Autonomous Injection Valve Using Phase-Change Piston Control
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Solution Overview
Problem
Existing technologies struggle to ensure that injected fluids, such as CO2 and H2, are maintained in a desired phase state during subterranean storage and injection, leading to inefficiencies in flow control and distribution.
Innovation Solution
The use of axially sliding piston-operated valves that adjust based on the phase change of a working fluid within a sealed chamber, ensuring that fluids are injected only when in a high-density phase, while blocking flow when not in the desired state, using a working fluid with similar vaporization characteristics to the injected fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional flow control valves are used for fluid injection, then the valve structure is simple, but the phase control precision is insufficient leading to inconsistent fluid distribution
Solution Approach 1:
The patent utilizes phase transitions of a working fluid (e.g., CO2 transitioning between liquid and gas phases) to automatically control valve operation. When the injected fluid is in the desired high-density phase, the working fluid undergoes phase change to actuate the piston, opening the valve for injection. When the fluid is in the wrong phase, the working fluid remains in its original phase, keeping the valve closed. This directly addresses the phase control precision issue while maintaining relatively simple valve structure.
Solution Approach 2:
The patent replaces conventional mechanical control systems (manual valves, electronic controls) with a physics-based automatic control system that uses phase transition thermodynamics. The piston-operated valve mechanism is driven automatically by the phase change of the working fluid in response to the phase state of the injected fluid, eliminating the need for complex external control systems and achieving precise phase-based flow control.
2Ease of operation
If fluids are injected without phase control, then the injection process is continuous and simple, but the flow velocity becomes uncontrolled leading to uneven distribution
Solution Approach 1:
The valve system performs self-service by automatically sensing the phase state of the injected fluid through the working fluid's phase response and autonomously controlling the valve opening/closing. The system uses the thermodynamic properties of the working fluid to self-regulate flow based on fluid phase, maintaining reliable and uniform distribution without requiring external control systems or complex operational procedures.
Solution Approach 2:
The automatic phase control mechanism uses phase transitions of the working fluid to regulate injection. When the injected fluid is in the correct high-density phase, the working fluid transitions phase to open the valve, allowing controlled injection. When the fluid is in the wrong phase, the working fluid does not transition, keeping the valve closed. This ensures only properly phased fluid is injected at controlled velocities, guaranteeing uniform distribution while keeping the operation simple.
3Productivity
If the valve allows continuous flow, then the injection efficiency is high, but the temperature control becomes poor affecting phase stability
Solution Approach 1:
The system uses phase transitions of the working fluid as a temperature-sensitive control mechanism. The working fluid's phase change temperature is calibrated to correspond to the desired injection temperature. When the injected fluid is at the appropriate temperature (maintaining high-density phase), the working fluid transitions phase to enable flow. When the temperature is incorrect (causing wrong phase), the working fluid remains in its original phase, blocking flow. This couples temperature control with flow control, ensuring both efficiency and stability.
Solution Approach 2:
The system implements implicit feedback control where the working fluid's phase state continuously responds to the temperature and phase conditions of the injected fluid. This phase-response feedback automatically regulates valve operation: the working fluid detects temperature/phase conditions through its own phase equilibrium and provides feedback by transitioning or not transitioning, thereby controlling whether the valve opens or remains closed. This ensures injection efficiency is maintained only when temperature and phase conditions are optimal.
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 ensures consistent phase control and even distribution of fluids, maintaining low flow velocities and appropriate temperatures, thereby enhancing the efficiency and control of fluid injection into subterranean formations or cavities.
Implementation Method 1
a phase change of a working fluid in a valve body causes movement of a piston
Implementation Method 2
movement of a piston in response to a pressure differential
Data Source
AI summary
Provided is a flow control valve, a well system, and a method. The flow control valve, in one aspect, includes a tubular configured to be positioned downhole in a wellbore, the tubular having a central longitudinal axis, and a piston located in the tubular, the piston configured to separate injection fluid located within the tubular from a working fluid located in a sealed working fluid chamber. The flow control valve, according to this aspect, further includes a valve assembly located within the tubular and coupled with the piston, wherein the piston is configured to axially slide within the tubular to move the valve assembly between an open position that provides a fluid passageway for the injection fluid from the tubular into a subterranean formation and a closed position that closes the fluid passageway for the injection fluid from the tubular into the subterranean formation, based upon a density of the injection fluid.