Closed-Loop Hydrogen Production With CO2 Brine Reinjection

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Solution Overview

Problem

Conventional natural gas reservoirs, while capable of producing methane, contribute significantly to greenhouse gases when burned, necessitating improved processes for hydrogen production to reduce atmospheric emissions.

Innovation Solution

A closed-loop system involving wellbores for extracting natural gas, processing it into hydrogen and carbon dioxide brine, and reinjecting hydrogen and carbon dioxide brine into the subsurface formation for storage, utilizing existing wells and facilities to maximize efficiency and reduce emissions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If natural gas is extracted and burned for energy production, then energy needs are met, but greenhouse gas emissions increase

Engineering Contradiction:
Improveenergy productionVSAvoidgreenhouse gas emissions
Core Design Contradiction:
Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

The patent extracts hydrogen from natural gas through processing facilities, separating it from methane and other hydrocarbon components. This extraction allows hydrogen to be used as a clean fuel source while removing the harmful methane component that would otherwise be burned and contribute to greenhouse gas emissions.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the harmful methane component of natural gas into a benefit by processing it to extract hydrogen. The methane that would have been burned and emitted is instead processed to produce clean hydrogen fuel, and the CO2 byproduct is captured and injected into saline aquifers for storage.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

2Ease of manufacture

If existing natural gas wells are used for hydrogen production, then infrastructure costs are reduced, but the complexity of processing and reinjection systems increases

Engineering Contradiction:
Improveinfrastructure utilizationVSAvoidprocessing and reinjection system
Core Design Contradiction:
Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent makes existing natural gas wells multi-functional by using them for both their original purpose of extracting hydrocarbons and as injection wells for storing hydrogen and CO2. This universal use of infrastructure reduces the need for additional wells while managing the complexity through systematic processing facilities.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines multiple functions into a unified system: extraction of natural gas, processing to separate hydrogen from methane, storage of hydrogen in depleted reservoirs, and injection of CO2 into saline aquifers. This merging of functions leverages existing infrastructure while creating an integrated carbon management system.

Inventive Principle:
Principle #5Merging (Combining)

3Quantity of substance

If hydrogen is stored in subsurface formations, then storage capacity is maximized, but the risk of contamination and leakage increases

Engineering Contradiction:
Improvehydrogen storage capacityVSAvoidcontainment safety
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The patent uses CO2 as an intermediary substance injected into saline aquifers alongside hydrogen. The CO2 acts as a sealant and pressure maintenance agent that helps contain the hydrogen in the storage reservoir, reducing the risk of leakage while maximizing storage capacity through the closed-loop system.

Inventive Principle:
Principle #24Intermediary (Mediator)

4Object-generated harmful factors

If CO2 is injected into saline aquifers for storage, then carbon capture is achieved, but the complexity of well management and monitoring increases

Engineering Contradiction:
Improvecarbon emissions reductionVSAvoidwell management and monitoring system
Core Design Contradiction:
Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The patent implements a closed-loop system with monitoring and feedback mechanisms that track the injection and storage of CO2 and hydrogen. This feedback system manages the complexity by providing real-time data on subsurface conditions, ensuring safe containment while achieving carbon capture goals.

Inventive Principle:
Principle #23Feedback

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 system enhances hydrogen production and storage while minimizing greenhouse gas emissions, leveraging existing infrastructure and maintaining reservoir pressure, thus reducing operational costs and environmental impact.

Implementation Method 1

processing the natural gas in a surface processing facility and thereby generating hydrogen and a carbon dioxide (CO2) brine

Methodology Applied
Scientific EffectMethane reforming: Chemical Transport Reactions

Implementation Method 2

injecting at least a portion of the hydrogen into the subsurface formation via a second wellbore penetrating the subsurface formation for hydrogen storage

Methodology Applied
Scientific EffectPressure-driven flow: Pressure Gradient

Implementation Method 3

injecting the CO2 brine into a saline aquifer forming part of the subsurface formation via a third wellbore penetrating the subsurface formation

Methodology Applied
Scientific EffectFluid injection: Pressure Gradient

Implementation Method 4

supporting reservoir pressure of the conventional subsurface formation with the CO2 brine

Methodology Applied
Scientific EffectPressure support: Pressure Gradient

Data Source

PatentUS12428941B2Closed loop hydrogen production and storage
Publication Date: 2025.09.30 SAUDI ARABIAN OIL CO
  • US12428941B2 patent drawing
  • US12428941B2 patent drawing
  • US12428941B2 patent drawing

AI summary

A method includes extracting natural gas from a subsurface formation including a conventional gas reservoir via a first wellbore penetrating the subsurface formation, processing the natural gas in a surface processing facility and thereby generating hydrogen and a carbon dioxide (CO2) brine, injecting at least a portion of the hydrogen into the subsurface formation via a second wellbore penetrating the subsurface formation for hydrogen storage, and injecting the CO2 brine into a saline aquifer forming part of the subsurface formation via a third wellbore penetrating the subsurface formation.