Turbocharger System for CO2 Capture and Compression
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Solution Overview
Problem
Current CO2 fracturing systems face challenges with high costs, energy consumption, and equipment size due to the need for efficient CO2 capture and compression, particularly in hydraulic fracturing processes, where CO2 must be injected as a supercritical liquid, and existing systems lack optimal recovery efficiency and cost-effectiveness.
Innovation Solution
A turbocharger system with three compressor stages in series, including low, mid, and high-pressure turbochargers, coupled with intercooling and adjustable choke and turbine bypass valves, to achieve desired pressure and flow rates, optimizing CO2 capture and reducing mechanical stress and equipment size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If CO2 is delivered from an external source and stored on site for fracturing operations, then CO2 availability is ensured, but equipment size and cost increase
Solution Approach 1:
The patent extracts the CO2 storage function from the overall system by capturing CO2 directly at the source (well site) and using it immediately for fracturing operations, eliminating the need for large external storage facilities and transport infrastructure
Solution Approach 2:
The system enables self-service by capturing CO2 generated at the well site directly and using it for fracturing operations without requiring external delivery infrastructure, thereby reducing equipment size while maintaining reliability
2Productivity
If CO2 is compressed to high pressure for supercritical injection, then injection efficiency improves, but energy consumption increases
Solution Approach 1:
The compression process is segmented into multiple stages with intercooling, where each stage compresses the gas to a intermediate pressure level rather than attempting single-stage compression to final pressure, reducing total energy consumption while achieving the required supercritical injection pressure
Solution Approach 2:
Intercoolers are introduced as intermediary components between compression stages to remove heat generated during compression, allowing the gas to be cooled between stages and reducing the work required for subsequent compression stages
3Device complexity
If single-stage compression is used to achieve high pressure, then device complexity is reduced, but mechanical stress increases
Solution Approach 1:
The compression system is divided into multiple stages, each handling a portion of the total pressure increase, which distributes mechanical stress across multiple components rather than concentrating it in a single high-pressure component
Solution Approach 2:
The system dynamically adjusts operating parameters between compression stages through intercooling and controlled pressure progression, allowing each stage to operate within optimal stress ranges while achieving the cumulative high pressure required for injection
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 system enhances CO2 capture efficiency, reduces energy consumption, and minimizes equipment costs by achieving higher process gas pressures, allowing for increased productivity in downstream processes and flexible operation across varying conditions without modifying turbine hardware.
Implementation Method 1
a heat exchanger positioned to receive hot inlet gas from a gas generating system via a first inlet; at least one low pressure turbocharger including a low pressure compressor... configured to receive cooled inlet gas discharged from the first outlet of the heat exchanger
Implementation Method 2
the low pressure compressor configured to receive cooled inlet gas discharged from the first outlet of the heat exchanger
Implementation Method 3
a low pressure turbocharger including a low pressure compressor rotationally coupled to a low pressure turbine
Implementation Method 4
the mid-pressure compressor configured to receive low pressure compressed gas discharged by the low pressure compressor
Implementation Method 5
a mid-pressure turbocharger including a mid-pressure compressor rotationally coupled to a mid-pressure turbine
Implementation Method 6
the high pressure compressor configured to receive mid-pressure compressed gas discharged by the mid-pressure compressor and output high pressure compressed gas
Implementation Method 7
a high pressure turbocharger including a high pressure compressor rotationally coupled to a high pressure turbine
Data Source
AI summary
Systems and methods are provided for a turbocharger system for use with a process gas capture system. In one example, the turbocharger system comprises: a heat exchanger positioned to receive inlet gas from a gas generating system via a first inlet; a low pressure compressor driven by a low pressure turbine and coupled to a first outlet of the heat exchanger; a mid-pressure compressor driven by a mid-pressure turbine and coupled in series with the low pressure compressor, the mid-pressure compressor configured to receive low pressure compressed gas from the low pressure compressor; and a high pressure compressor driven by a high pressure turbine and coupled in series with the mid-pressure compressor, the high pressure compressor configured to receive mid-pressure compressed gas from the mid-pressure compressor and output high pressure compressed gas to the process gas capture system and a second inlet of the heat exchanger.