Bi-fuel Reciprocating Engine for Fracturing Pumps
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Solution Overview
Problem
The existing systems for hydraulic fracturing operations face inefficiencies and increased emissions due to the use of additional internal combustion engines for powering auxiliary components, which have different fuel requirements and produce undesirable emissions.
Innovation Solution
A bi-fuel reciprocating engine system that supplies primary and secondary fuels based on the power load, using a controller to determine the optimal mix of fuels from a primary fuel source, such as natural gas, and a secondary fuel source, like diesel, to efficiently operate hydraulic and electrical auxiliary components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an additional internal combustion engine is used to power auxiliary components, then the fracturing unit can operate auxiliary systems, but emissions increase and operational costs increase
Solution Approach 1:
The prime mover is designed to perform multiple functions: it can directly drive the fracturing pump and simultaneously power auxiliary components through an electrical power generation device. This eliminates the need for a separate internal combustion engine for auxiliary systems, reducing emissions while maintaining full operational capability of all systems
Solution Approach 2:
The patent combines the functions of the prime mover, fracturing pump driver, and auxiliary power source into a single integrated system. The electrical power generation device connected to the prime mover's output combines mechanical power transmission with electrical power generation, allowing one engine to serve multiple purposes and eliminate the need for additional combustion engines
2Ease of operation
If an additional internal combustion engine is used to power auxiliary components, then the fracturing unit can operate auxiliary systems, but operational costs increase
Solution Approach 1:
The prime mover serves dual purposes by directly driving the fracturing pump while simultaneously powering the electrical power generation device for auxiliary systems. This multi-functional approach eliminates the need for a second engine, thereby reducing fuel consumption and operational costs while maintaining full system functionality
Solution Approach 2:
The patent merges the functions of mechanical power transmission and electrical power generation into a single integrated system. The electrical power generation device is connected to the prime mover's output, allowing one engine to provide both direct mechanical drive and electrical power, thus reducing total fuel consumption by eliminating redundant engine operation
3Ease of operation
If different fuel requirements are met for additional engines, then auxiliary systems can be powered, but system complexity increases
Solution Approach 1:
The prime mover is designed to operate on a single fuel type and simultaneously perform multiple functions: driving the fracturing pump and powering auxiliary systems through electrical generation. This eliminates the need for multiple engines with different fuel requirements, simplifying the fuel supply system while maintaining full operational capability
Solution Approach 2:
The patent combines the mechanical drive function and electrical power generation function into a single integrated system that uses one fuel supply. This merger eliminates the complexity of managing multiple fuel types and supply systems, as one unified system provides all necessary power for both fracturing operations and auxiliary systems
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces emissions and operational costs by optimizing fuel usage, allowing the system to operate efficiently across varying power demands while minimizing the reliance on more emissions-intensive fuels.
Implementation Method 1
A bi-fuel reciprocating engine system that supplies primary and secondary fuels based on the power load, using a controller to determine the optimal mix of fuels from a primary fuel source, such as natural gas, and a secondary fuel source, like diesel
Data Source
AI summary
Systems and methods for supplying primary fuel and secondary fuel to an internal combustion engine may include supplying a first amount of the primary fuel and a second amount of the secondary fuel to the internal combustion engine. The system may include a first manifold to provide primary fuel to the internal combustion engine, and a primary valve associated with the first manifold to provide fluid flow between a primary fuel source and the internal combustion engine. A second manifold may provide secondary fuel to the internal combustion engine, and a fuel pump and/or a secondary valve may provide fluid flow between a secondary fuel source and the internal combustion engine. A controller may determine a total power load, the first amount of primary fuel, and the second amount of secondary fuel to supply to the internal combustion engine to meet the total power load.