Methods for generating geothermal power in an organic Rankine cycle operation during hydrocarbon production based on working fluid temperature
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Solution Overview
Problem
Current geothermal power generation systems are not designed to operate effectively during hydrocarbon production, as they are not equipped to handle high-pressure wellhead fluids, leading to inefficiencies in energy conversion and waste of heat energy.
Innovation Solution
Implementing a high-pressure heat exchanger system at the wellhead to divert and transfer heat from high-pressure wellhead fluids to a working fluid, which then undergoes a phase change to generate electrical power in an Organic Rankine Cycle (ORC) unit, allowing for continuous geothermal power generation during hydrocarbon production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional geothermal power generation systems are used, then electrical power can be generated from geothermal heat, but the systems cannot handle high-pressure wellhead fluids during hydrocarbon production
Solution Approach 1:
A high-pressure heat exchanger is introduced as an intermediary component between the wellhead fluid source and the ORC system. This heat exchanger is specifically designed to withstand high pressures while transferring thermal energy to the working fluid, allowing the ORC system to operate at lower, safer pressures while still utilizing the high-pressure wellhead fluid's thermal energy.
2Productivity
If heat exchangers are not used and direct geothermal heat from underground conduits is utilized, then the system is simpler, but the system cannot efficiently utilize high-pressure wellhead fluid heat during hydrocarbon production
Solution Approach 1:
The high-pressure heat exchanger serves multiple functions: it acts as a pressure containment vessel, a heat transfer device, and a flow control component. By integrating these functions into a single component, the system achieves high energy conversion efficiency without proportionally increasing overall system complexity.
3Power
If wellhead fluid flow is diverted to heat exchangers, then heat energy can be converted to electrical power, but the flow of wellhead fluid to hydrocarbon production equipment may be reduced
Solution Approach 1:
The system incorporates dynamic flow control valves and regulators that can adjust the split of wellhead fluid flow in real-time. This allows the system to optimize the distribution of fluid between the heat exchanger (for power generation) and the hydrocarbon production equipment, adapting to changing production requirements and maximizing both power generation and hydrocarbon recovery.
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 solution enables the efficient conversion of waste heat into electrical power, supplying energy to in-field equipment, energy storage devices, and grid power structures, thereby optimizing energy utilization and reducing operational costs.
Implementation Method 1
The heat exchanger may indirectly transfer heat from the flow of the wellhead fluid to the flow of a working fluid
Implementation Method 2
As heat is transferred from the flow of the wellhead fluid to the flow of a working fluid, such a heat transfer may cause the working fluid to change phases from a liquid to a vapor
Implementation Method 3
The vaporous working fluid may then flow through an ORC unit to cause a generator to generate electrical power via rotation of a gas expander of the ORC unit
Implementation Method 4
The rotation of the gas expander may cause a generator to generate electrical power
Data Source
AI summary
Systems and methods for generating and a controller for controlling generation of geothermal power in an organic Rankine cycle (ORC) operation in the vicinity of a wellhead during hydrocarbon production to thereby supply electrical power to one or more of in-field operational equipment, a grid power structure, and an energy storage device. In an embodiment, during hydrocarbon production, a temperature of a flow of wellhead fluid from the wellhead or working fluid may be determined. If the temperature is above a vaporous phase change threshold of the working fluid, heat exchanger valves may be opened to divert flow of wellhead fluid to heat exchangers to facilitate heat transfer from the flow of wellhead fluid to working fluid through the heat exchangers, thereby to cause the working fluid to change from a liquid to vapor, the vapor to cause a generator to generate electrical power via rotation of an expander.