APPARATUS FOR THE WELLBORE SEPARATION OF
HYDROCARBON GAS AND CONTAMINANTS WITH
MEMBRANES FOR REMOVAL OF HYDROCARBON LIQUIDS
FIELD OF THE INVENTION
The invention relates to recovery of hydrocarbon gas from a wellbore, and more particularly, the invention relates to technology for separation of contaminants from hydrocarbon gas in a wellbore with membranes for removal of hydrocarbon liquids which cause damage to gas separation membranes.
BACKGROUND OF THE INVENTION AND BRIEF DESCRIPTION OF THE RELATED ART
Hydrocarbon gases have been recovered from underground wellbores for over a hundred years. The recovery technology generally involves drilling a wellbore into a hydrocarbon gas formation and withdrawing the hydrocarbon gas under reservoir pressure or by artificial lifting.
The current recovery technology involves removing the hydrocarbon gas and any liquid and gas contaminants which are present from the wellbore together, and separating the contaminants from the hydrocarbon gas above ground. This above ground separation of contaminants from the hydrocarbon gas is costly. Disposal of the removed contaminants may also present environmental problems. The contaminants which may be produced include gases, such as carbon dioxide, nitrogen, water vapor, hydrogen sulfide, helium, and other trace gases, and liquids such as water, heavy hydrocarbons, and others. The contaminants which are brought to the surface and separated from the hydrocarbon gas are released to the atmosphere or otherwise disposed of adding additional expense to the process. Due to environmental concerns about the release of greenhouse gases, many countries are placing greater and greater limitations on emission of byproduct gases to the atmosphere. For example, some countries now assess a tax on carbon dioxide emissions.
Accordingly, it would be highly desirable to maintain some or all of the contaminant materials, such as carbon dioxide, within the wellbore and/or selectively separate the contaminants in the wellbore for reinjection, removal, or other processing. Membrane technologies have been developed which allow the selective passage of materials. This technology has heretofore been used as a surface technology for separating hydrocarbon gas from contaminants after recovery and has not been used in a downhole situation. It is desirable to place these membrane materials downhole to remove contaminants downhole and avoid the cost intensive process of lifting, separating, and disposing of the contaminants. However, these membrane materials are not placed downhole for separation of the hydrocarbon gas from contaminants because of a number of potential difficulties including high temperatures and harsh conditions downhole which are not suitable for many membrane materials. One significant potential problem which may occur when membrane materials are placed downhole for separation of gases is the degradation of the membrane materials due to contact with liquids present in the wellbore. These liquids include, but are not limited to, liquid hydrocarbons and water.
U.S. Patent No. 6,015,011 describes a downhole hydrocarbon separator using membranes. The separator includes one or more permeable filters which selectively permit the migration of oil or natural gas through the filters and out of the well while leaving the contaminants behind within the wellbore. This configuration results in the substantial drawback that accumulated contaminants in the wellbore decrease the production of the well. This system also does not provide any way to protect sensitive membrane material from materials which may cause damage to the membrane material.
The membrane materials which are useable in the system of U.S. Patent No. 6,015,011 require a carefully controlled pressure differential across the membrane to allow the hydrocarbon to pass through and prevent the water from passing through. If a critical pressure differential (about 0.1 to 50 psig, commonly 5 psig) is exceeded water begins to permeate the membrane. Once water permeation begins, the water
flow rate through the membrane is much higher than the hydrocarbon flow rate. Total pressures in well bores may be in the thousands of pounds of pressure and quick fluctuations of over 100 psig are common. Accordingly, it would be extremely difficult to control the critical pressure differential in a wellbore to achieve the pressures which would be required by the membrane separation system of this patent. An additional problem with this approach, using a hydrophilic membrane is caused by the difference in viscosity between the hydrocarbon and water. Crude oil viscosity varies widely, but even relatively light crude oil is frequently more viscous than water. In order to achieve high permeation rates of oil through the membrane, a high trans-membrane pressure differential is desired. This is at odds with the need to maintain a low trans-membrane pressure to prevent water permeation.
These problems are further exasperated in practice by the presence of other components in the crude oil which serve as surfactants and fowling agents. Surfactants will further reduce the working range of trans-membrane pressure drop by making water breakthrough at a lower pressure differential.
It would be desirable to provide a downhole hydrocarbon gas separation system in which the gas separating membranes are protected from degradation due to contact with liquids by removal of liquids from the wellbore downstream of a location of the gas separating membranes. U.S. Patent No. 5,860,476 describes a downhole hydrocarbon cyclone separator system in which gas and liquid are separated from one another using a cyclone separator. Subsequently, condensate/oil is separated from water in an additional cyclone separator and unwanted gases are separated by membranes. However, separation of oil/condensate from water using cyclones is practically limited to cases of high water cut, that is where there is a relatively large amount of water. This approach is also limited to the case of where pure oil or pure water is required but it not well suited to the case where both pure oil and water phases are desired.
It would be desirable to provide a downhole hydrocarbon gas separation system in which the gas separating membranes are protected from degradation due to contact with liquids by removal of liquids from the wellbore by a liquid separation membrane positioned to reduce contact of the liquids with the gas separation
membrane and extend the life of the gas separation membrane. The liquid separation membranes which protect the gas separation membranes from degradation are capable of removing water at high and low water cuts.
SUMMARY OF THE INVENTION
The present invention provides a system for wellbore separation of gas contaminants from hydrocarbon gas with a gas separation membrane. In order to prevent degradation of the gas separation membranes, the present invention provides one or more liquid separation membranes positioned downstream of the gas separation membranes, positioned in parallel with the gas separation membranes, or interspersed with the gas separation membranes for removal of liquids.
According to one aspect of the present invention, a separation system for separating hydrocarbon gases and contaminants in a wellbore includes a gas separation membrane for separating gas phase contaminants from hydrocarbon gases and a liquid separation membrane for separating liquid phase contaminants from hydrocarbon gases, the liquid separation membrane positioned to reduce contact of the liquids with the gas separation membrane and extend the life of the gas separation membrane.
According to another aspect of the invention, a method of separating hydrocarbon gases and contaminants in a wellbore involves removing a predominantly liquid phase contaminant from a crude oil stream with a liquid separation membrane positioned in a wellbore and removing a gaseous contaminant from the crude oil stream with a gas separation membrane positioned in a wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in greater detail with reference to the preferred embodiments illustrated in the accompanying drawings, in which like elements bear like reference numerals, and wherein:
FIG. 1 is a schematic longitudinal sectional view taken through a well bore of a wellbore separation system according to a first embodiment of the invention;
FIG. 2 is a schematic longitudinal sectional view taken through a well bore of a wellbore separation system according to a second embodiment of the invention with multiple alternating gas and liquid removal membranes; and
FIG. 3 is a schematic longitudinal sectional view taken through a well bore of a wellbore separation system according to a third embodiment of the invention with gas and liquid removal membranes positioned in parallel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Membrane materials which are usable in separation systems for separating contaminants from hydrocarbon gases downhole are degraded or destroyed by contact with liquids, such as water and liquid (heavy) hydrocarbons. This is a significant problem in developing downhole membrane separation systems. Even relatively dry wells producing mostly gas will sometimes produce some liquids in the production stream which are damaging to the gas membranes. In addition, the production of a relatively dry well may change over time and liquids may begin to condense out of the production stream leading to damaged gas membranes. In addition, as contaminants, such as carbon dioxide, are removed from the hydrocarbon gas, liquids may condense out of the gas.
The present invention provides a system for wellbore separation of contaminants from hydrocarbon gas in which liquids and some gases which will degrade a gas separation membrane are removed with a liquid separation membrane. The liquid separation membrane is positioned to reduce contact of the liquids with a gas separation membrane to extend the life of the gas separation membrane.
Membranes which remove gas contaminants from hydrocarbon gas (referred to as gas separation membranes, herein) are susceptible to degradation due to contact with liquids. Examples of gas separation membrane materials which may be degraded by liquids include cellulose acetate, polysulfone, polyimide, carbon molecular sieve membranes, and composites of these. Cellulose acetate membranes tend to be degraded by contact with water. Polyimide and polysulfone membranes are degraded by heavy hydrocarbons and carbon molecular sieve membranes are harmed by contact with aromatics and heavy hydrocarbons.
In order to prevent degradation of these gas separation membranes, the present invention provides one or more liquid separation membranes positioned downstream of the gas separation membranes, positioned in parallel with the gas separation membranes, or interspersed with the gas separation membranes for removal of liquids. The removal of the liquids prior to contact of liquids with the gas separation membranes greatly prolongs the life the gas separation membranes and improves the efficiency of the well by reducing the amount of downtime for replacement of damaged membranes.
Liquid separation membranes generally function to remove a mixture of liquids and gases from a hydrocarbon stream but are termed liquid separation membranes based on their primary purpose of removing liquid phase or condensed contaminants from a hydrocarbon gas stream.
FIG. 1 illustrates a wellbore 10 having a well casing 12, and positioned within the well casing, a production string including a separation system. The separation system includes a gas separation membrane 14 and a liquid separation membrane 16 arranged in series. A series of packers 20, 22, 24 surround the production string and provide seals between particular zones within the wellbore 10. The wellbore 10 is divided by the packers into a production zone 26, a liquid collection zone 28, and a gas collection zone 30. In operation of the embodiment of FIG. 1, the gas and liquid separation membranes 14, 16 are tubular hollow fiber membranes which permeate contaminates out of the tubes as the hydrocarbon gas mixture passes through the center of the tubes. The hydrocarbon gas mixture including liquid and gas contaminants enters the wellbore 10 through the well casing 12 at the production zone 26. A perforated tube 32 allows the hydrocarbon gas mixture to enter the production string and pass upward through the inside of the production string.
Upon entering the tubular hollow fiber liquid separation membrane 16, the liquid contaminant, such as water or liquid hydrocarbon, passes out through the membrane and enters the surrounding liquid containment collection zone 28. The hydrocarbon gas plus any remaining contaminant that was not removed by the liquid separation membrane 16 continue out the top of the membrane 16 and pass into the
gas separation membrane 14. The liquid contaminants which have been collected in the liquid collection zone 28 may be disposed of by directing the contaminants to an underground disposal formation, as shown. Alternatively, the liquid contaminants may be removed from the liquid contaminant collection zone 28 by piping to the surface in a separate pipe (not shown). The liquid separation membrane 16 reduces contact of liquids with the gas separation membrane 14 decreasing degradation of the gas separation membrane due to contact with liquids and extending the life of the gas separation membrane.
The hydrocarbon gas mixture with reduced liquid contaminants is then passed to the gas separation membrane 14 where gas contaminants pass out through the membrane and enter the surrounding gas collection zone 30. The hydrocarbon gas with removed/reduced contaminants is passed to the surface 32 through the tube 36. The contaminants which have been collected in the gas collection zone 30 may be disposed of by directing the gas contaminants through perforations in the wellbore casing 12 to an underground disposal formation, as shown. Alternatively, the gas contaminants may be removed from the gas collection zone 30 to the surface in a separate pipe (not shown).
Although the embodiment of FIG. 1 has been illustrated with a single liquid separation membrane 14 and a single gas separation membrane 16 the system may include additional membranes for removal of the same or additional contaminants, as needed. For example, according to one embodiment of the invention, a separation system includes a first liquid separation membrane for removal of heavy hydrocarbons including natural gas liquids and liquid/gas mixtures. The heavy hydrocarbons are a valuable product removed to the surface. A second liquid separation membrane for removal of water and water vapor is positioned upstream of the first membrane and a third carbon dioxide gas separation membrane is positioned upstream of the second membrane. The removed water and carbon dioxide are preferably disposed of downhole.
FIG. 2 illustrates an alternative embodiment of the invention in which multiple liquid separation membranes 16a, 16b and liquid collection zones 28a, 28b are alternated with multiple gas separation membranes 14a, 14b and gas collection zones
30a, 30b. This alternating separation of liquids and gases addresses the case where as gas contaminants, such as carbon dioxide, are removed from the hydrocarbon gas stream, liquids condense out of the gas. These condensed liquids, which may damage the subsequent gas separation membranes 14b, are removed by interspersed or supplemental liquid separation membranes 16b. The supplemental liquid separation membranes 16b may be the same or different from the primary liquid separation membrane 16a. For example, the supplemental liquid separation membranes 16b may be smaller than the primary liquid separation membrane 16a.
FIG. 3 illustrates a further embodiment of the invention in which one or more liquid separation membranes is position in parallel with one or more gas separation membranes. FIG. 3 illustrates a wellbore 110 having a well casing 112 with a separation system positioned within the well casing. The separation system includes a gas separation membrane 114 and a liquid separation membrane 116 arranged in parallel. Each of the membranes 114, 116 is connected to a corresponding pipe 134, 136 for delivery of removed contaminants to the surface 144. A pipe 126 is provided for delivery of the hydrocarbon gas with reduced contaminants to the surface 144. One or more packer 120 surrounds the tubes 134, 136, 138 to isolate the production zone 126 within the wellbore 110.
In the embodiment of FIG. 3, the a the gas and liquid separation membranes 114, 116 are mbular hollow fiber membranes which permeate contaminates into the tubes as the hydrocarbon gas mixture passes around the exterior of the tubes. The hydrocarbon gas mixture including liquid and gas contaminants enters the wellbore 110 through the well casing 112 at the production zone 126. The hydrocarbon gas mixture passes upward in the wellbore 110 around the gas and liquid separation membranes 114, 116.
The liquid contaminants, such as water or liquid hydrocarbon pass through the liquid separation membrane 116 and out of the wellbore 110 through the tube 136. Correspondingly, the gas contaminants, such as carbon dioxide, pass through the gas separation membrane 114 and out of the wellbore 110 thorough the tube 134. Alternatively, the liquid and gas contaminants may be disposed of downhole as in the embodiments of FIGS. 1 and 2. The hydrocarbon gas plus any remaining liquid or gas
contaminants that were not removed passes to the surface 144 through the tube 138. The use of the liquid separation membrane 116 in close proximity to the gas separation membrane 114 reduces the amount of liquids contacting the gas separation membrane improving the life of the gas separation membrane. The operation of the present invention has been illustrated and described with respect to a vertical well, however, it should be understood that the invention may be employed in horizontal wells and other non- vertical wells.
The following membranes are given as examples of membranes which may be used to remove liquids (and some gases) from hydrocarbon gas. Membranes which are preferred for removal of heavy hydrocarbons include rubbery membranes, glassy membranes and nanoporous carbon membranes. Rubbery membranes include poly(dimethylsiloxane) and PEI (silicon rubber composite). Examples of glassy membranes are cellulose acetate and polysulfone.
The membranes according to the present invention are selected to be durable and resistant to high temperatures. The materials may be coated or otherwise protected to help prevent fouling and improve durability.
The number, type, and configuration of the membranes may vary depending on the particular well. The separation system may be specifically designed for a particular well taking into account the type and amounts of hydrocarbon and contaminants present in the well, and the well configuration. It should be understood that due to the nature of membranes, the separation process is imperfect with some of the hydrocarbon passing through the membranes with the contaminants and some of the contaminants remaining in the production stream. However, the imperfect downhole membrane separation system can be used to greatly reduce the above ground separation required.
The present invention may be combined with existing downhole technologies for mechanical physical separation systems, such as cyclones or centrifugal separation systems. The invention may also be used for partial removal of the contaminants to reduce the burden on surface removal facilities with the remaining contaminants removed by conventional surface technologies. Some types of separated contaminants
such as carbon dioxide can be reinjected into the productive horizon to maintain pressurization of the reservoir.
While the invention has been described in detail with reference to the preferred embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made and equivalents employed, without departing from the present invention.