Wellbore Clean-Up Syngas Processing for CO2 Emission Control

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Solution Overview

Problem

Existing wellbore clean-up operations face challenges in accurately tracking CO2 emissions due to unstable flow conditions and varying simulator types, making it difficult to develop a single flow plan suitable for all scenarios and facilities, and emissions monitoring is complex.

Innovation Solution

A system comprising a mixer to combine air and hydrocarbons, a burner to generate syngas, a cooling system to form cooled syngas, a collector to capture carbon as soot, and a flare stack to burn off excess syngas, along with a method to simulate and control CO2 emissions using parameter sets and tables.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional emissions monitoring methods are used during wellbore clean-up, then the monitoring system is simple, but the measurement precision of CO2 emissions is insufficient due to unstable flow conditions and varying simulator types

Engineering Contradiction:

ImproveCO2 emissions measurement precisionVSAvoidemissions monitoring system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The emissions monitoring system is segmented into multiple specialized components: a mixer to homogenize gas samples, a cooling system to condense water vapor, a collector to separate liquid condensate, and a flare stack to burn excess hydrocarbons. This segmentation allows each component to perform a specific function that collectively improves measurement precision while managing system complexity through functional decomposition.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs preliminary actions on the gas sample before measurement: mixing the sample to ensure homogeneity, cooling it to condense water vapor, and collecting the liquid phase. These preliminary actions prepare the sample in advance, eliminating the need for complex real-time corrections during measurement and improving overall measurement precision.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If a single clean-up flow plan is developed, then the plan is simple to implement, but it cannot be suitable for all scenarios, facilities, and objective functions due to varying conditions

Engineering Contradiction:

Improveflow plan adaptabilityVSAvoidflow plan complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The flow plan is designed to be dynamic rather than static, allowing adjustments based on real-time measurements of CO2 emissions, flow rates, and composition. The system can adapt to different scenarios, facilities, and objective functions by modifying operational parameters such as choke settings, burn rates, and collection efficiency, making it versatile across various conditions while maintaining manageable complexity through standardized adjustment procedures.

Inventive Principle:

Principle #15Dynamics

3Object-affected harmful factors

If CO2 emissions are not controlled during wellbore clean-up, then the operation is simpler, but harmful environmental factors increase due to excessive CO2 emissions

Engineering Contradiction:

ImproveCO2 emissions impactVSAvoidemissions control system complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The system converts the harmful CO2 emissions into a beneficial process by directing excess hydrocarbons to a flare stack where they are burned to generate heat. This heat can be utilized for other purposes, such as maintaining temperature in the collection system or generating power. The harmful emissions are thus transformed into a useful energy source, reducing environmental impact while the system remains relatively simple through this elegant conversion approach.

Inventive Principle:

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

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

Enables precise monitoring and control of CO2 emissions during wellbore clean-up, optimizing operations to minimize emissions and adhere to regulatory standards.

Implementation Method 1

a mixer configured to mix air and hydrocarbons

Methodology Applied

Scientific EffectMixing:

Implementation Method 2

a burner configured to receive the mixed air and hydrocarbons and to generate syngas

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 3

a cooling system configured to receive the syngas and to cool the syngas to form cooled syngas

Methodology Applied

Scientific EffectCooling: Cooling

Implementation Method 4

a collector configured to collect carbon from the cooled syngas as soot

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 5

a flare stack configured to receive the cooled syngas and to burn off at least part of the cooled syngas

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS20250264005A1Reducing co2 emissions during a wellbore clean-up

Publication Date: 2025.08.21 SCHLUMBERGER TECH CORP

AI summary

Systems and methods of the present disclosure includes a mixer configured to mix air and hydrocarbons and a burner configured to receive the mixed air and hydrocarbons and to generate syngas. The system also includes a cooling system configured to receive the syngas and to cool the syngas to form cooled syngas. The system further includes a collector configured to collect carbon from the cooled syngas as soot. Moreover, the system includes a flare stack configured to receive the cooled syngas and to burn off at least part of the cooled syngas.