Natural Gas Fracturing Engine On-Site Fuel Recovery

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Solution Overview

Problem

Diesel engines used for fracturing operations face logistical, environmental, and operational challenges due to high fuel consumption, noise, thermal output, and maintenance requirements, which increase costs and emissions.

Innovation Solution

A natural gas fracturing engine that utilizes 100% natural gas recovered on-site, eliminating the need for fuel trucks and reducing operational costs, emissions, and maintenance needs, while providing the necessary power and torque for fracturing processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If diesel engines are used for fracturing operations, then sufficient power and torque are provided, but fuel consumption is high and logistics complexity increases

Engineering Contradiction:

ImprovepowerVSAvoidfuel consumption

Core Design Contradiction:

PowerVSUse of energy by moving object

Solution Approach 1:

The patent changes the fuel parameter from diesel to natural gas, fundamentally altering the energy consumption characteristics. Natural gas has a higher energy density and burns more efficiently, reducing overall fuel consumption while maintaining the required power output for fracturing operations

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses recovered natural gas from the fracturing operation itself as fuel, creating a self-sufficient system. The natural gas produced during fracturing is captured and used to power the engines, eliminating the need for external fuel supply chains and reducing net fuel consumption

Inventive Principle:

Principle #26Copying

2Power

If diesel engines are used for fracturing operations, then sufficient power and torque are provided, but emissions and environmental impact increase

Engineering Contradiction:

ImprovepowerVSAvoidemissions

Core Design Contradiction:

PowerVSObject-generated harmful factors

Solution Approach 1:

The patent changes the fuel type parameter from diesel to natural gas, which fundamentally alters the emission profile. Natural gas combustion produces significantly lower particulate matter, sulfur oxides, and carbon monoxide emissions compared to diesel, while still delivering the necessary power for fracturing operations

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the naturally occurring natural gas that would be present during fracturing operations into a beneficial fuel source. By capturing and utilizing this gas for engine power, the system transforms a potential environmental concern into an advantage, reducing net emissions while maintaining operational capability

Inventive Principle:

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

3Power

If diesel engines are used for fracturing operations, then sufficient power and torque are provided, but noise and thermal output are high

Engineering Contradiction:

ImprovepowerVSAvoidnoise

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The patent changes the fuel combustion parameter from diesel to natural gas, which alters the thermal and acoustic characteristics of engine operation. Natural gas combustion is cleaner and produces less soot and thermal stress, leading to reduced noise levels and lower thermal output from the engine system

Inventive Principle:

Principle #35Parameter changes

4Power

If diesel engines are used for fracturing operations, then sufficient power and torque are provided, but maintenance requirements and operational costs increase

Engineering Contradiction:

ImprovepowerVSAvoidmaintenance requirements

Core Design Contradiction:

PowerVSEase of operation

Solution Approach 1:

The patent changes the fuel type parameter from diesel to natural gas, which fundamentally improves engine reliability and reduces maintenance needs. Natural gas is a cleaner-burning fuel that produces less carbon buildup, reduces lubricant contamination, and minimizes thermal stress on engine components, all of which extend component life and reduce maintenance frequency

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes natural gas, an abundant and relatively inexpensive fuel source available at the fracturing site, replacing expensive diesel fuel. This substitution reduces both fuel costs and maintenance costs, making the overall operation more economically viable

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 natural gas engine significantly reduces fuel costs, emissions, and maintenance requirements, allowing for more efficient and environmentally friendly fracturing operations with lower noise and thermal output, and extended component life, resulting in substantial economic and environmental benefits.

Implementation Method 1

A natural gas fracturing engine that utilizes 100% natural gas recovered on-site

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS20230235654A1Natural Gas Fracturing Engine System and Method

Publication Date: 2023.07.27 CATALYST ENERGY SERVICES LLC

AI summary

A natural gas engine is utilized for fracturing. The natural gas engine can utilize recovered natural gas as the fuel source. This eliminates the need for expensive diesel fuel. The natural gas system results in several benefits including economic savings as well as environmental advantages in the reduction of particulate, greenhouse gases, including NOx, methane, CO2, CO, VOC etc.