CO2 Recovery from Hydraulic Fracturing Flowback
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Solution Overview
Problem
Current hydraulic fracturing systems face inefficiencies and environmental challenges due to high costs, CO2 availability issues, and significant hydrocarbon gas loss during the flowback period, particularly when using CO2 as a stimulating fluid, as conventional techniques often vent or flare CO2-rich flowback streams due to high variability in flowrates and gas compositions.
Innovation Solution
A method and system for processing and purifying the CO2-rich flowback stream at a temporary processing facility (TPF), allowing for the recovery and reuse of the stimulating fluid, which involves transferring the working fluid from the well site to a TPF, purifying it, and then transporting it back to injection sites, optimizing equipment use and reducing waste by managing flowback stream logistics and fluid handling efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If CO2 is used as a stimulating fluid in hydraulic fracturing, then environmental benefits and improved hydrocarbon production are achieved, but high costs and availability issues arise
Solution Approach 1:
The patent implements a flowback stream processing system that recovers CO2 from produced fluids after hydraulic fracturing. The system separates CO2 from hydrocarbon gases and other components in the flowback stream, then reinjects the recovered CO2 into the formation for enhanced oil recovery, creating a closed-loop system that eliminates waste and reduces the need for external CO2 sourcing
Solution Approach 2:
The system uses the well's own flowback stream as the source of CO2 for reinjection, making the operation self-sufficient. The CO2 required for enhanced oil recovery is obtained from the well's production fluids rather than requiring external CO2 supply infrastructure, thereby solving the availability and cost issues
2Ease of operation
If conventional techniques are used to handle CO2-rich flowback streams, then operational simplicity is maintained, but significant CO2 loss occurs through venting or flaring
Solution Approach 1:
The patent employs a separation system that extracts CO2 from the flowback stream by separating it from hydrocarbon gases, water, and other components. The separation process uses pressure differential and phase behavior to isolate CO2, which is then routed to reinjection while other components are handled separately, thereby preventing CO2 loss while maintaining operational efficiency
Solution Approach 2:
Instead of venting or flaring CO2-rich flowback streams as conventional practices do, the system recovers CO2 through separation and reinjects it into the formation. This transforms what would be waste material into a valuable resource for enhanced oil recovery, eliminating CO2 loss while creating additional production value
3Productivity
If large equipment and storage vessels are deployed for fluid handling, then processing capability is improved, but land area requirements increase
Solution Approach 1:
The patent integrates multiple functions into a single flowback stream processing system that combines separation, purification, and reinjection capabilities. The system processes the entire flowback stream in one integrated unit rather than requiring separate facilities for each function, thereby achieving high processing capability with minimal land area
Solution Approach 2:
The flowback stream processing system performs multiple functions simultaneously: it separates CO2 from other components, purifies the CO2, stores it temporarily, and reinjects it into the formation. This multi-functional approach eliminates the need for separate dedicated facilities for each operation, significantly reducing land area requirements while maintaining full processing capability
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 enhances the recovery and reuse of stimulating fluids like CO2, reducing waste and operational costs by stabilizing flowrates and compositions, thereby improving hydrocarbon production and minimizing environmental impact.
Implementation Method 1
purifying the working fluid at the current TPF, thereby providing the stimulating fluid
Implementation Method 2
The purification system receives a feed stream and separates a first portion of the feed stream into a CO2-rich liquid stream and a CO2-lean gas stream
Data Source
AI summary
Method includes recovering a stimulating fluid, which includes transferring working fluid having the stimulating fluid from an operating site (102) to a current temporary processing facility (TPF) (110) that is located remotely with respect to the operating site in the geographical region. After purifying the working fluid at the current TPF (110), thereby providing the stimulating fluid, the stimulating fluid is transferred from the current TPF to an injection site (103) that is located remotely with respect to the current TPF and the operating site. The method also includes transporting fluid-handling equipment after a designated condition has been satisfied. The fluid-handling equipment is transported from the current TPF (110) to a new TPF (110). The recovering of the stimulating fluid, the transferring of the stimulating fluid, and the transporting of the fluid-handling equipment is repeated a plurality of times. The current and new TPFs are at different locations within the geographical region.