Wellhead ORC Heat Exchanger for High-Pressure Fluid Isolation
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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 such conditions and typically waste this energy.
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 undergoes a phase change to vapor and drives an ORC unit to generate electrical power, with a controller managing the heat exchanger valves and fluid flow to optimize energy conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional geothermal generators are used, then electrical power can be generated from geothermal heat, but they cannot handle high-pressure and high-temperature fluids from wellheads
Solution Approach 1:
The patent introduces a heat exchanger as an intermediary component between the high-pressure wellhead fluid and the ORC system. The heat exchanger transfers thermal energy from the wellhead fluid to a working fluid without requiring direct contact, allowing the system to handle high temperatures and pressures indirectly through the heat transfer medium.
Solution Approach 2:
The system changes the operational parameters by using a heat exchanger to decouple the high-pressure wellhead fluid conditions from the ORC system operating conditions. This allows the ORC unit to operate at lower, safer pressures while still utilizing the thermal energy from high-temperature wellhead fluids.
2Loss of energy
If heat exchangers are added to transfer heat from high-pressure fluids, then waste heat can be converted to electrical power, but system complexity increases
Solution Approach 1:
The system is segmented into distinct functional modules: a heat exchanger unit for heat transfer, an ORC unit for power generation, and a controller for system management. This modular segmentation allows each component to perform its specific function efficiently while making the overall system more manageable and maintainable.
Solution Approach 2:
The ORC unit serves multiple functions: it generates electrical power from waste heat, can operate with different working fluids, and can be integrated with various heat sources including wellhead fluids from different wells. The controller provides universal control capabilities for optimizing system performance under varying operating conditions.
3Use of energy by moving object
If high-pressure heat exchangers are used to withstand wellhead pressure, then heat transfer efficiency improves, but manufacturing and maintenance difficulty increases
Solution Approach 1:
The heat exchanger acts as an intermediary that allows efficient heat transfer from high-pressure wellhead fluids without requiring the entire ORC system to withstand those high pressures. Only the heat exchanger needs to be pressure-rated, simplifying the manufacturing and maintenance requirements compared to a fully high-pressure system.
4Power
If ORC units are deployed at wellheads during hydrocarbon production, then electrical power can be supplied to in-field equipment, but space and installation requirements increase
Solution Approach 1:
The patent combines the heat exchanger and ORC unit into an integrated system that can be installed at the wellhead location. This merging of components reduces the overall space requirement compared to separate installations and allows the system to utilize the existing wellhead infrastructure and fluid flow paths.
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 conversion of waste heat from high-pressure wellhead fluids into electrical power, supplying in-field equipment, energy storage devices, and grid power structures, thereby addressing the energy generation gap in hydrocarbon production environments.
Implementation Method 1
transfer heat from high-pressure, high-temperature fluids to a working fluid
Implementation Method 2
undergoes a phase change to vapor
Implementation Method 3
drives an ORC unit to generate electrical power
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.