# US 10,246,979 B2 · Remote steam generation and water-hydrocarbon separation in steam-assisted gravity drainage operations > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,246,979 B2 - Document ID: US10246979B2 - Status: Granted - Kind: B2 - Application number: 14/671,104 - Filed: 2015-03-27 - Published: 2015-10-01 - Granted: 2019-04-02 - Earliest claimed: 2014-03-28 - Assignees: Suncor Energy Inc. - Applicants: Suncor Energy Inc. - Inventors: Andrew Donald; Todd Stewart Pugsley; Gary L. Bunio; Ian Donald Gates - Web page: https://patentgrep.com/patent/US10246979B2 ## CPC - E21B 43/2408: {SAGD in combination with other methods} - E21B 43/164: {Injecting CO2 or carbonated water (in combination with organic material C09K8/594)} - E21B 43/40: Separation associated with re-injection of separated materials {(E21B43/385 takes precedence)} - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS ## Abstract A Steam-Assisted Gravity Drainage (SAGD) method for recovering hydrocarbons from a reservoir can include generating steam and CO2 from feedwater, fuel and oxygen; transferring a steam-CO2 mixture comprising at least a portion of the steam and at least a portion of the CO2, to a proximate SAGD injection well; injecting the steam-CO2 mixture into the SAGD injection well; obtaining produced fluids from a SAGD production well underlying the SAGD injection well; transferring the produced fluids for separation proximate to the SAGD production well; separating the produced fluids into a produced gas and a produced emulsion; transferring the produced emulsion for separation proximate to the SAGD production well; separating the produced emulsion to obtain a produced hydrocarbon-containing component and produced water; supplying at least a portion of the produced water as at least part of the feedwater; and supplying the produced hydrocarbon-containing component to a central processing facility. ## Claims ### Claim 1 A system for recovering hydrocarbons from a reservoir, the system comprising: a processing facility comprising a first water-hydrocarbon separator; and a remote hydrocarbon recovery facility connected to the processing facility by a supply line, the remote hydrocarbon recovery facility comprising: a steam generator for receiving feedwater and generating a steam-based mixture therefrom, wherein the steam generator comprises a Direct-Contact Steam Generator (DCSG); a well pad supporting a well pair comprising: an injection well in fluid communication with the steam generator to receive the steam-based mixture; and a production well for recovering produced fluids from the reservoir; and a second water-hydrocarbon separator in fluid communication with the production well to receive the produced fluids and produce a produced water component and a hydrocarbon mixture comprising an amount of water, the supply line providing fluid communication between the first water-hydrocarbon separator and the second water-hydrocarbon separator to transport the hydrocarbon mixture to the processing facility without transporting the produced water component, the first water-hydrocarbon separator separating the hydrocarbon mixture into treated water and produced hydrocarbons. ### Claim 2 (depends on 1) The system of claim 1, wherein the DCSG is a Direct-Fired Steam Generator (DFSG). ### Claim 3 (depends on 1) The system of claim 1, further comprising: a fuel line for supplying fuel from the processing facility to the steam generator. ### Claim 4 (depends on 1) The system of claim 1, further comprising: an oxygen supply assembly for supplying an oxygen-containing gas to the steam generator for combustion. ### Claim 5 (depends on 1) The system of claim 1, wherein the amount of water in the hydrocarbon mixture is up to about 10 wt %. ### Claim 6 (depends on 1) The system of claim 1, further comprising: a second recycle line for conveying at least a portion of the treated water back to the remote hydrocarbon recovery facility to recycle at least a portion of the treated water as part of the feedwater to the steam generator. ### Claim 7 (depends on 1) The system of claim 1, further comprising: a gas-emulsion separator in fluid communication with the production well to receive the produced fluids and produce a produced gas and gas-depleted produced fluids, the second water-hydrocarbon separator being configured to receive the gas-depleted produced fluids to produce the produced water component and the hydrocarbon mixture. ### Claim 8 (depends on 7) The system of claim 7, further comprising a produced gas line for transporting the produced gas from the gas-emulsion separator to the processing facility. ### Claim 9 (depends on 1) The system of claim 1, wherein the second water-hydrocarbon separator comprises a free water knockout drum. ### Claim 10 (depends on 9) The system of claim 9, wherein the first water-hydrocarbon separator comprises a treater. ### Claim 11 (depends on 9) The system of claim 9, wherein the water-hydrocarbon separator further comprises a skim tank. ### Claim 12 (depends on 9) The system of claim 9, wherein the water-hydrocarbon separator further comprises an induced floatation unit. ### Claim 13 (depends on 9) The system of claim 9, wherein the water-hydrocarbon separator further comprises a walnut shell filtering unit. ### Claim 14 (depends on 9) The system of claim 9, wherein the water-hydrocarbon separator further comprises a slop-oil tank. ### Claim 15 (depends on 1) The system of claim 1, further comprising: a diluent line to supply a diluent to the produced fluids to produce diluted produced fluids that are separated in the second water-hydrocarbon separator. ### Claim 16 (depends on 15) The system of claim 15, wherein the diluent line is connected upstream of the water-hydrocarbon separator. ### Claim 17 (depends on 15) The system of claim 15, wherein the diluent line is in fluid communication with the processing facility to receive the diluent therefrom. ### Claim 18 (depends on 15) The system of claim 15, wherein the diluent line is in fluid communication with a diluent tank or diluent truck located at the remote hydrocarbon recovery facility. ### Claim 19 (depends on 1) The system of claim 1, further comprising: a water recycle line for recycling at least a portion of the produced water component from the second water-hydrocarbon separator as at least part of the feedwater received by the DCSG. ### Claim 20 (depends on 19) The system of claim 19, wherein recycling at least a portion of the produced water component comprises recycling all of the produced water component. ### Claim 21 (depends on 19) The system of claim 19, wherein the feedwater further comprises makeup water. ### Claim 22 (depends on 21) The system of claim 21, wherein the makeup water is at least partially obtained from the processing facility. ### Claim 23 (depends on 21) The system of claim 21, wherein the concentration of the makeup water in the feedwater is about 0 wt% to about 90 wt%. ### Claim 24 (depends on 21) The system of claim 21, wherein the concentration of the makeup water in the feedwater is about 0 wt% to about 20 wt%. ### Claim 25 (depends on 21) The system of claim 21, further comprising: a makeup water line for supplying the makeup water to the steam generator from a water source. ### Claim 26 (depends on 25) The system of claim 25, wherein the water source comprises a water tank located at the remote hydrocarbon recovery facility. ### Claim 27 (depends on 1) The system of claim 1, wherein the hydrocarbons are recovered from the reservoir by Steam-Assisted Gravity Drainage (SAGD). ### Claim 28 (depends on 7) The system of claim 7, wherein the injection well is a SAGD injection well and the production well is a SAGD production well underlying the SAGD injection well. ### Claim 29 (depends on 27) The system of claim 27, wherein the steam-based mixture comprises a steam-CO2 mixture that includes steam and combustion gases produced by the DCSG. ### Claim 30 (depends on 29) The system of claim 29, wherein the steam-CO2 mixture comprises between about 1 wt. % and about 12 wt. % of CO2. ### Claim 31 (depends on 1) The system of claim 1, wherein the steam generator of the remote hydrocarbon recovery facility consists of a DCSG. ### Claim 32 (depends on 31) The system of claim 31, comprising a feedwater supply line in fluid communication between the DCSG and the second water-hydrocarbon separator, and configured to supply all of the produced water component to the DCSG. ### Claim 33 (depends on 31) The system of claim 31, comprising a plurality of the remote hydrocarbon recovery facilities being connected to the processing facility by respective supply lines to supply respective hydrocarbon mixtures to the processing facility. ### Claim 34 (depends on 31) The system of claim 31, wherein the steam generator and the second water-hydrocarbon separator are located within 200 meters of the well pad, and the processing facility is located multiple kilometers away from the remote hydrocarbon recovery facility. ### Claim 35 (depends on 34) The system of claim 34, wherein the steam generator and the second water-hydrocarbon separator are located on the well pad.