Drilling Rig ORC Power Generation Using Waste Heat Recovery
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Solution Overview
Problem
Current systems lack the ability to effectively utilize heat generated at drilling rigs to generate electrical power efficiently, leading to increased wear on drill bits and decreased equipment lifespan, as well as higher electrical power consumption.
Innovation Solution
Implementing an organic Rankine cycle (ORC) system that harnesses heat from drilling fluids, engine exhaust, and coolant to generate electrical power by transferring heat to a working fluid, which then drives a generator to produce power, while optimizing engine performance and reducing overall energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If heat from drilling fluid is not utilized, then energy efficiency is low and electrical power consumption is high, but implementing heat utilization systems increases device complexity
Solution Approach 1:
The patent combines multiple heat sources (drilling fluid, engine exhaust, water jacket fluid) into a single ORC power generation system. The heat exchangers from different thermal sources are integrated to heat a common working fluid, merging previously separate thermal management functions into one unified energy recovery system that reduces overall device complexity while improving energy efficiency.
Solution Approach 2:
The ORC system serves multiple functions simultaneously: it generates electrical power from waste heat, cools drilling fluid, cools engine components, and produces usable thermal energy. This multi-functionality allows a single system to address multiple energy management needs without proportionally increasing complexity, thereby improving overall energy efficiency.
2Use of energy by moving object
If drilling fluid temperature is not optimized, then energy efficiency is reduced, but implementing temperature control increases electrical power consumption
Solution Approach 1:
The system incorporates temperature sensors and controllers that continuously monitor drilling fluid temperature and ORC system performance. Based on feedback from these sensors, the system automatically adjusts heat exchanger operations and working fluid flow rates to optimize energy recovery while maintaining drilling fluid within acceptable temperature ranges, thereby improving energy efficiency without excessive electrical power consumption.
Solution Approach 2:
The system dynamically adjusts operational parameters such as working fluid flow rate, heat exchanger surface area engagement, and ORC turbine speed based on the temperature of available heat sources and the cooling needs of drilling fluid. By changing these parameters in real-time, the system optimizes energy efficiency while minimizing the electrical power required for control and pumping.
3Power
If heat sources are not harnessed, then electrical power generation is insufficient, but implementing heat recovery systems increases loss of substance through working fluid circulation
Solution Approach 1:
The system recovers waste heat from drilling fluid, engine exhaust, and water jacket fluid that would otherwise be discarded. By capturing this otherwise lost thermal energy and converting it to electrical power through the ORC system, the system generates sufficient electricity while the working fluid is continuously circulated and recovered without significant loss, as it operates in a closed-loop configuration.
Solution Approach 2:
The ORC system is designed to be largely self-sufficient, using the recovered heat to drive working fluid circulation and power generation without requiring significant external energy input. The system serves itself by using the waste heat to maintain working fluid temperature and pressure, minimizing the need for additional pumps or heating devices that would increase substance loss.
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
The ORC system effectively extends the lifespan of drill bits and equipment, reduces electrical power usage, and enhances engine efficiency by utilizing waste heat, thereby improving the overall energy efficiency of drilling operations.
Implementation Method 1
a heat exchanger to transfer heat to a working fluid flow
Implementation Method 2
the heat from the heat source causes the working fluid in the loop to change phases from a liquid to a vapor
Implementation Method 3
The vaporous working fluid may then flow to a gas expander, causing the gas expander to rotate
Implementation Method 4
The rotation of the gas expander may cause a generator to generate electrical power
Implementation Method 5
The condenser or heat sink may cool the working fluid, causing the working fluid to change phase from the vapor to the liquid
Data Source
AI summary
Embodiments of systems and methods for generating power in the vicinity of a drilling rig are disclosed. During a drilling operation, heat generated by drilling fluid flowing from a borehole, exhaust from an engine, and/or fluid from an engine's water (or other fluid) jacket, for example, may be utilized by corresponding heat exchangers to facilitate heat transfer to a working fluid. The heated working fluid may cause an ORC unit to generate electrical power.