Systems and methods for generation of electrical power in an organic rankine cycle operation
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Solution Overview
Problem
There is a need for systems and methods to generate geothermal power in an organic Rankine cycle (ORC) operation during hydrocarbon production, particularly at wellheads where high-pressure and high-temperature fluids are present, as existing geothermal generators are not designed to handle high pressures and do not utilize heat from these sources effectively.
Innovation Solution
The implementation of high-pressure heat exchangers connected to wellheads or production sites to transfer heat from high-pressure, high-temperature fluids to a working fluid, which then drives an ORC unit to generate electrical power, with a controller managing the heat exchanger valves and flow control to optimize energy transfer and production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional geothermal generators are used, then electrical power can be generated from geothermal heat, but they cannot withstand high pressures from wellhead fluids
Solution Approach 1:
A high-pressure heat exchanger is introduced as an intermediary component between the wellhead fluid source and the ORC system. This heat exchanger is specifically designed to withstand high pressures while transferring thermal energy to a working fluid, thereby protecting the ORC unit from direct exposure to high-pressure conditions while still enabling power generation
2Productivity
If heat exchangers are added to transfer heat from wellhead fluids, then electrical power generation efficiency improves, but system complexity increases
Solution Approach 1:
The high-pressure heat exchanger serves multiple functions: it withstands high pressures from wellhead fluids, transfers thermal energy to the working fluid, and protects downstream ORC components. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in system complexity while maintaining improved power generation efficiency
3Reliability
If high-pressure heat exchangers are implemented, then heat transfer from high-pressure fluids is enabled, but manufacturing and installation difficulty increases
Solution Approach 1:
The system is segmented into distinct functional modules: a high-pressure heat exchanger module designed specifically for high-pressure service, and a separate ORC module operating at lower pressures. This segmentation allows each module to be optimized and manufactured independently, potentially simplifying the overall manufacturing and installation process despite the specialized requirements of the high-pressure component
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 solution enables the efficient generation of electrical power from geothermal energy at wellheads during hydrocarbon production, providing power to in-field equipment, energy storage devices, and grid structures by effectively utilizing high-pressure and high-temperature fluids, thereby addressing the limitations of existing geothermal power generation technologies.
Implementation Method 1
The heat exchanger may be a high-pressure heat exchanger configured to withstand the high-pressure of the fluid from a source. The heat exchanger may indirectly transfer heat from the flow of the fluid to the flow of a working fluid.
Implementation Method 2
As heat is transferred from the flow of the fluid to the flow of a working fluid, such a heat transfer may cause the working fluid to change phases from a liquid to a vapor.
Implementation Method 3
The vaporous working fluid may then flow through an ORC unit to cause a generator to generate electrical power via rotation of a gas expander of the ORC unit.
Implementation Method 4
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
Systems and methods for generating and a controller for controlling generation of geothermal power in an organic Rankine cycle (ORC) operation to thereby supply electrical power to one or more of in-field operational equipment, a grid power structure, and an energy storage device. In an embodiment, during hydrocarbon production, a temperature of a flow of heated fluid from a source or working fluid may be determined. If the temperature is above a vaporous phase change threshold of the working fluid, heat exchanger valves may be opened to divert flow of heated fluid to heat exchangers to facilitate heat transfer from the flow of wellhead fluid to working fluid through the heat exchangers, thereby to cause the working fluid to change from a liquid to vapor, the vapor to cause a generator to generate electrical power via rotation of an expander.