Fuel Cell Power for Well Stimulation Equipment

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Solution Overview

Problem

Well stimulation operations rely on inefficient diesel engines for powering equipment, leading to low energy efficiency, frequent refueling needs, high emissions, and noise pollution, which are problematic in regulated environments.

Innovation Solution

Implementing fuel cell systems to generate electricity for powering well stimulation equipment, using fuel cells in conjunction with DC/AC converters and variable frequency drives to provide efficient, low-emission, and quieter power, with the option to utilize natural gas or hydrogen sulfide as fuel, and incorporating heat recovery systems to enhance efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If diesel engines are used to power well stimulation equipment, then the equipment can operate with sufficient power, but energy efficiency is low and refueling frequency is high

Engineering Contradiction:

Improveenergy efficiencyVSAvoidrefueling frequency

Core Design Contradiction:

Use of energy by moving objectVSLoss of time

Solution Approach 1:

The patent replaces diesel engines (mechanical combustion system) with fuel cell systems (electrochemical conversion system) to power well stimulation equipment. This substitution eliminates the need for frequent refueling while dramatically improving energy efficiency, as fuel cells convert chemical energy directly to electrical energy with higher efficiency and continuous operation capability compared to internal combustion engines.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental operating parameters of the power generation system by transitioning from combustion-based power generation to electrochemical power generation. This parameter change enables continuous operation without frequent refueling interruptions and achieves energy efficiency improvements from approximately 32% for diesel engines to over 50% for fuel cell systems.

Inventive Principle:

Principle #35Parameter changes

2Power

If diesel engines are used to power well stimulation equipment, then adequate power is provided, but emissions and noise pollution increase

Engineering Contradiction:

Improvepower outputVSAvoidemissions and noise

Core Design Contradiction:

PowerVSObject-generated harmful factors

Solution Approach 1:

The patent substitutes diesel engine power systems with fuel cell power systems, maintaining adequate power output for well stimulation equipment while eliminating harmful emissions and noise. Fuel cells generate electricity electrochemically without combustion, thereby producing no exhaust emissions and operating silently compared to noisy diesel engines.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the harmful byproducts of diesel combustion (emissions and noise) into beneficial outcomes by using fuel cells that produce only water and heat. The electrochemical reaction in fuel cells transforms the chemical energy of fuel directly into electrical energy without producing harmful emissions, thereby converting a harmful power generation method into a clean one while maintaining sufficient power output.

Inventive Principle:

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

3Power

If multiple individual diesel powered units are used, then equipment power needs are met, but operational complexity and refueling logistics increase

Engineering Contradiction:

Improvepower availabilityVSAvoidsystem complexity

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The patent merges multiple separate diesel-powered units into a unified fuel cell power system. Instead of having multiple individual diesel engines distributed across the equipment, a single or centralized fuel cell system provides power to multiple pieces of equipment, simplifying refueling logistics and reducing operational complexity while maintaining adequate power availability for all stimulation operations.

Inventive Principle:

Principle #5Merging (Combining)

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

Fuel cells offer higher energy efficiency, reduced refueling frequency, lower emissions, and quieter operations compared to diesel engines, improving the overall efficiency and environmental impact of well stimulation processes.

Implementation Method 1

The fuel cell stack includes one or more fuel cells for converting chemical energy from a fuel to electrical power at an output of the fuel cell stack

Methodology Applied

Scientific EffectFuel cell electrochemical conversion: Fuel Cell

Data Source

PatentUS10577910B2Fuel cells for powering well stimulation equipment

Publication Date: 2020.03.03 HALLIBURTON ENERGY SERVICES INC

AI summary

In accordance with presently disclosed embodiments, a system and method for using fuel cells to generate electricity for powering well stimulation equipment (e.g., high pressure hydraulic pumping units) at a well stimulation site are provided. The fuel cells may be coupled to the stimulation equipment via a DC/AC converter and, in some embodiments, via a variable frequency drive (VFD). The fuel cells may be arranged in a fuel cell stack that is used to generate electricity to power various electrical devices (e.g., electric motors) on the equipment. The fuel cells generally operate at higher efficiencies than is available through the use of diesel engines. In addition, the fuel cells may require less frequent refueling and provide a more centrally located area for refueling, lower emissions, and quieter operations than are currently available using diesel engines.