Mobile Nitrogen Generation Device for Drilling Operations
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Solution Overview
Problem
Current systems for generating inert gases on mobile platforms, such as those used in drilling operations, face challenges in efficiently producing high-purity inert gases like nitrogen, particularly in displacing oxygen and preventing corrosion, while being portable and self-sufficient.
Innovation Solution
A mobile inert gas separation system comprising a feed air compressor, filtration assembly, carbon tower filter, membrane separation assembly, and booster compressor, supported by a wheeled vehicle, which compresses and filters atmospheric air to produce nitrogen-rich gas, and further increases its pressure to 1000 psi using an electronic control system for monitoring and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mobile platform is used to generate inert gas, then portability and mobility are improved, but system complexity and space constraints worsen
Solution Approach 1:
The patent implements nesting by placing the membrane separation assembly inside the skid-mounted framework, and further nesting the filtration assembly within the same compact structure. The feed air compressor, booster compressor, and control systems are integrated within the skid framework, creating a nested configuration that maximizes space utilization while maintaining mobility.
Solution Approach 2:
The patent combines multiple gas processing functions (compression, filtration, separation, and boosting) into a single integrated mobile unit mounted on a skid. The feed air compressor, membrane separation assembly, booster compressor, and control systems are merged into one cohesive system that can be transported and deployed as a single unit, resolving the contradiction between mobility and system complexity.
2Manufacturing precision
If high-purity nitrogen is produced through multiple separation stages, then nitrogen purity is improved, but device complexity and space requirements worsen
Solution Approach 1:
The patent replaces complex multi-stage mechanical separation systems with a membrane separation assembly that uses selective gas permeation through polymeric membranes. This substitution achieves high nitrogen purity (up to 99.9%) while reducing mechanical complexity, as the membrane process is inherently simpler than multiple mechanical separation stages would require.
Solution Approach 2:
The patent changes the separation mechanism from mechanical/thermal processes to membrane-based selective permeation. By utilizing the different permeability rates of various gases through the polymeric membrane material, the system achieves high nitrogen purity through a parameter-based separation approach rather than complex mechanical staging.
3Stress or pressure
If compression pressure is increased to 1000 psi for drilling applications, then gas delivery capability is improved, but energy consumption and compressor complexity worsen
Solution Approach 1:
The patent segments the compression process into two distinct stages: a feed air compressor that initially compresses atmospheric air to a moderate pressure, and a booster compressor that further compresses the nitrogen-rich gas from the membrane separation assembly to the final high pressure of 1000 psi. This segmentation allows each compressor to operate in its optimal efficiency range, reducing total energy consumption compared to a single high-pressure compressor.
Solution Approach 2:
The feed air compressor performs preliminary compression of atmospheric air before the gas enters the membrane separation assembly. This preliminary action reduces the workload on the booster compressor, as it only needs to compress the already-prepared nitrogen-rich gas to final pressure rather than compressing raw atmospheric air from ambient pressure, thereby reducing overall energy consumption.
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 produces high-purity nitrogen gas, capable of displacing oxygen and preventing corrosion, while being mobile and self-sufficient, enhancing drilling operations by providing a reliable source of inert gas for various applications.
Implementation Method 1
a screw compressor with an inlet and outlet driven by an air/fuel engine so as to compress atmospheric air to a pressure of at least 200 psi at the outlet of the screw compressor
Implementation Method 2
A filtration assembly can comprise at least first, second, third, and fourth coalescence filters supported on a filter frame
Implementation Method 3
The carbon tower filter can have an inlet communicating with an outlet of the carbon tower filter and can be connected to an inlet of the fourth coalescence filter
Implementation Method 4
A membrane separation assembly can have a plurality of membrane separation devices arranged in at least first and second vertical stacks
Data Source
AI summary
A mobile inert gas generator can include various components supported by a wheeled vehicle. The generator can include a feed air compressor, a separation device for separating an inert gas from a feed air gas, and a booster compressor, each of which can have various sensors and actuators for controlling the operation thereof. An electronic control system can be connected to the sensors and actuators to allow for convenient operation of the generator. The electronic control system can include a control panel disposed in a cab.