Back to results
US 11,598,320 B2Granted
Systems and methods for generation of electrical power at a drilling rig
AssigneeICE Thermal Harvesting, LLC
InventorsAdrian Benjamin Bodishbaugh, Carrie Jeanne Murtland
Life of this patent
Estimating the term…
Abstract
Embodiments of systems and methods for generating power in the vicinity of a drilling rig are disclosed. During a drilling operation, heat generated by drilling fluid flowing from a borehole, exhaust from an engine, and/or fluid from an engine's water (or other fluid) jacket, for example, may be utilized by corresponding heat exchangers to facilitate heat transfer to a working fluid. The heated working fluid may cause an ORC unit to generate electrical power.
Claims13
A method for generating power in the vicinity of a drilling rig, the method comprising:
- during a drilling operation:
- pumping drilling fluid from a drilling fluid container to a proximal end of a drill pipe, the drilling fluid to flow through an interior of the drill pipe to the distal end adjacent a location that generates a heated drilling fluid from flow of the drilling fluid during the drilling operation, the heated drilling fluid to flow up a borehole to a drilling fluid return pipe above the subsurface;
- diverting one or more of:
- (1) the heated drilling fluid, via a first heat exchanger supply valve, from the drilling fluid return pipe to a first heat exchanger, the first heat exchanger connected to a working fluid manifold via a first working fluid flow control device and positioned to transfer heat from the heated drilling fluid to a flow of a first portion of a working fluid, thereby to generate a cooled drilling fluid and a heated first portion of the working fluid, the heated first portion of the working fluid positioned to cause a generator to generate electrical power, (2) exhaust, via a second heat exchanger supply valve, produced by one or more engines, to a second heat exchanger connected to the working fluid manifold via a second working fluid flow control device, the second heat exchanger positioned to transfer heat from the exhaust to a flow of a second portion of the working fluid to generate a heated second portion of the working fluid, the heat second portion of the working fluid to cause a generator to generate electrical power, or (3) heated coolant, via a third heat exchanger supply valve, from a water jacket associated with the one or more engines to a third heat exchanger connected to the working fluid manifold via a third working fluid control device, the third heat exchanger to transfer heat from the heated coolant to a flow of a third portion of the working fluid to generate a heated third portion of the working fluid, the heated third portion of the working fluid positioned to cause a generator to generate electrical power;
- sensing, via an exhaust inlet sensor, an exhaust thermal mass of the exhaust produced by the one or more engines;
- sensing, via an ambient temperature sensor, an ambient temperature of the drilling rig;
- in response to one or more of (1) a determination that the exhaust thermal mass of the exhaust from the one or more engines is outside of an exhaust thermal mass range, or (2) a determination that an ambient temperature exceeds an engine operating range;
- adjusting one or more of (1) the second heat exchanger supply valve configured to (a) partially or fully prevent or (b) allow flow of the exhaust from the one or more engines to the second heat exchanger, or (2) (a) the second working fluid flow control device or (b) the third working fluid flow control device;
- and
- returning the cooled drilling fluid to the drilling fluid container.
7 more elements
A method for generating power at a drilling rig, the method comprising:
- during a drilling operation:
- receiving, via a return pipe positioned above a subsurface, a heated drilling fluid from a fluid channel defined by a space between an outer surface of a drilling pipe and an inner surface of a borehole;
- diverting one or more of:
- (1) the heated drilling fluid from the drilling fluid return pipe to a first heat exchanger connected to a working fluid manifold via a first working fluid flow control device, the first heat exchanger positioned to transfer heat from the heated drilling fluid to a flow of a first portion of a working fluid, thereby to generate a cooled drilling fluid and a heated first portion of working fluid positioned to cause a generator to generate electrical power, (2) exhaust produced by one or more engines to a second heat exchanger connected to the working fluid manifold via a second working fluid flow control device, the second heat exchanger positioned to transfer heat from the exhaust to a flow of a second portion of the working fluid, thereby to generate a heated second portion of the working fluid, the heated second portion of the working fluid positioned to cause a generator to generate electrical power, and (3) heated coolant from a water jacket associated with the one or more of the engines to a third heat exchanger connected to the working fluid manifold via a third working fluid flow control device, the third heat exchanger to transfer heat from the heated coolant to a flow of a third portion of the working fluid, thereby to generate a heated third portion of the working fluid, the heated third portion of the working fluid positioned to cause a generator to generate electrical power;
- sensing, via an exhaust inlet sensor, an exhaust thermal mass of the exhaust produced by the one or more engines;
- determining electrical power utilized by a drilling fluid chiller;
- in response to one or more of (1) a determination that the exhaust thermal mass of the exhaust from the one or more engines is outside of an exhaust thermal mass range, or (2) a determination that the electrical power utilization of the drilling fluid chiller exceeds an operating range;
- adjusting one or more of (1) an exhaust control valve configured to (a) partially or fully prevent or (b) allow flow of the exhaust from the one or more engines to the second heat exchanger, or (2) the first working fluid flow control device to increase an amount of the first portion of the working fluid flowing from the working fluid manifold to the first heat exchanger;
- and
- returning the cooled drilling fluid to a drilling fluid container.
7 more elements
A method for generating power in the vicinity of a drilling rig, the method comprising:
- during a drilling operation:
- pumping, via a pump driven by an engine at the drilling rig, drilling fluid from a drilling fluid container to a proximal end of a drill pipe, the drilling fluid to flow through an interior of the drill pipe to the distal end adjacent a location that generates a heated drilling fluid from flow of the drilling fluid, the heated drilling fluid to flow up a borehole to a drilling fluid return pipe above the subsurface;
- receiving, via the drilling fluid return pipe, the heated drilling fluid;
- sensing, via a return pipe temperature sensor, a temperature of the heated drilling fluid in the return pipe;
- sensing one or more of:
- (1) a temperature of a flow of a first portion of a working fluid, via a first working fluid temperature sensor, from a first heat exchanger connected to a working fluid manifold via a first working fluid flow control device, the flow of the first portion of the working fluid to flow through the first heat exchanger, the first heat exchanger connected to the return pipe via a first heat exchanger valve and positioned to allow the heated drilling fluid to flow therethrough, the first heat exchanger to facilitate transfer of heat from heated drilling fluid to the flow of the first portion of the working fluid, thereby to generate a cooled drilling fluid and a heated first portion of the working fluid, the heated first portion of the working fluid positioned to cause a generator to generate electrical power or, (2) a temperature of a flow of a second portion of the working fluid, via a second working fluid temperature sensor, from a second heat exchanger connected to the working fluid manifold via a second working fluid flow control device, the flow of the second portion of the working fluid to flow through the second heat exchanger, the second heat exchanger to facilitate transfer of heat from exhaust to the flow of the second portion of the working fluid, thereby to generate a heated second portion of the working fluid, the heated second portion of the working fluid positioned to cause a generator to generate electrical power;
- sensing, via an exhaust inlet sensor, an exhaust thermal mass of the exhaust produced by the engine or one or more engines;
- determining electrical power utilized by a drilling fluid chiller;
- and
- in response to one or more of (1) a determination that the temperature of heated drilling fluid in the return pipe is greater than or equal to a threshold, (2) a determination that one or more of the temperature of the flow of the first portion of the working fluid or the temperature of the flow of the second portion of the working fluid are within an operating range, (3) a determination that the exhaust thermal mass of the exhaust from the one or more engines is outside of an exhaust thermal mass range, or (4) a determination that the electrical power utilization of the drilling fluid chiller exceeds an operating range:
- adjusting one or more of (1) a first heat exchanger supply valve to allow continuous diversion of the heated drilling fluid to the first heat exchanger, (2) a second heat exchanger supply valve configured to (a) partially or fully prevent or (b) allow flow of the exhaust from the one or more engines to the second heat exchanger, or (3) (a) the first working fluid flow control device or (b) the second working fluid flow control device;
- and
- returning the cooled drilling fluid to the drilling fluid container.
10 more elements
Dependencies are inferred from the claim text.