Steam generation system with subcooled water spray for wellbore steam injection

A steam supply system for a wellbore comprising:

• a once-through steam generator having a wet steam outlet;
• a steam separator having a separation vessel with a wet steam inlet in fluid communication with the wet steam outlet of the once-through steam generator, a dry saturated steam outlet and a saturated condensate outlet;
• a superheater having a tube bundle with a dry saturated steam inlet and a superheated steam outlet, wherein the dry saturated steam inlet is in fluid communication with the dry saturated steam outlet of the steam separator;
• a subcooler having a vessel with a tube bundle disposed therein, a saturated condensate inlet in fluid communication with the tube bundle, a subcooled condensate outlet in fluid communication with the tube bundle, a cooling fluid inlet disposed in the vessel and a cooling fluid outlet disposed in the vessel, wherein the saturated condensate inlet of the subcooler is in fluid communication with the saturated condensate outlet of the steam separator;
• and
• a steam mixing vessel having a chamber with one or more nozzles disposed in the chamber, a superheated steam inlet in fluid communication with the superheated steam outlet of the superheater;
• and a process steam outlet in fluid communication with a wellbore tool;
• wherein the subcooled condensate outlet of the subcooler is in fluid communication with the one or more nozzles of the steam mixing vessel.

A steam supply system comprising:

• a steam source;
• a steam separator in fluid communication with the steam source, the steam separator having a dry saturated steam outlet and saturated condensate outlet;
• a superheater in fluid communication with the steam outlet of the steam separator, the superheater having a superheated steam outlet;
• a subcooler in fluid communication with the saturated condensate outlet of the steam separator, the subcooler having a subcooled condensate outlet and a cooling fluid inlet;
• a cooling fluid source in fluid communication with the cooling fluid inlet of the subcooler;
• and
• a mixing vessel in fluid communication with the superheated steam outlet of the superheater and the subcooled condensate outlet of the subcooler, the mixing vessel having a process steam outlet.