Mobile Natural Gas Processing Unit for Wellhead Fuel Supply
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Solution Overview
Problem
Natural gas at the wellhead often contains impurities like CO2, H2S, nitrogen, and solid contaminants, which cause corrosion and require costly infrastructure for processing, leading to inefficiencies and waste when not utilized on-site for powering engines.
Innovation Solution
A transportable, self-contained natural gas processing system that includes a mobile platform with a water separator and particulate filter to remove contaminants, a thermoelectric generator for power, and a process control system to manage gas pressure and quality, allowing on-site processing and utilization of natural gas for engine fuel without the need for pipelines or specialized equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If natural gas is transported through pipelines to refineries for processing, then the gas can be purified and used as fuel, but corrosion problems occur due to CO2 and H2S impurities dissolving in water to form acids
Solution Approach 1:
The patent extracts and removes harmful impurities (CO2, H2S, water, particulates) from natural gas at the wellhead using a mobile processing unit with specific removal equipment, preventing these substances from causing corrosion in pipelines during transport
Solution Approach 2:
The patent performs preliminary processing of natural gas at the wellhead location before transport, removing corrosive impurities in advance to protect downstream pipeline infrastructure from acid corrosion
2Manufacturing precision
If natural gas is processed at centralized refineries, then complete purification is achieved, but costly pipeline infrastructure and transportation are required
Solution Approach 1:
The patent segments the centralized processing function into a mobile, self-contained processing unit that can be deployed at multiple wellhead locations, eliminating the need for extensive pipeline infrastructure while maintaining purification capabilities
Solution Approach 2:
The mobile processing unit serves multiple functions: it can process gas from different wellheads, provide on-site purification, and supply fuel locally, replacing the need for dedicated pipeline infrastructure for each location
3Use of energy by moving object
If diesel fuel or gasoline is trucked in to power engines at wellhead sites, then engines can operate, but costs increase and employee safety risks arise
Solution Approach 1:
The system enables wellhead sites to self-supply their own fuel by processing raw natural gas on-site, eliminating the need to purchase and transport external fuels like diesel or gasoline, thereby reducing operational costs and safety risks
4Use of energy by moving object
If refined natural gas products like LNG or CNG are delivered to sites, then engines can run on natural gas, but specialized equipment and trucking infrastructure are needed
Solution Approach 1:
The patent divides the refined gas distribution system into mobile processing units deployed at individual wellhead sites, eliminating the need for centralized LNG/CNG production facilities and specialized delivery infrastructure
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
Enables efficient on-site processing and utilization of natural gas, reducing costs, environmental impact, and maintenance needs by providing a consistent, high-quality fuel source for engines, while eliminating the need for diesel fuel and specialized equipment delivery.
Implementation Method 1
A water separator removes water liquid from the natural gas
Implementation Method 2
A particulate filter removes particulate matter from the natural gas
Implementation Method 3
A thermoelectric generator supplies process electricity to the natural gas processing system
Data Source
AI summary
A natural gas processing system is mounted on a mobile platform that is transported to a natural gas source, such as a well. The system supplies natural gas to operate multi-fuel engines for wellfield equipment such as pumps, compressors, and drills. A liquid drain discharges contaminants. A water separator and a particulate filter remove particulate matter and liquid contaminant matter from the natural gas. A thermoelectric generator powered by the natural gas supplies process electricity. A process control monitors and controls the natural gas processing system, including pressure, temperature, moisture, and flow sensors. A gas chromatograph will determine the chemical composition of the natural gas. An emergency shutdown system will halt the process in the event of high liquid levels, a gas leak, fire, or gas composition out of specification, to include: H2S, H2O, Percent Mole Composition (BTU), Pressure, Temperature, and Flow Rate.