Fracturing Power Generation Assembly Using Waste Heat Recovery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hydraulic fracturing operations require significant electrical power, often exceeding the capacity of remote wellsite power distribution infrastructure, and existing power generation systems are inefficient and bulky, leading to space constraints and environmental heat dissipation issues.
Innovation Solution
A power generation assembly that integrates with the hydraulic fracturing system by circulating fracturing fluid to cool the working fluid and utilizing waste heat from hydraulic fracturing components to heat the working fluid, eliminating the need for large heat exchange devices and enhancing integration and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional power generation systems are used at remote wellsites, then electrical power can be generated, but the systems are bulky and require large heat exchange devices that dissipate thermal energy to the surrounding environment, leading to space constraints and reduced efficiency
Solution Approach 1:
The patent merges the power generation system with the hydraulic fracturing system by using the fracturing fluid as the working fluid in the heat engine. The fracturing fluid circulation system is integrated with the heat exchange process, eliminating the need for separate large heat exchange devices and reducing the overall space requirement while maintaining power generation capacity
Solution Approach 2:
The fracturing fluid serves multiple functions: it cools the subterranean formation during hydraulic fracturing operations and simultaneously acts as the working fluid for the heat engine to generate electrical power. This multi-functionality eliminates the need for dedicated cooling systems and large heat exchange equipment, reducing space requirements
2Power
If conventional power generation systems are used at remote wellsites, then electrical power can be generated, but the systems require additional heat sources and large heat exchange devices, increasing device complexity
Solution Approach 1:
The patent combines the heating function with existing hydraulic fracturing components. The heat-generating components of the hydraulic fracturing system (such as compressors and pumps) provide the thermal energy needed to heat the fracturing fluid, which then drives the heat engine. This integration eliminates the need for separate heat sources and simplifies the overall system architecture
Solution Approach 2:
The hydraulic fracturing system provides its own heat source through its operational components (compressors, pumps), which generate waste heat that is utilized by the heat engine. The system serves itself by using its own operational byproducts (heat and fluid circulation) to generate additional electrical power, eliminating the need for external heat sources and complex heat exchange equipment
3Temperature
If large heat exchange devices are used to dissipate thermal energy, then cooling can be achieved, but the devices become bulky and occupy significant space at the wellsite
Solution Approach 1:
The fracturing fluid circulation system performs dual functions: it cools the subterranean formation during hydraulic fracturing operations and simultaneously serves as the cooling mechanism for the heat engine by absorbing thermal energy. This eliminates the need for separate large heat exchange devices dedicated to cooling, reducing the space required at the wellsite
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 system effectively generates electrical power using waste heat, reducing the size and complexity of the power generation assembly, increasing overall efficiency and reducing environmental impact.
Implementation Method 1
a condenser connected along the working fluid circuit, the condenser fluidly connected to the fracturing fluid reservoir such that heat is transferred from the working fluid to the fracturing fluid within the condenser
Implementation Method 2
an electrical generator and a working fluid circuit connected to the electrical generator such that circulation of a working fluid along the working fluid circuit actuates the electrical generator to generate electrical power
Data Source
AI summary
Embodiments of systems and methods include a hydraulic fracturing assembly configured to inject a fracturing fluid into a subterranean formation. The hydraulic fracturing assembly includes a fracturing fluid reservoir and a power generation assembly. The power generation assembly includes an electrical generator. In addition, the power generation assembly includes a working fluid circuit connected to the electrical generator such that circulation of a working fluid along the working fluid circuit actuates the electrical generator to generate electrical power. Further, the power generation assembly includes a condenser connected along the working fluid circuit. The condenser is fluidly connected to the fracturing fluid reservoir such that heat is transferred from the working fluid to the fracturing fluid within the condenser.