U.S. patent application number 11/759118 was filed with the patent office on 2008-01-24 for method and apparatus for generating pollution free electrical energy from hydrocarbons.
Invention is credited to Steven A. Sarada.
Application Number | 20080017369 11/759118 |
Document ID | / |
Family ID | 38970345 |
Filed Date | 2008-01-24 |
United States Patent
Application |
20080017369 |
Kind Code |
A1 |
Sarada; Steven A. |
January 24, 2008 |
METHOD AND APPARATUS FOR GENERATING POLLUTION FREE ELECTRICAL
ENERGY FROM HYDROCARBONS
Abstract
The present invention relates to the generation of substantially
pollution free energy by utilizing hydrocarbons to create
electrical energy, while reinjecting exhaust fumes or other
byproducts into a subterranean formation. The present invention
further relates to managing and supplying this electrical energy to
at least one of a variety of subprocesses for producing a fuel
product, such as hydrogen or ethanol. Alternatively, electrical
power can be generated from a non-hydrocarbon source such as
thermal, solar, wind or other power source to produce electrical
energy, which in turn may be used to produce fuel products or other
forms of usable energy. Thus, remote, low reserve oil and gas
fields may be exploited and produced without requiring the
construction of expensive gas transmission lines.
Inventors: |
Sarada; Steven A.;
(Englewood, CO) |
Correspondence
Address: |
SHERIDAN ROSS PC
1560 BROADWAY
SUITE 1200
DENVER
CO
80202
US
|
Family ID: |
38970345 |
Appl. No.: |
11/759118 |
Filed: |
June 6, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10985344 |
Nov 9, 2004 |
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11759118 |
Jun 6, 2007 |
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10199430 |
Jul 18, 2002 |
6820689 |
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10985344 |
Nov 9, 2004 |
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Current U.S.
Class: |
166/244.1 ;
166/266 |
Current CPC
Class: |
E21B 43/40 20130101 |
Class at
Publication: |
166/244.1 ;
166/266 |
International
Class: |
E21B 43/40 20060101
E21B043/40 |
Claims
1. A method for generating substantially pollution free electrical
power from a hydrocarbon wellbore for use in a local electrical
transmission grid, comprising: a) producing a hydrocarbon fluid
from at least one wellbore from a subterranean formation to a
surface location; b) separating non-combustible constituents from
said hydrocarbon fluids at said surface location, wherein water is
substantially removed from said hydrocarbon fluids; c) generating
electrical energy from said hydrocarbon fluids at said surface
location or proximate thereto; d) supplying said electrical energy
to at least one subprocess for producing at least one fuel product;
and e) injecting a waste byproduct gas from said generating
electrical energy step into at least one of said subterranean
formation or a secondary subterranean formation.
2. The method of claim 1 wherein said at least one subprocess is
selected from at least one of the group comprising a thermal
subprocess, a electroclytic subprocess, or a photolytic
subprocess.
3. The method of claim 1 wherein said at least one fuel product is
hydrogen.
4. The method of claim 1 wherein said at least one fuel product is
ethanol.
5. The method of claim 1, further comprising metering said
hydrocarbon fluids prior to generating electrical energy.
6. The method of claim 1, wherein producing a hydrocarbon fluid
comprises commingling produced hydrocarbon fluids from a plurality
of producing wells.
7. The method of claim 1, wherein said hydrocarbon fluids comprise
at least one of an oil, a condensate and a natural gas.
8. The method of claim 1, wherein said hydrocarbon wellbore is used
for the production of said hydrocarbons and additionally for
injection of a waste byproduct gas.
9. A method for generating substantially pollution free electrical
energy for local distribution and use from a remote location,
comprising: a) providing a wellbore which extends from a surface
location to a subterranean formation which contains hydrocarbons;
b) producing the hydrocarbons from the subterranean formation to
the surface location; c) separating non-combustible constituents
from said hydrocarbons at said surface location; d) operating an
engine at least partially with said hydrocarbons to generate
electrical energy and create a first waste exhaust gas; e)
supplying said electrical energy to at least one subprocess for
producing at least one fuel product; f) scrubbing said waste
exhaust gas to substantially remove non-volatile constituents from
said waste exhaust gas; g) compressing said waste exhaust gas to
increase a pressure of said waste exhaust gas; h) capturing a
second waste exhaust gas from compressing the waste exhaust gas;
and i) injecting at least one of said first waste exhaust gas and
said second exhaust gas into the subterranean formation or a
secondary formation, wherein substantially no waste exhaust gas
from said operating an engine and compressing said waste exhaust
gas is discharged into the atmosphere.
10. The method of claim 9, wherein said wellbore which produces
said hydrocarbons is further utilized for the injection of at least
one of said first waste exhaust gas and said second exhaust
gas.
11. The method of claim 9, further comprising the step of injecting
said water separated from said hydrocarbons into a subterranean
formation.
12. The method of claim 9, further comprising the step of storing
said waste exhaust gas in a storage vessel prior to injecting said
waste exhaust gas.
13. The method of claim 9, wherein providing a wellbore comprises
drilling a well into the subterranean formation and running at
least one string of production piping to facilitate the extraction
of said hydrocarbons.
14. The method of claim 9, wherein providing a wellbore comprises
utilizing a pre-existing wellbore which penetrates the subterranean
formation.
15. The method of claim 9, wherein separating non-combustible
constituents comprises flowing the hydrocarbons and the
non-combustible constituents through at least one vessel which
utilizes in part a gravitational force to separate the hydrocarbons
and the non-combustible constituents.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and is a
Continuation-in-Part application of pending prior application Ser.
No. 10/985,344, filed Nov. 9, 2004, which is a Continuation-in-Part
application of prior application Ser. No. 10/199,430, filed Jul.
18, 2002, now issued as U.S. Pat. No. 6,820,689, which are
incorporated in their entireties by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to electrical power
generation, and more specifically substantially pollution free
power generation obtained from naturally occurring hydrocarbons
with the reinjection of waste byproducts into subterranean
formations.
BACKGROUND OF THE INVENTION
[0003] As a result of worldwide industrialization in the 19th and
20th centuries and the discovery of the internal combustion engine,
an ever increasing demand for hydrocarbon fuel exists throughout
the world. More specifically, "hydrocarbons" as discussed herein
include all carbon based combustible fuels such as coal, petroleum
products such as oil and tar, and natural gas, and any organic
compound of hydrogen and carbon which occurs naturally in gaseous,
liquid or solid form and is generated through either biogenic or
thermogenic means. Although extremely beneficial as a fuel source,
these hydrocarbon energy sources emit toxic fumes and carbon
containing compounds in their exhaust when burned, and are thus
believed to be a major contributor to global warming, air pollution
and other undesirable conditions known to cause harm to human
health and the environment.
[0004] Although recent improvements to power generating exhaust
systems including catalytic converters, exhaust scrubbers and other
similar products have improved the efficiency and reduced emissions
of power plants which rely on hydrocarbon fuel sources, there is
still a significant problem with regard to how these toxic
emissions from hydrocarbon fuels can be significantly reduced or
eliminated.
[0005] In conjunction with the aforementioned problem of toxic and
carbon containing gas emissions, an additional problem exists in
producing and transporting hydrocarbon fuels from remote locations
to existing electrical power plants located near high population
densities. More specifically, significant numbers of hydrocarbons
reservoirs, and more specifically natural gas fields are discovered
in remote locations which are often hundreds of miles from a major
city or power plant. Since the discovered reserves are not
sufficient to justify the economic expense of a gas transmission
pipeline, many of these smaller hydrocarbon reservoirs are never
exploited, thus preventing the production of valuable energy
resources from remote locations.
[0006] Thus, a significant need exists for an apparatus and method
for exploiting hydrocarbon reservoirs in remote locations to
provide cost effective, and substantially pollution free energy to
local communities and municipalities.
SUMMARY OF THE INVENTION
[0007] It is thus one aspect of the present invention to provide a
cost effective, economical apparatus and method to exploit and
produce combustible products from hydrocarbon reservoirs and
generate electrical energy in remote and isolated locations. Thus,
in one embodiment of the present invention, produced natural gas
from a subterranean formation is utilized to power an electrical
generator which produces electrical energy for transmission through
local power lines and grid systems.
[0008] It is a further aspect of the present invention to provide a
method and apparatus for generating substantially pollution free
energy from hydrocarbon reservoirs which contain oil and natural
gas. Thus, in one embodiment of the present invention the exhaust
byproducts from an engine used to drive an electrical generator is
contained, scrubbed to remove water and other impurities, and
reinjected into a subterranean formation to eliminate emissions of
toxic and carbon containing exhaust gases to the atmosphere.
[0009] It is a further aspect of the present invention to provide
an apparatus and method for improving in a cost effective manner
the productivity of an existing hydrocarbon reservoir, which at the
same time substantially eliminating toxic gases and exhaust
byproducts from entering the atmosphere. Thus, in one aspect of the
present invention the exhaust gases created during electrical
generation are collected, compressed and reinjected into the
producing hydrocarbon reservoir. The injection of the exhaust gases
thus increases the reservoir pressure and enhances the production
rate and ultimate recovery from the hydrocarbon reservoir.
[0010] It is a further aspect of the present invention to provide a
method and process for utilizing electrical power drawn from
electrical transmission grid or used directly from electrical
current generated on site for facilitating a number of subprocesses
to produce at least one alternative energy sources. Thus, in one
embodiment of the present invention, electrical power generated by
the methods described herein may be redistributed or reused to
produce, on site, additional low-carbon/carbon-free fuels such as
hydrogen and ethanol.
[0011] Thus, in one embodiment of the present invention a method
for creating substantially pollution free energy is provided,
comprising the steps of:
[0012] a) producing hydrocarbon fluids from a subterranean
formation;
[0013] b) separating non-combustible constituents from said
hydrocarbon fluids;
[0014] c) generating electrical energy from said hydrocarbon
fluids;
[0015] d) transmitting said electrical energy into a local
electrical transmission line;
[0016] e) supplying said electrical energy to at least one
subprocess for producing at least one fuel product; and
[0017] f) injecting a waste byproduct gas from said generating
electrical energy step into at least one of said subterranean
formation or a secondary subterranean formation.
[0018] In an alternate embodiment, a method and process for
generating electrical power from one of the following sources:
thermal energy, solar energy, wind power, and/or oil shale is
disclosed. Any one of these sources of power may be used alone or
in conjunction with the methods and processes described herein
relating to production of oil and gas, and any pollution or other
undesired constituents may be injected into at least one
subterranean formation. Additionally, thermal energy derived from
these processes and methods may be used in lieu of electrical power
to produce hydrogen, ethanol, biomass, and other fuel products.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a flow schematic identifying one embodiment of the
present invention and depicting a producing wellbore, process
equipment, an injection wellbore and electrical power transmission
lines;
[0020] FIG. 2 is a front elevation view identifying a producing
hydrocarbon wellbore and the various components associated
therewith;
[0021] FIG. 3 is a flow schematic of process equipment utilized
downstream from a producing wellbore in one embodiment of the
present invention;
[0022] FIG. 4 is a flow schematic of additional process equipment
related processing produced hydrocarbon and exhaust gases in one
embodiment of the present invention;
[0023] FIG. 5 is a front elevation view of an injection wellbore in
one embodiment of the present invention and depicting the injection
of waste gas into a subterranean formation; and
[0024] FIG. 6 is a front elevation view of a combined production
and injection wellbore which depicts the production of hydrocarbon
fluids from production tubing and the reinjection of exhaust gas
into a second non-producing subterranean formation through the
annulus defined by the production tubing and production casing.
DETAILED DESCRIPTION
[0025] Referring now to the drawings, FIG. 1 depicts a flow
schematic of one embodiment of the present invention and which
identifies the flow path of a hydrocarbon fluid and the creation of
electrical energy associated therewith. More specifically, the flow
schematic depicts a producing geologic formation 2 which generally
comprises a porous and permeable subterranean formation which is
capable of storing, a hydrocarbon fluid such as oil, natural gas,
condensate, or other combustible hydrocarbons (hereinafter
"hydrocarbon fluid"). The natural gas may be comprised of methane,
ethane, butane, propane, as well as liquid condensate associated
therein. As well known in the oil and gas industry, these
hydrocarbon fluids may be produced through a producing wellbore 6
either naturally due to a high bottom hole pressure in the
producing geologic formation, or by means of artificial lift using
pumps, down-hole motors, sucker-rods, and other available means
well known in the art to extract the hydrocarbons from the geologic
formation to a surface location.
[0026] Upon production of the hydrocarbon fluids through the
producing wellbore 6, the hydrocarbon fluids generally flow through
a wellhead 44, which typically has a plurality of valves 38 and
pressure gauges 40. The valves 38 or "choke bodies" generally
restrict and regulate the pressure and flow rate of the hydrocarbon
fluids. After flowing downstream from the wellhead 44, the
hydrocarbon fluids generally enter a phase separator 10 which is
used to separate the condensate liquid and gas components of the
hydrocarbon fluid stream from any water which may be present in the
fluid. The water is generally removed to an oil/water storage
vessel 42, where it is transported via a truck to a secondary
location and/or the water is treated and reinjected into a
subterranean geologic formation.
[0027] Once the substantially water free hydrocarbon fluids exit
the phase separator 10, the hydrocarbon fluids typically flows
through a metering device 12 to identify the volume of dry gas or
liquid condensates being produced. After discharge from the meter,
the hydrocarbon fluids are used to run a reciprocating or turbine
engine 16, which in turn drives an electrical generator 16 to
produce electrical energy in the form of an electrical current.
[0028] As identified in FIG. 1, the electrical energy generated
from the electric generator 16 may be transformed with an electric
transformer 18 to modify the amount of voltage being introduced
into the electric transmission grid 20. This electric transmission
grid 20 is preferably an electrical power line which is located in
close proximity to the producing wellbore, and thus reduces the
significant costs involved with installing a gas utility pipeline
for transmission of the natural gas to an electrical generating
plant at a distant location, this process is generally known in the
art as distributive power generation.
[0029] As further depicted in FIG. 1, the exhaust gas 50 generated
from the engine 16 flows into an exhaust gas collection and
treatment/cooling vessel 22 which is further used to treat the
exhaust gas 50 and remove any water content and/or vapor associated
therewith. The engine 16 is generally an internal combustion engine
(IC), a combustion turbine engine (CT) or a reciprocating
combustion engine (RC), which are well known by those skilled in
the art. The water is removed to a secondary water storage vessel
42 where it is either reinjected into a subterranean formation or
transported via a truck to a secondary location for treatment. The
exhaust gas 50 produced from the turbine or reciprocating engine is
now substantially cooler and dryer and is piped to an exhaust gas
compressor 26 which increases the pressure of the exhaust gas from
a low of between about 0-50 psi to a high of 10,000 and 30,000 psi
between about psi, the discharge pressure being determined by the
pressure of the subterranean geologic formation used for injection
purposes (at rates from 10 active to over 10,000 active).
[0030] More specifically, the exhaust gas is compressed in the gas
compressor 26 to a pressure which is sufficient to allow the
exhaust gas 50 to be injected down an injection wellbore 8 (and
overcoming the friction pressure loss in the pipe) and into a
subterranean formation with a lower pressure.
[0031] Thus, the exhaust gas is metered for volume and constituent
and then injected through an injection wellbore 8 which is in
operable communication with either a porous and permeable
non-producing geologic formation 4, or the producing geologic
formation 2 itself. In summary, FIG. 1 depicts an apparatus and
process which utilizes produced hydrocarbon products to create
electrical energy for transmission through an electrical grid
system, and which reinjects any exhaust gas or other pollutants
into either a secondary subterranean formation or the producing
geologic formation to substantially eliminate any pollution created
from the producing hydrocarbon.
[0032] Referring now to FIG. 2, a front elevation view of a
producing wellbore used in one embodiment of the present invention
is provided herein. More specifically, FIG. 2 depicts a producing
geologic formation 2 which is typically a porous and permeable
sandstone or other rock formation capable of storing significant
volumes of hydrocarbon fluids. Upon penetration of the geologic
formation 2 by a producing wellbore 6, the producing wellbore is
stabilized by running surface and production wellbore casing 34 to
prevent earth materials from collapsing into the producing wellbore
6. To enhance production, the producing geologic formation may be
"fractured" with high pressure fluids and supported with sand or
other proppant materials to improve the relative permeability of
the hydrocarbon reservoir and enhance production. Wellbore tubing
36 is subsequently lowered into the wellbore casing 34, and which
provides a flow pathway for the hydrocarbon products produced from
the producing geologic formation 2. The wellbore tubing 36 is
generally isolated from the wellbore casing 34 by means of a packer
58, which provides a seal to isolate the producing formation and
fluids from the annulus and casing positioned above the packer
58.
[0033] To allow flow from the producing geologic formation 2 into
the production casing 34 and production tubing 36, perforations 48
are provided which are generally a plurality of apertures
positioned in the casing to provide communication from the
producing geologic formation 2 and the wellbore production tubing
36. In a typical hydrocarbon fluid production operation, the bottom
hole pressure of the producing geologic formation 2 is generally
greater than the surface pressure, and the hydrocarbon fluids flow
from the producing geologic formation 2 to the surface wellhead 44
which is otherwise known in the art as a "Christmas tree".
Preferably, a valve 38 is used to control the producing wellbore
and thus regulate the flow rate and surface pressure. Numerous
types of "chokes" and other valves are additionally well known in
the art and can be made from a variety of different materials and
designs. Upon flowing through the valve 38, the hydrocarbon fluids
flow towards the process separator as shown in FIG. 3, and which
may include oil, natural gas, and water.
[0034] Referring now to FIG. 3, an equipment battery depicting one
embodiment of the present invention is provided herein, and which
identifies the various process equipment generally required to
scrub i.e., clean the hydrocarbon produced liquids, create
electrical energy, and transmit the electrical energy through an
existing electrical transmission grid. More specifically, produced
hydrocarbon fluids enter a phase separator 10 which is generally
either two phase such as a "gun barrel" or three phase depending on
the particular design. A two phase separator typically separates
gas from liquids with a plurality of vanes or baffles, while a
three phase separator separates gas from liquid and additionally
the water component from the hydrocarbon fluids in the liquid
phase. In either embodiment, the liquid phase i.e. typically water,
is removed from one portion of the phase separator 10 by means of
the baffles and gravity, while the dry natural gas flows downstream
through a meter 12. As previously stated, the water from the phase
separator 10 is either trucked to a secondary location, or
reinjected into a subterranean formation.
[0035] Once the natural gas flows through the gas meter 12, the
hydrocarbon fluids flows into a combustion engine 14 which creates
sufficient horsepower to drive an electrical generator 16. The
combustion turbine engines may be similar to aircraft turbofan
engines, or heavy framed models with massive casings and rotors.
Either type generally have a multi-fuel capability, and can be
operated with natural gas or high quality hydrocarbon liquid
distillates (dual fuel). Reciprocating combustion engines 14 have
numerous designs, and can again run on different types of
hydrocarbon fluids. Although, reciprocating engines are generally
more efficient than turbine engines, they generally generate higher
levels of toxic emissions and noise and require greater
maintenance.
[0036] The electrical generator 16 creates electrical current from
a rotating shaft driven from the combustion turbine or
reciprocating combustion engine 15, which is transformed into
electrical power at a rate ranging from a low of 20 kw to a high of
over 1000 kw. Electric power created by the generator is
transmitted to a transformer 18 which converts the current to an
output suitable for an electric line, generally 3 phase 480 volt.
Transforming equipment used to transform electrical energy from a
first voltage to a second voltage which is compatible with a local
electrical transmission line can include, but is not limited to
rectifiers, inverters, transformers, main breakers, automatic
transfer switch/switchgear, paralleling and synchronizing relays,
and an interfacing transformer as appreciated by one skilled in the
art. The electrical current is subsequently transmitted through an
electrical transmission grid 20 which is typically located in close
proximity to a small town or other community which utilizes the
electrical current for household needs such as light and power
generation, etc.
[0037] Both combustion turbine engines and reciprocating combustion
engines utilize produced mechanical energy in the form of a
rotating shaft to drive an electric generator in power rating sizes
generally ranging from 20 to 500 kW although large heavy-farmed
turbines can drive generators in excess of 1000 kW. These single
shaft generator designs produce high frequency electric power at
cycle speeds greater than 1000 Hz, which in turn is converted to
high voltage DC current and then inverted back to 60 Hz current.
Single-shaft turbine/generator designs mount the compressor,
turbine, and electrical generator on a single shaft, which
generally has only one major moving part. Dual-shaft designs
require that a gearbox and associated moving parts be mounted
between the turbine and the generator. Single-shaft systems require
power electronics to convert high frequency generated power to
standard 50 or 60 Hz power. Dual-shaft systems rely on gear
reductions to regulate generator rotation speed to produce the
desired standard frequency power.
[0038] Reciprocating combustion engine driven electric generators
16 range in size from lightweight, portable designs with an output
of around 10 kW or less, to very large, low speed designs that can
generate up to 25 MWe of electrical output. Typically,
reciprocating combustion engines are classified as low speed
(300-750 rpm), medium speed (750-1,200 rpm), and high speed
(>1,200 rpm). The latter are more compact and lighter than low
speed designs and are often used for emergency/back-up or peaking
power with reduced operating hours. Low speed designs are typically
used for baseload power applications due to their lower maintenance
requirements. Combustion turbine driven electric generators range
in size from small micro turbines ranging in size from 30 to 80 kW,
all the way up to very large, stationary designs that deliver up to
175 MWe in output in a simple cycle mode.
[0039] One technique for improving the efficiency and/or output
from a combustion turbine is to recover some of the energy in the
hot exhaust gases-commonly referred to as waste heat recovery. By
directing the exhaust gases into a heat recovery steam generator,
high pressure steam can be generated to drive a steam turbine for
additional electrical output. This is referred to as a combined
cycle process because it is a combination of both a Brayton cycle
(the air-gas working fluid of a combustion turbine) and a Rankine
cycle (the water-steam working fluid used to drive the steam
turbine). Alternatively, a waste heat recovery boiler can be used
to generate hot water and/or low pressure steam that can be used
for process heat in a commercial or industrial application.
[0040] Waste heat recovery is also commonly used with combustion
engine applications. In this process, hot water and low pressure
steam can be generated by circulating water/antifreeze solutions
through the engine block and oil cooling systems, or by installing
heat exchangers in the exhaust gas path. The recovered heat can
then be used in various industrial and commercial processes. An
efficiency enhancement technique used for waste heat recovery on a
combustion turbine engine is to utilize the energy in the exhaust
to pre-heat the combustion air prior to entering the combustion
zone. This improves the simple cycle efficiency and is accomplished
via an air-gas heat exchanger called a recuperator. These devices
are commonly used on micro turbines and small combustion turbines
(less than 10 MWe), but become complex and cost prohibitive on
larger designs, in part due to increases in operating pressures and
the associated air gas sealing requirements of the recuperator.
[0041] Microturbines operate a low compression ratios (4-5:1) and
firing temperatures, resulting in relatively low simple cycle
efficiencies. When equipped with recuperators, simple cycle
efficiencies between 20 and 28% (LHV) can be expected. Efficiencies
for small to medium-sized simple cycle combustion turbines in the
500 to 25,000 kW size range typically vary between 25% to 35%
(lower heating value-LHV) depending on pressure ratio and turbine
inlet temperature. High pressure ratios and turbine inlet
temperatures, achieved by using more exotic turbine blade materials
and/or blade cooling technologies, results in higher efficiencies
in the 35% to 40% range. Combined cycle applications boost the
efficiency to levels in the 35% to 55% range. The efficiencies of
combustion turbine driven power systems are dependent on
temperature, with values increasing at lower ambient or compressor
inlet temperature. Typical efficiencies for IC engines vary between
25% and 40% (LHV).
[0042] There are numerous manufacturers of reciprocating combustion
engine generators 16 in the U.S. and around the world. These
include Caterpillar, Waukesha, Wartsila, Jenbacher, Cummins,
Kohler, Cooper Bessemer, Fairbanks-Morse, Detroit Diesel, and
General Motors. An example of Caterpillar's natural gas fired
engine line is listed below: TABLE-US-00001 Model kW Output Speed
G3304 55-65 High - 1,800 rpm G3306 85-150 High - 1,800 rpm G3406
150-240 High - 1,800 rpm G3408 175-310 High - 1,800 rpm G3412
250-475 High - 1,800 rpm G3508 210-395 Medium - 1,200 rpm G3512
365-600 Medium - 1,200 rpm G3516 465-820 Medium - 1,200 rpm G3606
1,070-1,135 Medium - 900 rpm G3608 1,430-1,515 Medium - 900 rpm
G3612 2,160-2,290 Medium - 900 rpm G3616 2,880-3,050 Medium - 900
rpm
[0043] Major manufacturers of micro turbines include Capstone (30
and 60 kW models), Ingersoll-Rand (70 kW), Elliott/Ebara (80 kW),
Bowman, and Turbec. Manufacturers of larger turbine units include
General Electric, Siemens-Westinghouse, Ahlstom, Solar (a division
of Caterpillar), Rolls-Royce, Pratt-Whitney, US Turbine, Allison,
Hitachi and Kawasaki. Solar's line of turbine generator sets,
typical of the mid-range sizes used in distributed power
applications, are listed below: TABLE-US-00002 Model KW Output Type
Saturn 20 1,210 Simple Cycle Centaur 40 3,515 Simple Cycle Mercury
504,600 Recuperated Centaur 50 4,600 Simple Cycle Taurus 60 5,200
Simple Cycle Taurus 70 6,890 Simple Cycle Mars 90 9,285 Simple
Cycle Mars 100 10,685 Simple Cycle Titan 130 12,832 Simple
Cycle
[0044] The exhaust gas created from the turbine or reciprocating
engine is subsequently piped though exhaust gas piping 50 for
further treatment and injection as shown in FIG. 4. With regard to
the electric power generation, there are generally 1) direct
current generators and 2) alternating current generators as
discussed herein:
[0045] A generator is fundamentally a magnet spinning inside a coil
of wire. If a magnetic core, or armature, revolves between two
stationary coils of wire called field poles an electric current is
produced. This produced current in the armature moves in one
direction during half of each revolution, and in the other
direction during the other half. To produce current moving in only
one direction it is necessary to provide a means of reversing the
current flow outside the generator once during each revolution. In
original generators this reversal was accomplished by means of a
commutator, a split metal ring mounted on the shaft of the
armature. The two halves of the ring were insulated from each other
and served as the terminals of the armature coil. This was
accomplished by having fixed brushes of metal or carbon being held
against the split metal ring as it revolves. As the armature turns,
each brush is in contact alternately with the halves of the ring,
changing position at the moment when the current in the armature
coil reverses its direction producing a current flow in one
direction, or direct current (DC). In modern DC generators this
reversal is accomplished using power electronic devices such as
diode rectifiers. DC generators have the advantage of delivering of
comparatively constant voltage under varying electrical loads over
short line distances.
[0046] Like a CD generator an alternating current (AC) generator is
a simple generator without a commutator which will produce an
electric current that alternates in direction as the armature
revolves. Alternating current is more efficient over long line
electric power transmission distances. Due to this inherent
efficiency most power generators in use today are of the AC type.
Because it is often desirable to generate as high a voltage as
possible, rotating armatures as found in simple AC generators are
not practical because of the possibility of sparking between
brushes and slip rings and the danger of mechanical failures that
might cause short circuits. To eliminate this problem, AC
generators known as alternator rises to a peak, sink to zero, drop
to a negative peak, and rise again to zero numerous times each
second at a frequency dependent on input shaft rotation speed.
Single winding armatures produce single-phase alternating current
while two windings produce two phase current and so on. A larger
number of phases may be obtained by increasing the number of
windings in the armature, but in modern electrical-engineering
practice three-phase alternating current is most commonly used, and
the three-phase alternator is the dynamoelectric machine typically
employed for the generation of electric power.
[0047] A typical small-to-mid-sized combustion turbine that could
be used for distributed power by an electric utility, or for
on-site commercial or industrial power is the Solar Taurus 60. This
combustion turbine generator has a continuous ISO output of 5,200
KWe and heat rating of 11,263 Btu/kW-hr. The exhaust temperature
for this machine is 906 F at ISO conditions. The combustion turbine
and generator comes in a skid-mounted package with a length of 28
ft.-9 in. and 8 ft.-6 in. in height and a weight of approximately
65,000 pounds. The package includes an exhaust collector, turbine
assembly, combustor, compressor, air inlet, gearbox, base frame,
including fuel and oil systems, generators, starter, and
microprocessor-based control system. The system may be purchased
with an optional weather-resistant outdoor enclosure, fire
protection system, inlet air filters and ducting, and outlet
silencers and exhaust ducting. Along with this equipment, a
complete installation will include natural gas or fuel delivery
systems (piping, pressure regulation, metering, filtering,
valving), substation equipment (step-up transformer, breakers,
protective relaying, electrical metering equipment), foundations,
compressor wash equipment, stack, perimeter fencing, and lighting.
The site may also include a natural gas compressor (if required),
distillate storage and transfer equipment, emissions control
equipment (including stack analyzers), control room.
[0048] Upon creation of the desired electrical current from the
electrical generators, an electrical transformer substage may be
utilized. More specifically, several microturbine designs operate
at very high speed (greater than 50,000 rpm) and are coupled to an
electric generators on the same shaft. High frequency alternating
current (AC) is converted to direct current (DC) via a rectifier,
and then to 50 or 60 Hz AC power via an inverter. However, most IC
engine and CT electric generators, including one of the
microturbine designs, used a gearbox between the power unit and the
generators so that the generator rotates at 3,600 rpm (or a
multiple of this) to produce 60 Hz AC power.
[0049] The most common electrical output for microturbines and
small IC engine or CT generators is 3 phase, 480 volt power,
although there are variations in this between manufacturers. Larger
units typically produce 3 phase, 5 to 15 kilovolt power. In all
cases, a step-up (or step-down) transformer will be required if the
generators is to be connected to an electrical circuit or
distribution system that operates at voltages different than
these.
[0050] A large number of small industrial and commercial buildings
are connected to a 3 phase, 480 volt power supply. In this
instance, a microturbine with this output would not require a
step-up transformer. Electric distribution lines typically operate
at higher voltages. Examples would be 7.2 kV, 12.5 kV, 24.9 kV, 44
kV and 69 kV. Electric transmission lines operate at even higher
voltages including 115 kV, 230 kV, 345 kV, 500 kV and higher. In
all cases, transformers will be required if the voltage output of
the electrical generator is different than the electrical circuit
at the point of interconnection.
[0051] Electric generators that supply power to an isolated circuit
are said to be operating in a stand-alone or grid-independent
configuration. If the electric generators simultaneously supply
power to both a low voltage circuit (building or industrial
process) and an electric distribution or transmission system, it is
said to be operating in a grid-parallel mode. In the event of a
loss (fault) on the electric distribution or transmission line, an
automatic transfer switch can be used under the right circumstances
to transfer power directly from the electric generators to the low
voltage circuit.
[0052] Upon generation of the electricity from the turbine or
reciprocating engine 14, electric generator 16 and electric
transformer 18, the electrical current must be compatible for
transmission into an existing electrical line grid 56. More
specifically, the lines of high-voltage transmission systems are
usually composed of wires of copper, aluminum, or copper-clad or
aluminum-clad steel, which are suspended from tall latticework
towers of steel by strings of porcelain insulators. By the use of
clad steel wires and high towers, the distance between towers can
be increased, and the cost of the transmission line thus reduced.
In modem installations with essentially straight paths,
high-voltage lines may be built with as few as six towers to the
mile. In some areas high voltage lines are suspended from tall
wooden poles spaced more closely together. For lower voltage
subtransmission and distribution lines, wooden poles are generally
used rather than steel towers. In cities and other areas where open
lines create a hazard, insulated underground cables are used for
distribution. Some of these cables have a hollow core through which
oil circulates under low pressure. The oil provides temporary
protection from water damage to the enclosed wires should the cable
develop a leak. Pipe-type cables in which three cables are enclosed
in a pipe filled with oil under high pressure (14 kg per sq cm/200
psi) are frequently used. These cables are used for transmission
and subtransmission of current at voltages as high as 3465,000 V
(or 345 kV).
[0053] Long transmission lines have considerable inductance and
capacitance. When a current flows through the line, inductance and
capacitance have the effect of varying the voltage on the line as
the current varies. Thus, the supply voltage varies with the load.
Several kinds of devices are used to overcome this undesirable
variation, in an operation called regulation of the voltage. The
devices include induction regulators and three-phase synchronous
motors (called synchronous condensers), both of which vary the
effective amount of inductance and capacitance in the transmission
circuit. Inductance and capacitance react with a tendency to
nullify one another. When a load circuit has more inductive than
capacitive reactance, as almost invariably occurs in large power
systems, the amount of power delivered for a given voltage and
current is less than when the two are equal. The ratio of these two
amounts of power is called the "power factor". Because
transmission-line losses are proportional to current, capacitance
is added to the circuit when possible, thus bringing the power
factor as nearly as possible to 1. For this reason, large
capacitors are frequently inserted as a part of power-transmission
systems.
[0054] Modem electric power grid systems use transformers to
convert electricity into different voltages. With transformers,
each stage of the system can be operated at an appropriate voltage.
In a typical system, the generators at the power station deliver a
voltage from about 1,000 to 26,000 volts (V). Transformers step
this voltage up to values ranging from 138,000 to 765,000 V for the
primary transmission line. At the substation, the voltage may be
transformed down to levels of 69,000 to 138,000 V for further
transfer on the subtransmission system. Another set of transformers
step the voltage down again to a distribution level such as 2,400
or 4,160 V or 15, 27, or 33 kilovolts (kV). Finally the voltage is
transformed once again at the distribution transformer near the
point of use to 240 or 120 V.
[0055] Referring now to FIG. 4, the exhaust gas 50 is shown being
processed and reinjected with additional process equipment needed
in one embodiment of the present invention. More specifically, the
exhaust gas piping 50 is operably interconnected to a subsequent
two phase separator 10 which removes any vapor and/or water content
from the exhaust gas. The piping is preferably high temperature
corrosion resistant materials which are specifically designed for
high temperature corrosive environment applications. The separator
10 may be a dehydration vessel with coalescing elements in one
compartment and a knitted wire mesh mist extractor in a second
compartment. These types of vessels are well known in oil and gas
industry and are manufactured by companies such as Anderson, Van
Air, J. L. Bryan, Process Equipment Co. and Wright-Austin.
[0056] The vapor or water removed from the exhaust gas is
subsequently reinjected into a subterranean formation and/or placed
in the storage tank for removal at a later date. The exhaust gas
exits the phase separator 10 and subsequently enters into a heat
exchanger/cooler which additionally removes any impurities from the
exhaust gas and/or creates condensation to remove additional water
content. Electrical or mechanical power produced in the power
generation stage could be used to power air cooling fans in the
exhaust gas collection and cooling stage. One example of such a
device is a blazed or aluminum heat exchanger to cool the gas to
allow efficient compressor operation. These types of coolers are
manufactured by companies such as Lytron, Fafco, Sewep, Power
Equipment and Hydro Thrift. The remaining cooled and dry exhaust
gas is then piped to a low pressure exhaust gas storage reserve
vessel which may be used to store static volumes of between about
6,000 scf and 60,000 scf of exhaust gas as desired.
[0057] The exhaust gas storage vessel 52 is in operable
communication with a gas compressor 26, which may be driven by an
electric motor 54 which obtains the electrical energy from the
electric generator which is being run by the produced hydrocarbon
fluids. The gas compressor may also be driven by direct mechanical
connection (shaft) from the generator or have its own secondary
drive engine. The gas compressor 26 is generally used to increase
the exhaust pressure from between about atmospheric pressure and
2.5 psi to about 420 and 5000 psi depending on the downhole
reservoir pressure of the subterranean formation in which the gas
is intended to be injected. Thus, the size and horsepower required
for the compressor 26 is dictated by the bottom hole pressure of
the subterranean formation utilized for reinjection purposes.
[0058] Compressors are designed to increase the pressure and
decrease the volume of a gaseous fluid. The three general types
currently in manufacture are 1) positive-displacement, 2) dynamic,
or 3) thermal types. Positive displacement compressors fall into
two basic categories including 1) reciprocating and 2) rotary.
Reciprocating compressors consist of one or more cylinders each
with a piston or plunger that moves back and forth, displacing a
positive volume of gas with each stroke. Rotary compressors types
are either lobe, screw, vane or liquid ring, with each having a
casing with one or more rotating elements that either mesh with
each other such as lobes or screws, or that displace a fixed volume
with each rotation. Dynamic type compressors include radial-flow,
axial-flow and mixed flow machines which are all rotary continuous
flow compressors in which rotating elements (impellers or blades)
accelerate the gas as it passes through the element. Thermal
"ejector" compressors use a high velocity gas or stream jet to
entrain an inflowing gas, then convert the velocity of the mixture
to pressure in a diffuser. Reciprocating (positive displacement)
compressors, which makeup the majority type for oil and gas
applications, have horsepower ratings that vary from fractional to
more than 20,000 hp per unit. Pressure ranges from low vacuum at
suction to 30,000 psi and higher at discharge with inlet flow
volumes ranging from less than 10 cubic feet/minute (cfm) to over
10,000 cfm. Reciprocating compressors are supplied in either
single-stage or multi-stage configurations depending on the overall
compression ratio needed. The compression ratio per stage is
generally limited by the discharge temperature and usually does not
exceed 4:1, although some small sized units are furnished with
compression ratios as high as 8:1. On multistage machines,
intercoolers may be installed between stages to remove the heat of
compression from the gas and reduce its temperature resulting in
overall higher efficiencies. Reciprocating compressors should be
supplied with clean gas as they cannot handle liquids and solid
particles that may be entrained in the inlet gas. Compressor types
and flow ratings to be unutilized for exhausted gas compression for
subterranean injection is dependent on the producing well(s) outlet
flow rate to the combustion generators, combustion engine types and
number, exhaust flow rates and cooling efficiencies. Some current
manufacturers of compressors for oil and gas facility applications
include Ariel, Atlas, Copco, Cooper, Dresser-Rand, Gardner Denver,
Gemini, Howden, Mycom, Neuman & Esser, Rix and Sundyne.
Compressors and drive engines/motors are generally sold as modular
units where all the various components are located on one skid or
truck mounted unit. Modular compressor units can be obtained for
any application from low pressure to high pressure. Some currently
available compressor/drive engine modules include the Caterpillar
G379TA/Knight KOA-2, Superior 6GTLB/Superior MW-62, Ajax
DPC-230/Single Stage, Waukesha VRG301/Ariel JGP1-2, and Waukesha
817/Inight KOA-2. Compressor induction exhaust gas flow rates by
constituent in lbs/hr for a 75 kW combustion turbine generator
engine: TABLE-US-00003 O2 1407 N2 5370 CO2 87 NOx 0.03 CO 0.02
[0059] Compressor induction exhaust gas flow rates by constituent
in lbs/hr for a 250 kW combustion turbine generator engine:
TABLE-US-00004 O2 4213 N2 16079 CO2 261 NOx 0.06 CO 0.07
[0060] Referring now to FIG. 5, a typical injection wellbore 8 of
the present invention is provided herein. More specifically, the
compressed exhaust gas which exits the compressor is operatively
piped via exhaust gas piping 50 to a wellhead of an injection
wellbore 8. In some applications it may be desirable to have the
exhaust gas metered for total volume and monitored for molecular
constituents prior to injection. The injection wellbore may again
include pressure gauges 40 and other valves 38 to regulate the flow
and/or back pressure of the injection wellbore 8 positioned
downstream from the gas compressor 26. In the embodiment shown in
FIG. 5, the injection wellbore 8 comprises wellbore tubing 36 which
is positioned between two or three strings of wellbore casing 34
which protects the wellbore from the surrounding earth materials
and to prevent any unwanted communication of produced fluids. The
production tubing 36 is isolated from the wellbore casing 34 by
means of a packer 58, which prevents communication of the injected
exhaust gas to the wellbore casing 34. The wellbore casing 34
additionally has a plurality of perforations 48 positioned opposite
the non-producing geologic formation 4 and which allows the
injected exhaust gas to flow from the exhaust gas piping 50 through
the injection wellbore 8 and into the non producing geologic
formation 4.
[0061] As appreciated by one skilled in the art, in a further
embodiment of the present invention the exhaust gas may be injected
into a currently producing geologic formation 2 to enhance the
ultimate recovery of the natural gas since the bottom hole pressure
is increased. Depending on the bottom hole pressure of the existing
producing geologic formation 2, and the availability of other
non-producing geologic formations 4, the operator may determine
whether or not to utilize the producing geologic formation 2 and/or
utilize a non-producing geologic formation 4 for injection
purposes. On some occasions, the exhaust gas may be injected in
both a non-producing geologic formation 4 and a producing geologic
formation 2 simultaneously as engineering principles and economics
dictate.
[0062] Referring now to FIG. 6, one alternative embodiment of the
present invention is shown herein, wherein the same wellbore is
utilized for both production and injection purposes. More
specifically, the producing geologic formation 2 is shown on the
lower portion of the drawing, while a non-producing geologic
formation 4 is shown positioned above at a shallower depth. Thus,
the natural gas or other hydrocarbons are produced from the
producing geologic formation 2 into the production tubing 36 and
subsequently through the wellhead, into the phase separator 10 and
other process equipment. After treatment of the natural gas and
subsequent generation of electrical energy, the exhaust gas is
returned to the wellbore via exhaust gas piping 50 and is injected
through the production casing/production tubing annulus 60 through
the perforations 48 and into the non-producing geologic formation
4.
[0063] Thus, in this particular example, the produced hydrocarbons
are flowed through the production tubing 36, while waste exhaust
gas is reinjected into the wellbore casing/production tubing
annulus 60 and reinjected into the non-producing geologic formation
4. Thus, one producing wellbore can be utilized for both production
and injection purposes, provided that at least one producing
geologic formation 2 is located at a greater depth from a non
producing geologic formation 4. As appreciated by one skilled in
the art, depending on the various geologic formations and available
downhole wellbore designs, any variety of combinations of injection
and/or production scenarios may be utilized to accomplish the scope
of the present invention.
[0064] As described above, electrical current generated from the
methods and processes described herein may subsequently be
transmitted to an electrical transmission grid 20, which is
typically located in close proximity to a small town or other
community for utilizing the electrical power for residential needs
including, but not limited to, electrical power for lighting,
heating and other power requirements. However, electrical power can
also be drawn from electrical transmission grid 20 for facilitating
a number of subprocesses and production of alternative energy
sources. Alternatively, electrical current generated from the
methods and processes described above may be used directly for a
variety of purposes, without first transmitting to an electrical
transmission grid 20, including for the purpose of producing
alternative energy sources as described in greater detail below. By
way of example, but not by limitation, electrical power generated
by the methods above may be redistributed or reused to produce, on
site, additional low-carbon/carbon-free fuels such as hydrogen and
ethanol.
[0065] According to one embodiment of the present disclosure,
hydrogen production may be facilitated by one of a variety of
subprocesses, including but not limited to thermal, electrolytic,
and/or photolytic subprocesses. Thermal subprocesses produce energy
from various energy sources such as natural gas, coal, biofuel,
and/or other natural resources, including hot water springs or
seeps which may provide heat as a source of thermal energy. In one
particular embodiment of the present invention, thermal energy is
provided from the hydrocarbons produced from the oil/gas
production. In alternative embodiments, the thermal energy may be
provided by heat produced from the wellbore during the oil/gas
production process, or without limitation from any of the various
energy sources listed above. Perhaps the most common known thermal
subprocess is based on a process of steam methane reforming, during
which a high temperature steam is used to separate hydrogen from a
known methane source such as natural methane gas.
[0066] Electrolytic subprocesses, on the other hand, use
electricity to separate water molecules into hydrogen and oxygen.
Electrolytic subprocesses typically occur in an electrolyzer, or
similar apparatus, which produces an electric current to break the
bond between the hydrogen and oxygen molecules.
[0067] Photolytic subprocesses rely on energy from light emitted
from a source to separate the hydrogen from water molecules.
Although many photolytic subprocesses are still under development,
it is contemplated that a light source could be provided by the
electrical current generated by the methods and processes described
above to produce hydrogen.
[0068] The preceding subprocesses may be incorporated into the
method and system of the present disclosure in such a way as to
facilitate the production of hydrogen as an alternative fuel
source. By utilizing the electrical power generated by the method
according to one embodiment of the present disclosure, these
methods may further be streamlined to create efficient alternative
energy production subprocesses.
[0069] Similarly, ethanol production may also be facilitated using
the methods and processes described herein. For example, electrical
energy generated according to various embodiments of the present
disclosure may be utilized and employed during the subprocess of
ethanol distillation, as opposed to hydrogen production. Other
known methods and subprocesses for producing ethanol as a byproduct
of the present disclosure are also contemplated.
[0070] In an alternate embodiment, a method and process is
disclosed for generating electrical power from one of the following
sources: thermal energy, solar energy, wind power, and/or oil
shale. Any one of these sources of power may be used alone or in
conjunction with the methods and processes described herein
relating to production of oil and gas, and any pollution or other
undesired constituents may be injected into at least one
subterranean formation. Additionally, thermal energy derived from
these processes and methods may be used in lieu of electrical power
to produce hydrogen, ethanol, biomass, and other fuel products. By
way of example but not by limitation, the high temperature steam
required to separate hydrogen from a known methane source such as
natural methane gas may be derived from the thermal energy produced
by the methods and processes described above in relation to
producing oil and gas. Similarly, available thermal energy may be
utilized during the subprocess of ethanol distillation
[0071] For clarity purposes, the following list of the components
and the numbering associated therein in the drawings is provided
herein: TABLE-US-00005 Number Component 2 Producing geologic
formation 4 Non producing geologic formation 6 Producing geologic
formation 8 Injection wellbore 10 Phase separator 12 Meter 14
Turbine or reciprocating engine 16 Electric generator 20 Electric
transmission grid 22 Exhaust gas treatment vessel 24 Piping 26 Gas
compressor 28 Gas storage vessel 30 Heat exchanger/cooler 32 Gas
scrubber/cleaner 34 Wellbore casing 36 Wellbore tubing 38 Valve 40
Pressure gauge 42 Oil/water storage vessel 44 Wellhead 46 Ground
surface 48 Perforations 50 Exhaust gas piping 52 Exhaust gas
storage vessel 54 Electric motor 56 Electric line 58 Wellbore
packer 60 Production casing/tubing annulus
[0072] The foregoing description of the present invention has been
presented for purposes of illustration and description. The
description is not intended to limit the invention to the form
disclosed herein. Consequently, the invention and modifications
commensurate with the above teachings and skill and knowledge of
the relevant art are within the scope of the present invention. The
preferred embodiment described above is also intended to explain
the best mode known of practicing the invention and to enable
others skilled in the art to utilize the invention in various
embodiments and with the various modifications required by their
particular applications for use of the invention. It is intended
that the claims be construed to include all alternative embodiments
as permitted by the prior art.
* * * * *