ORC Power Generation from Drilling Rig Waste Heat
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Solution Overview
Problem
Current systems lack a method to effectively utilize heat generated at drilling rigs for electrical power generation, particularly in organic Rankine cycle (ORC) operations, and fail to optimize drilling fluid temperature to enhance energy efficiency and extend equipment lifespan.
Innovation Solution
The implementation of a system and method that utilizes heat from drilling fluid, engine exhaust, and water jacket fluid through heat exchangers to generate electrical power in an ORC unit, with flow control devices managing the working fluid flow to optimize power generation and engine performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If heat from drilling fluid is utilized for ORC power generation, then electrical power generation is improved, but drilling fluid temperature control becomes more difficult
Solution Approach 1:
The system segments the drilling fluid flow into different pathways: a first portion is directed to the heat exchanger for ORC power generation, while a second portion is directed to the mud chiller for temperature control. This segmentation allows independent optimization of both power generation and temperature control functions without interference between them.
Solution Approach 2:
The heat exchanger acts as an intermediary device that transfers heat from the drilling fluid to the working fluid in the ORC system. This intermediary mechanism enables heat recovery for power generation while the drilling fluid can be separately cooled by the mud chiller, resolving the temperature control challenge.
2Power
If working fluid flow is increased to heat exchanger, then electrical power generation is improved, but heat transfer efficiency decreases
Solution Approach 1:
The system employs variable speed pumps and adjustable flow control valves that dynamically adjust the working fluid flow rate based on real-time operating conditions such as drilling fluid temperature, ambient temperature, and power demand. This dynamic adjustment optimizes the balance between power generation and heat transfer efficiency under varying conditions.
Solution Approach 2:
The system changes operating parameters including working fluid flow rate, heat exchanger temperature differential, and pump speed to optimize performance. By adjusting these parameters dynamically, the system achieves maximum power generation while maintaining acceptable heat transfer efficiency.
3Temperature
If mud chiller is used to cool drilling fluid, then drilling fluid temperature control is improved, but electrical power consumption increases
Solution Approach 1:
The system converts the waste heat from the drilling fluid, which would otherwise be discarded, into useful electrical energy through the ORC power generation system. This turns the thermal energy that contributes to drilling fluid overheating into a beneficial resource, reducing or eliminating the need for energy-intensive mud chilling operations.
Solution Approach 2:
The drilling fluid itself serves dual purposes: it cools the drill bit during drilling operations and subsequently provides thermal energy to the ORC system for power generation. This self-service approach eliminates the need for external energy input to cool the drilling fluid, as the system harnesses its thermal energy instead.
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 approach increases energy efficiency, reduces electrical power consumption, extends the lifespan of drilling equipment, and optimizes engine performance by harnessing waste heat from drilling operations.
Implementation Method 1
heat from the heat source causes the working fluid in the loop to change phases from a liquid to a vapor
Implementation Method 2
the heat from the heat source causes the working fluid in the loop to change phases from a liquid to a vapor
Implementation Method 3
The vaporous working fluid may then flow to a gas expander, causing the gas expander to rotate
Implementation Method 4
The rotation of the gas expander may cause a generator to generate electrical power
Implementation Method 5
The vaporous working fluid may then flow to a condenser or heat sink. The condenser or heat sink may cool the working fluid, causing the working fluid to change phase from the vapor to the liquid
Data Source
AI summary
Embodiments of systems and methods for generating power in the vicinity of a drilling rig are disclosed. During a drilling operation, heat generated by drilling fluid flowing from a borehole, exhaust from an engine, and/or fluid from an engine's water (or other fluid) jacket, for example, may be utilized by corresponding heat exchangers to facilitate heat transfer to a working fluid. The heated working fluid may cause an ORC unit to generate electrical power.