Modular HCl Production for Remote Tight Oil Refining
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Solution Overview
Problem
The demand for hydrochloric acid (HCl) in hydraulic fracturing operations is high, but its transportation is challenging due to the remote locations of oil production fields, necessitating local production and efficient processing of tight gas and tight oil to minimize transportation needs and optimize energy usage in harsh environments.
Innovation Solution
A modular system for producing HCl, including a purified salt production facility and a regional modular HCl production facility, which utilizes purified salt to generate HCl through electrolysis, and an autothermal reformer to produce excess hydrogen, integrated with optimized hydraulic fracturing and refining processes for tight gas and tight oil, ensuring efficient operation and reduced transportation requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If HCl is transported to remote oil production fields, then the demand for HCl in hydraulic fracturing can be met, but transportation difficulties and costs increase due to inaccessible locations
Solution Approach 1:
The system divides HCl production into modular units that can be independently deployed at remote locations. Each module contains specific equipment (electrolysis cells, reformers, separators) that can function autonomously or in coordination with other modules, enabling localized production without requiring centralized bulk transportation
Solution Approach 2:
The modular HCl production system performs preliminary action by producing HCl on-site before it is needed for hydraulic fracturing operations. This eliminates the need for advance transportation and storage of large quantities of HCl at remote locations, as the acid is generated locally when required
2Ease of operation
If modular HCl production facilities are established locally, then transportation needs are minimized, but the complexity of setting up and operating electrolysis and reforming processes increases
Solution Approach 1:
The modular system employs multi-functional equipment that performs multiple operations within single units. For example, the autothermal reformer simultaneously converts hydrocarbons to syngas and provides thermal energy for the electrolysis process, while the caustic solution evaporator also serves to concentrate NaOH for product recovery. This reduces the number of separate equipment items needed and simplifies overall system complexity
Solution Approach 2:
The system merges the electrolysis process with hydrocarbon reforming by using the reformer as both a chemical conversion unit and a heat source for electrolysis. The syngas produced is immediately consumed in the HCl synthesis reactor, combining multiple chemical transformation steps into an integrated flow that reduces intermediate handling and equipment complexity
3Loss of substance
If tight gas and tight oil are refined locally to produce fuels like ULSD, naphthas, and kerosene, then transportation of raw tight oil is reduced, but the complexity and energy consumption of refining processes increase
Solution Approach 1:
The modular refining system performs preliminary processing of tight oil at the production site, converting raw oil into refined fuels and chemical feedstocks before transportation. This preliminary action removes the need to transport large volumes of crude tight oil over long distances, as only the smaller quantities of refined products require transportation to market centers
Solution Approach 2:
The refining process utilizes self-service by using the tight gas produced alongside tight oil as the primary fuel source for powering the refining operations. The system generates its own thermal energy requirements through combustion of associated gas, minimizing external energy inputs and reducing the net energy cost of local refining
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 modular system effectively produces HCl locally, optimizing energy use and reducing transportation needs, while enhancing the efficiency of tight gas and tight oil refining processes, thereby supporting sustainable and efficient hydraulic fracturing operations.
Implementation Method 1
an autothermal reformer to produce excess hydrogen
Implementation Method 2
which utilizes purified salt to generate HCl through electrolysis
Implementation Method 3
The hydrogen and the chlorine are reacted to produce HCl gas
Data Source
AI summary
Modular, portable processes and apparatus for the production of tight gas (including shale gas) and tight oil (including shale oil) and for the conversion of tight oil into a plurality of marketable fuels are described which enable easy deployment and start-up and are specifically useful in remote areas. Furthermore, these modular processes and apparatus are configured to use co-produced tight gas as a source of processing energy. Another feature of the modular processes is to substantially reduce the use of fracking water and process water. In some embodiments modular processes include (A) Purified Salt Production; (B) Modular Hydrochloric Acid (HCl) Production; (C) Hydrogen Production by Autothermal Reformer; (D) Optimized Hydraulic Fracturing; (E) Desalting with Bi-Electric Configuration with an Interchanger; (F) Desalter Water Recovery and Recyclling; (G) Precut Column with a Gas-Fired Heater; (H) Crude Distillation with a Gas-Fired Heater; (I) Hydrodesulfurization using Reactive Distillation; and (J) Vacuum Distillation.