber configured to hold a manganese dioxide catalyst for decomposing the liquid hydrogen peroxide solution into oxygen and steam;   providing a liquid hydrogen peroxide source configured to contain the liquid hydrogen peroxide solution, the liquid hydrogen peroxide solution having a concentration below a self-heat concentration of the liquid hydrogen peroxide solution and less than about 64.7 weight percent and greater than 30 weight percent;   providing a first coupling connecting the liquid hydrogen peroxide source to the chamber and configured to provide a first fluid communication pathway between the liquid hydrogen peroxide source and the chamber configured to receive the body; and   providing a second coupling connecting to chamber and providing a second fluid communication pathway from the body.   
     
     
         19 . The method of  claim 18 , wherein the second coupling is provided to connect the chamber to a steam applicator. 
     
     
         20 . The method of  claim 18 , wherein the second coupling is provided to connect the chamber to a geologic formation to communicate steam from the chamber to the geologic formation.