Engine-Driven Instrument Air Retrofit to Replace Methane Pneumatics

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The oil and gas industry faces challenges in reducing greenhouse gas emissions from pneumatic control systems that rely on methane gas, as standalone air compressors require additional power sources and increase emissions when grid electricity is unavailable, and existing solutions fail to utilize ancillary industrial engines for gas compression.

Innovation Solution

Retrofitting engine-driven air compressors designed for commercial truck air brake systems onto ancillary industrial engines to produce compressed instrument air, leveraging surplus mechanical horsepower and existing engine designs to power pneumatic measurement and control systems without the need for standalone compressors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If standalone air compressors are installed to produce instrument air, then pneumatic control systems can operate without methane gas, but additional power sources and exhaust emissions are required when grid electricity is unavailable

Engineering Contradiction:

Improvegreenhouse gas emissions from pneumatic control systemsVSAvoidexhaust emissions from standalone compressors

Core Design Contradiction:

Object-affected harmful factorsVSObject-generated harmful factors

Solution Approach 1:

The patent combines the air compression function with the existing industrial engine by integrating a compressor driven by the engine's mechanical power output. This merging eliminates the need for separate standalone compressors and their associated emissions, while still providing instrument air to replace methane gas in pneumatic control systems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The industrial engine serves multiple functions: its primary function for hydrocarbon production and facilitation, and a secondary function to drive the air compressor for instrument air generation. This multi-functionality eliminates the need for dedicated compressor power sources, reducing overall emissions while maintaining pneumatic control system operation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Object-affected harmful factors

If standalone air compressors are installed to produce instrument air, then methane gas usage is eliminated, but system complexity and cost increase due to additional equipment

Engineering Contradiction:

Improvemethane gas venting to atmosphereVSAvoidnumber of separate components required

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent merges the air compression system with the existing industrial engine infrastructure, eliminating the need for separate standalone compressors, electric motors, and associated control systems. This integration reduces device complexity while still achieving the goal of eliminating methane gas venting.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The industrial engine serves itself by utilizing its own mechanical power output to drive the air compressor, eliminating the need for external power sources or additional equipment. This self-service approach reduces system complexity and eliminates the need for separate compressor installations.

Inventive Principle:

Principle #25Self-service

3Device complexity

If engine-driven air compressors are retrofitted onto ancillary industrial engines, then separate compressors and power sources are eliminated, but the engines must be modified to accept the compressor integration

Engineering Contradiction:

Improvenumber of separate componentsVSAvoidretrofitting complexity

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The patent leverages the universal compatibility between industrial engines and air brake system compressors, both of which share core components and design principles. This universality simplifies the retrofitting process by allowing the use of standardized compressors that can be adapted to various engine types without requiring custom-designed integration solutions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 carbon emissions and operational costs by utilizing existing engine components, eliminating the need for separate air compressors and diesel electric generation, while maintaining system functionality and efficiency.

Implementation Method 1

produce compressed instrument air

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

internal combustion engine

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS20230332536A1Instrument and Process Air Alternative Source

Publication Date: 2023.10.19 PRUITT III CHARLES EDMOND

AI summary

A method of mitigating greenhouse gases by producing compressed air supply for pneumatic instrument air powered measurement and control systems in place of process methane fuel gas. Exploiting ancillary industrial engines when present, by adding an air compressor designed for commercial truck and equipment air brake systems, that is affixed to and energized by said industrial engine, as an accessory to said engine wherein the primary product and function of the engine is to supply power for larger system processes and the production of pneumatic air is a secondary product. Eliminating the necessity of adding standalone air compressors for instrument air supply when applicable and the accumulative carbon foot print associated with the standalone air compressor through energy generation and or carbon emissions.