US20100071561A1 - Mobile nitrogen generation device - Google Patents
Mobile nitrogen generation device Download PDFInfo
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- US20100071561A1 US20100071561A1 US12/560,330 US56033009A US2010071561A1 US 20100071561 A1 US20100071561 A1 US 20100071561A1 US 56033009 A US56033009 A US 56033009A US 2010071561 A1 US2010071561 A1 US 2010071561A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/22—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by diffusion
- B01D53/229—Integrated processes (Diffusion and at least one other process, e.g. adsorption, absorption)
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
- B01D53/75—Multi-step processes
Abstract
A mobile inert gas generator can include various components supported by a wheeled vehicle. The generator can include a feed air compressor, a separation device for separating an inert gas from a feed air gas, and a booster compressor, each of which can have various sensors and actuators for controlling the operation thereof. An electronic control system can be connected to the sensors and actuators to allow for convenient operation of the generator. The electronic control system can include a control panel disposed in a cab.
Description
- The present application claims priority to U.S. Provisional Application Ser. No. 60/700,672, filed Jul. 19, 2005 and U.S. Provisional Application Ser. No. 60/812,843, filed Jun. 12, 2006, the entire contents of each of which is hereby expressly incorporated by reference.
- 1. Field of the Inventions
- The present inventions are directed to systems and methods for generating inert gas, and more particularly, systems and methods for producing inert gas on a mobile platform.
- 2. Description of the Related Art
- In the art of drilling, such as drilling for oil or natural gas, inert gases are commonly used for numerous purposes. Typically, inert gases are often used to displace oxygen from the volume of space above a liquid surface in a storage tank used for storing flammable substances, such as, for example, crude oil.
- Additionally, inert gases are often used to suppress fire or explosion and prevent corrosion during a drilling operation. For example, an inert gas such as nitrogen, can be injected into a borehole during a drilling operation to prevent ignition of substances within the borehole and to prevent corrosion of the drill bit.
- In accordance with at least one of the embodiments disclosed herein, a system can be configured to separate nitrogen from atmospheric air. The system can comprise a feed air compressor unit having a screw compressor with an inlet and outlet driven by an air/fuel engine so as to compress atmospheric air to a pressure of at least 200 psi at the outlet of the screw compressor. A filtration assembly can comprise at least first, second, third, and fourth coalescence filters supported on a filter frame, the first, second, and third coalescence filtered being connected in series with an inlet of the first coalescence filter connected to the outlet of the screw compressor, the first, second, third, and fourth coalescence filters disposed adjacent to each other on the filter frame. A carbon tower filter can have an inlet communicating with an outlet of the carbon tower filter and can be connected to an inlet of the fourth coalescence filter. The carbon tower filter can also be disposed in a position that is not spatially between the third and fourth coalescence filters. A heater device can have an inlet connected to an outlet of the third coalescence filter and an outlet connected to an inlet of the carbon tower filter. A membrane separation assembly can have a plurality of membrane separation devices arranged in at least first and second vertical stacks, at least first and second vertical members supporting the first and second vertical stacks, at least the first vertical member defining either an inlet or an outlet manifold of a plurality of the membrane separation devices, an inlet of the membrane separation assembly being connected to an outlet of the fourth coalescence filter and being configured to distribute a filtered gas from the fourth coalescence filter to inlets of a plurality of the membrane separation devices. The heater device can be supported by at least one of the first and second vertical members. A booster compressor can have an inlet connected to an outlet of the membrane separation assembly and can be configured to raise a pressure of nitrogen rich gas discharged from the membrane separation assembly. The booster compressor can also have an engine driving a compressor device having an outlet. The compressor device can be configured to raise a pressure of the nitrogen rich gas to at least 1000 psi. Additionally, a control can have an electronic control system comprising at least a first sensor configured to detect an operational parameter of the feed air compressor, at least a second sensor being configured to detect an operational parameter of the membrane separation assembly, and at least a third sensor configured to detect an operational parameter of the booster compressor. The electronic control system can further comprise an electronic control unit connected to the first second and third sensors and can be configured to allow an operator of the electronic control system to monitor the output of the first, second, and third sensors. A wheeled vehicle can support the feed air compressor, the filtration assembly, the carbon tower filter, the heater device, the membrane separation assembly, the booster compressor, and the control cab.
- In accordance with at least one of the embodiments disclosed herein, a system can be configured to separate an inert gas from atmospheric air. The system can comprise a wheeled vehicle comprising at least one pair of wheels, a feed air compressor and a booster compressor, the feed air compressor and the booster compressor being disposed on opposite sides of the at least one pair of wheels, in the longitudinal direction of the wheeled vehicle.
- In accordance with at least one of the embodiments disclosed herein a system can be configured to separate nitrogen from atmospheric air. The system can comprise a filter assembly comprising at least first and second coalescence filters supported on a first filter support assembly, the first and second coalescence filters being disposed adjacent to each other. Additionally, a carbon tower filter device can have an inlet connected to an outlet of the first coalescence filter and can have an outlet connected to an inlet of the second coalescence filter, the carbon tower being disposed in a position that is not spatially between the first and second coalescence filters.
- In accordance with at least one of the embodiments disclosed herein a system can be configured to separate a component gas from atmospheric air. The system can comprise a plurality of membrane separation devices supported by at least first and second generally vertical members, wherein at least one of the generally vertical members define an intake or discharge manifold for the plurality of membrane separation devices.
- In accordance with at least one of the embodiments disclosed herein a system can be configured for separating and inert gas from atmospheric air. The system can comprise at least a first compressor. At least a first separation device can be configured to separate the inert gas from atmospheric air, the first separation device being connected to the first compressor. An electronic control system can be configured to control an operation of at least the first compressor. The control system can also comprise at least one sensor configured to detect an operational parameter of the first compressor and at least a second sensor configured to detect an operational parameter of the first separation device. A wheeled vehicle clone support the first compressor, the first separation device, and the electronic control system. Additionally, a third sensor that is not supported by the wheeled vehicle can be configured to detect a parameter external to the system.
- In accordance with at least one of the embodiments disclosed herein, a system can be configured to separate an inert gas from atmospheric air. The system can comprise a feed air compressor configured to compress and thereby raise a pressure of atmospheric air. A separation device can be configured to separate the inert gas from the pressurized atmospheric air from the feed air compressor. A booster compressor can be configured to raise a pressure of the inert gas from the separation device. At least a first sensor can be configured to detect an operational parameter of the feed air compressor. At least a second sensor can be configured to detect an operational parameter related to the operation of the separation device. At least a third sensor can be configured to detect an operational parameter of the booster compressor. Additionally, an electronic control system can be connected to the first, second, and third sensors. The electronic control system can comprise a display device configured to display a graphical user interface having at least first, second, and third screens. The first screen can include a plurality of data related to the operation of the feed air compressor including data indicative of the output of the first sensor. The second screen can include a plurality of data related to the operation of the separation device including data indicative of the output of the second sensor. Additionally, the third screen can include a plurality of data related to the operation of the booster compressor including data indicative of the output of the third sensor.
- In accordance with at least one of the embodiments disclosed herein, a system can be configured to separate an inert gas from atmospheric air. The system can comprise a feed air compressor subsystem configured to pressurize atmospheric air. A filter subsystem can be configured to filter the pressurized air from the feed air compressor. A separation subsystem can be configured to separate an inert gas from the pressurized atmospheric air from the feed air compressor. A booster compressor subsystem can be configured to raise a pressure of an inert gas discharged from the separation subsystem. A lubricant circulation subsystem can be configured to circulate lubricant and from at least one of the feed air compressor subsystem and the booster compressor subsystem to at least one of the filter subsystem and the separation subsystem. A wheeled vehicle can support the feed air compressor subsystem, the filter subsystem, the separation subsystem, the booster compressor subsystem, and the lubricant circulation subsystem.
- In accordance with at least one of the embodiments disclosed herein, a system can be configured to separate inert gas from atmospheric air. The system can comprise a feed air compressor having an air fuel engine and an exhaust discharge configured to guide exhaust gases away from the air fuel engine. The feed air compressor can have an inlet connected to the exhaust discharge and can be configured to exhaust gas from the exhaust discharge. A separation assembly can be configured to separate an inert gas from the pressurized exhaust gas from the booster compressor. A booster compressor can be configured to raise a pressure of the inert gas from the separation assembly. A wheeled vehicle can support the feed air compressor, the separation assembly, and the booster compressor.
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FIG. 1 is a schematic view of a drilling stem arrangement showing delivery of an inert gas to a downhole drilling region. -
FIG. 2 is a cross-sectional schematic view of a well with a horizontally disposed section including casings and upper and lower liners with an inert rich gas present therein. -
FIG. 3 is a cross-sectional schematic view of an initial injecting of a cement slurry for cementing a casing within a well. -
FIG. 4 is a cross-sectional schematic view of the casing ofFIG. 3 with the cement in place to secure the casing within the well. -
FIG. 5 is a cross-sectional schematic view of a well and equipment for removing gas and/or oil from a well with the assistance of an inert rich gas. -
FIG. 6 is a cross-sectional schematic view of a reservoir and the injection of an inert rich gas to remove gas and/or oil from the reservoir. - The above-mentioned and the other features of the inventions disclosed herein are described below with reference to the drawings of the preferred embodiments. The illustrated embodiments are intended to illustrate, but not to limit the inventions. The drawings contain the following figures:
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FIG. 6A is a schematic diagram of a mobile inert gas separation system. -
FIG. 7 is a schematic diagram of an embodiment of an inert gas separation system in which air or exhaust from an engine is subjected to a separation process to separate inert gas therefrom. -
FIG. 7A is a schematic illustration of an embodiment of the separation system ofFIG. 7 . -
FIG. 7B is a schematic illustration of an embodiment of the separation system ofFIG. 7 . -
FIG. 7C is a schematic illustration of another embodiment of the separation system ofFIG. 7 . -
FIG. 7D is a schematic illustration of yet another embodiment of the separation system ofFIG. 7 . -
FIG. 7E is a schematic illustration of a further embodiment of the separation system ofFIG. 7 and can include a single bed pressure swing adsorption system with a buffer tank. -
FIG. 7F is a schematic illustration of another embodiment of the separation system ofFIG. 7 and can include a combination of adsorption and/or membrane separation units. -
FIG. 7G is a schematic illustration of yet another embodiment of the separation system ofFIG. 7 and can include multiple membrane separation units. -
FIG. 7H is a schematic illustration of a further embodiment of the separation system ofFIG. 7 . -
FIG. 8 is a schematic diagram of another embodiment in which air or exhaust from an engine is subjected to a separation process to produce inert rich gas therefrom. -
FIG. 9A is a top plan view of a mobile inert gas separation system mounted on a trailer, which can include any of the above described separation systems, the trailer being configured to be towed over the road by a towing vehicle. -
FIG. 9B is a side elevational view of the system shown inFIG. 9A . -
FIG. 10 is a schematic diagram of an exemplary feed air compressor that can be used with any of the above illustrated inert gas separation systems. -
FIG. 11 is a schematic illustration of an exemplary filter assembly that can be used with any of the above illustrated inert gas separation systems. -
FIG. 12 is a top plan view of the filter system illustrated inFIG. 11 . -
FIG. 13 is a front elevational view of the filter assembly illustrated inFIG. 12 . -
FIG. 14 is a side elevational view of the filter assembly illustrated inFIG. 12 . -
FIG. 15 is a top plan view of an exemplary carbon tower that can be used with any of the above-identified inert gas separation systems. -
FIG. 16 is a front elevational view of the carbon tower ofFIG. 15 . -
FIG. 17 is a side elevational view of the carbon tower ofFIG. 15 . -
FIG. 18 is a bottom plan view of the carbon tower ofFIG. 15 . -
FIG. 19 is a schematic illustration of an exemplary membrane separation unit that can be used with any of the above-illustrated inert gas separation systems. -
FIG. 20 is a top plan view of an exemplary embodiment of the membrane unit ofFIG. 19 . -
FIG. 21 is a right side elevational view of the membrane unit illustrated inFIG. 20 . -
FIG. 22 is a rear elevational view of the membrane unit illustrated inFIG. 20 . -
FIG. 23 is a left side elevational view of the membrane unit illustrated inFIG. 20 . -
FIG. 24 is a schematic diagram of an exemplary booster compressor that can be used with any of the above-illustrated inert gas separation systems. -
FIG. 25 is a schematic diagram of an exemplary auxiliary heater system that can be used with any of the above-illustrated inert gas separation systems. -
FIG. 26 is a schematic electrical diagram that can be used to operate the compressor ofFIG. 10 . -
FIG. 27 is a schematic electrical diagram that can be used to operate the booster compressor ofFIG. 24 . -
FIG. 28 is a schematic electrical diagram of a lighting system that can be used with any of the above-illustrated inert gas separation systems. -
FIG. 29 is a schematic electrical diagram of a circuit that can be used to operate a portion of the heater system ofFIG. 25 . -
FIG. 30 is a schematic electrical diagram of a circuit that can be used to operate a portion of the heater system ofFIG. 25 . -
FIG. 31 includes a legend defining the symbols used in the figures contained herein. -
FIG. 32 is an illustration of another modification of the inert gas separation systems illustrated above, which can utilize any of the above-identified components and systems, and which includes a power take-off (PTO) device driven by an engine used for moving the system and which can be used to -
FIG. 33 is a schematic diagram illustrating a control panel with a touch screen that can be used for remotely controlling any of the above-illustrated mobile systems. -
FIG. 34 is a schematic electrical diagram of a power supply system that can be used with any of the above-illustrated mobile systems. -
FIG. 35 is a schematic diagram of an optional display arrangement that can be used with any of the above-illustrated mobile systems. -
FIG. 36 is a schematic diagram of control devices that can be used with any of the above-illustrated mobile systems. -
FIG. 37 is a schematic diagram of control devices that can be used with any of the above-illustrated mobile systems. -
FIG. 38 is a schematic illustration of an electronic control system that can be used with any of the above illustrated mobile systems. -
FIG. 39 is a perspective view of a control panel that can be used with any of the above illustrated mobile systems. -
FIG. 40 is a nitrogen generating unit screen of a graphical user interface that can be used in conjunction with a control panel ofFIG. 39 . -
FIG. 41 is a feed air compressor screen of a graphical user interface that can be used in conjunction with a control panel ofFIG. 39 . -
FIG. 42 is a membrane section screen of a graphical user interface that can be used in conjunction with a control panel ofFIG. 39 . -
FIG. 43 is a booster compressor screen of a graphical user interface that can be used in conjunction with a control panel ofFIG. 39 . -
FIG. 44 is another screen of a graphical user interface that can be used in conjunction with a control panel ofFIG. 39 . -
FIG. 45 is a system configuration screen of a graphical user interface that can be used with a control panel ofFIG. 39 . -
FIG. 46 is a temperature control screen of a graphical user interface that can be used in conjunction with a control panel ofFIG. 39 . -
FIG. 47 is a temperature tuning screen of a graphical user interface that can be used in conjunction with a control panel ofFIG. 39 . -
FIG. 48 is a device selection screen of a graphical user interface that can be used in conjunction with a control panel ofFIG. 39 . -
FIG. 49 is a device setting screen of a graphical user interface that can be used in conjunction with a control panel ofFIG. 39 . -
FIG. 50 is an oxygen sensor calibration screen of a graphical user interface that can be used in conjunction with a control panel ofFIG. 39 . -
FIG. 51 is a flow device calibration screen of a graphical user interface that can be used in conjunction with the control panel ofFIG. 39 . -
FIG. 52 is a pressure device calibration screen of a graphical user interface that can be used in conjunction with the control panel ofFIG. 39 . -
FIG. 53 is a temperature device calibration screen of a graphical user interface that can be used in conjunction with the control panel ofFIG. 39 . - The present embodiments generally relate to an improved system and methods for producing inert gases on a mobile platform. The systems and methods for producing inert gases are generally described in conjunction with the production of inert gas, such as nitrogen gas (N2), for use during a drilling operation because this is an application in which the present systems and methods have particular utility. Additionally, the systems and methods can be used to produce inert gas having different levels of purity. Those of ordinary skill in the relevant art can readily appreciate that the present systems and methods described herein can also have utility in a wide variety of other settings, for example, but without limitation, offshore drilling rigs as discussed in greater detail below.
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FIG. 1 is a schematic view of a typicaldrill stem arrangement 18 showing the delivery of an inert rich gas to adownhole drilling region 19. Generally, inert rich gas flows down thedrill stem arrangement 18 until it reaches adrill stem assembly 20 which is typically connected in lengths known as “pipe stands”. Thedrill stem assembly 20 can be fed through the well head assembly (identified generally by numeral 22) which may contain a series of pipe rams, vents, and choke lines. The inert rich gas is exhausted through anoutlet 24 which is connected to a blooey line. - For non-drilling applications, the
drill stem assembly 20 may be removed and the inert rich gas can be pumped into the downhole region through thepathway 26. - The surface installation may optionally include an injector manifold (not shown) for injecting chemicals, such as surfactants and special foaming agents, into the inert rich gas feed stream, to help dissolve mud rings formed during drilling or to provide a low density, low velocity circulation medium of stiff and stable foam chemicals to cause minimum disturbance to unstable or unconsolidated formations.
- Extending below the surface of the ground into the downhole region is the
drill stem arrangement 18 which provides a pathway for the flow of pressurized inert rich gas to the drilling region. There is also provided a second pathway for the flow of nitrogen gas and the drill cuttings out of the downhole region and away from the drilling operation. - With continued reference to
FIG. 1 , the drill stem arrangement includes an outlet orsurface pipe 24 and acasing 32. Thedrill stem assembly 20 extends concentrically with and spaced apart from thesurface pipe 24 andproduction casing 32 so as to define apathway 42 for the return of inert rich gas and the drill cuttings. The center of thedrill stem assembly 20 provides apathway 26 for the flow of inert rich gas to the drilling region. At thelower end 75 of thedrill stem arrangement 18, in vicinity of thelower drilling region 34, is a conventional tool joint 35, adrill collar 36 and adrill bit 38. - The inert rich gas (e.g., nitrogen rich gas) is typically pressurized by a compressor and is then delivered to the
drill stem assembly 20. Because the inert rich gas is under pressure, it can swirl around thedrilling region 34 with sufficient force and velocity to carry the drill cuttings upwards into thepathway 42. The drill cutting containing stream then exits theoutlet 24 of the surface installation equipment where it is carried to a blooey line and eventually discarded into a collection facility, typically at a location remote from the actual drilling site. - The inert rich gas described above for removing drilling cuttings can also be injected into the drilling fluid to reduce the density thereof. This provides greater control over the drilling fluid and is particularly adapted for “underbalanced” drilling where the pressure of the drilling fluid is reduced to a level below the formation pressure exerted by the oil and/or gas formation. The inert rich gas can be provided to the drilling fluid in the following exemplary but non-limiting manner.
- With continued reference to
FIG. 1 , the inert rich gas can be injected into a drilling fluid through an assembly shown inFIG. 1 absent thedrill stem assembly 20. In one embodiment, the inert rich gas is pumped through thepathway 26 which can be in the form of linear pipe strings or continuous coiled tubing known as a “drill string”. Alternatively, the inert rich gas can be pumped into theannular space 42 between the drill string orpathway 26 and thecasing 32 inserted into the well. In this embodiment a drill string can be inserted directly into theannular space 42 to provide the inert rich gas directly therein. As such, the inert rich gas can be used to modify the flow properties and weight distribution of the cement used to secure the casings within the well. - With reference to
FIGS. 2 , 3 and 4, a well 44 is supported by tubular casings including anintermediate casing 88, asurface casing 50, and aconductor casing 48. Theconductor casing 48 is set at the surface to isolate soft topsoil from the drill bit so as to prevent drilling mud from eroding the top section of the well bore. - The
surface casing 50 also extends from the surface of the well and is run deep enough to prevent any freshwater resources from entering the well bore. In addition to protecting the fresh water, thesurface casing 50 prevents the well bore from caving in and is an initial attachment for the blow-out-prevention (BOP) equipment. Typical lengths of thesurface casing 50 are in the range of about 200 to 2500 ft. - The
intermediate casing 88 protects the hole from formations which may prove troublesome before the target formation is encountered. Thecasing 88 can be intermediate in length, i.e., longer than thesurface casing 50, but shorter than the final string of casing (production casing) 32. - The production casing (oil string or long string) extends from the bottom of the hole back to the surface. It isolates the prospective formation from all other formations and provides a conduit through which reserves can be recovered.
- The diameter of the
various casings intermediate casing 88 extends the furthest into thewell 44. Theintermediate casing 88 is typically filled with adrilling fluid 58 such as drilling mud. - The process of securing the casing within the well using a cement-like material is illustrated in
FIGS. 3 and 4 . With reference toFIG. 3 , a well 44 contains acasing 60 which is initially filled with adrilling fluid 58 such as drilling mud or a drilling mud modified with a nitrogen rich gas. Awiper plug 62 is inserted into thecasing 60 and urged downward to force the drilling fluid out of thebottom opening 65 and up along theannular space 64 between thewalls 66 defining the well bore and thecasing 60. The drilling fluid proceeds upwardly through theannular space 64 and out of theopening 70 at the top of the well 44. - While the drilling fluid is being evacuated a cement-like material in the form of a slurry is loaded into the
casing 60. Asecond wiper plug 66 is then urged downwardly as shown inFIG. 4 to force the cement out of thebottom opening 65 until theannular space 64 is filled. Excess cement escapes out of theopening 70 of the well. - An inert rich gas, preferably nitrogen gas, which can be produced as described below, can be used to reduce the density of the cement in a manner similar to that described for the drilling fluid. The inert rich gas can be injected into the casing while the cement is being added therein. The injection of the inert rich gas into the cement modifies the density and flow characteristics of the cement while the cement is being positioned in the well.
- The inert rich gas is injected into the casing through a drill string of the type described in connection with
FIG. 1 with thedrill stem assembly 20 removed. The rate of injection and the precise composition of the inert rich gas is controlled by a compressor. - The inert rich gas can be used to improve the buoyancy of the casings so as to minimize the effects of friction as the casings are inserted into the well. This is particularly apparent when casings are inserted into horizontal sections in the downhole region. In horizontal sections, the weight of the casing causes it to drag along the bottom surface of the wellbore. In extreme cases the casing may become wedged in the wellbore and not be able to be advanced as far into the downhole region as desirable. Introducing an inert rich gas into the interior of the casing will increase the buoyancy of the casing, allowing it to float in the mud or drilling fluid surrounding the casing.
- With continued reference to
FIG. 2 , there is shown a casing assembly including a tubular member orliner 68 which is designed to enter ahorizontal section 70 of the well 44. Theliner 68 is any length of casing that does not extend to the surface of the well. - The
liner 68 includes anupper section 72 which contains a drilling fluid and alower section 73. The upper and lower sections are separated by aninflatable packer 74. Thelower section 73 is charged with the inert rich gas which makes it lighter and more buoyant than theupper section 72 which is filled with mud. Thelower section 73 may therefore move easily into thehorizontal section 70 of the well 44. - After the completion of drilling in the downhole region, inert rich gas can be used to improve well performance and maximize output of gas and/or oil from the reservoir. Quite often well production declines because of the presence of fluids, such as water, excess drilling mud and the like in the downhole region. The inert rich gas can be used to clean out the well by displacing the heavier fluids that collect therein. Removal of the heavier fluids will regenerate the flow of gas and/or oil from the reservoir if there is sufficient formation pressure within the reservoir. The inert rich gas can be used to provide an additional boost for lifting the gas and/or oil from the downhole region to a collection area. In this case the inert rich gas is pumped down into the downhole region within the casing under sufficient pressure so that the gas and/or oil entering the downhole region from the reservoir is lifted upwardly and out of the well.
- With reference to
FIG. 5 , there is shown an assembly particularly suited for injecting an inert rich gas into the gas and/or oil within the downhole region to facilitate delivery thereof upwardly through the well for collection. Such a system is applicable to downholes having reduced formation pressure. As a result the gas and/or oil has difficulty entering the downhole from the reservoir. - The inert rich gas can be injected into the
annulus 80 between thecasing 84 and atubing 86. The inert rich gas is metered into thetubing 86 through avalve assembly 88. Thetubing 86 has anopening 90 enabling gas and/or oil from the downhole region to enter and rise up to the surface of the well. The injection of the inert rich gas from thevalve assembly 88 into thetubing 86 assists the gas and/or oil by providing buoyancy to the flow upwardly to the aboveground collection area 94. This process is commonly referred to as artificial gas lift. - In another application for inert rich gas, the nitrogen rich gas is used to stimulate the well in the downhole region to enhance gas and/or recovery. More specifically, the walls of the wellbore in the downhole region characteristically have cracks or fissures through which the gas and/or oil emerges from the reservoir. As the pressure in the reservoir decreases, the fissures begin to close thereby lowering production. The most common form of stimulating the downhole region is by acidizing or fracturing the wellbore. The inert rich gas can be used as a carrier for the acid to treat the wellbore. The inert rich gas expands the volume of the acid, retards the reaction rate of the acid resulting in deeper penetration, and permits faster cleanup because there is less liquid to be displaced by the high energy inert rich gas.
- Cracking of the wellbore in the downhole region can be performed by pumping a fluid such as acid, oil, water, or foam into a formation at a rate that is faster than what the existing pore structure will accept. At sufficiently high pressures, the formation will fracture, increasing the permeability of the downhole. When the stimulation procedure is completed, the pressure in the formation will dissipate, and the fracture will eventually close. Sand and/or glass beads or other so-called “poppants” may be injected into the formation and embedded in the fractures to keep the fractures open. The inert rich gas may be used as a carrier gas to carry the poppants to the wellbore.
- It is well established that the pressure in a reservoir (formation pressure) provides for the flow of gas and/or oil to the downhole region. As the reserves of gas and/or oil become depleted, the formation pressure decreases and the flow gradually decreases toward the well. Eventually the flow will decrease to a point where even well stimulation techniques as previously described will be insufficient to maintain an acceptable productivity of the well. Despite the reduced formation pressure, nonetheless, the reservoir may still contain significant amounts of gas and/or oil reserves.
- In addition, gas-condensate reservoirs contain gas reserves which tend to condense as a liquid when the formation pressure decreases below acceptable levels. The condensed gas is very difficult to recover.
- The lack of formation pressure in a reservoir can be remedied by injecting an inert rich gas directly into the reservoir. As illustrated highly schematically in
FIG. 6 , an inert gas generation system is shown generally bynumeral 210. The assembly is constructed above a gas and/oroil reservoir 102. Inert rich gas is pumped down the well, often called an injector well 44 a, through atubing 104 to exert pressure on the reserves in the direction of the arrow. The increased pressure on the gas and/or oil causes the same to flow to a producing formation and up a producing well 44 b through atubing 106 into an aboveground collection vessel 108. - The flow rate of inert rich gas to the drilling region of an oil and/or gas well or a geothermal well can vary over a wide range depending on the size of the downhole, the depth of the well, the rate of drilling, the size of the drilling pipe, and the makeup of the geologic formation through which the well must be drilled. Some typical drilling operations require the production of 1,500 to 3,000 standard cubic feet per minute (scfm) of nitrogen gas from the inert
gas separation system 210; however, other flow rates can also be used. The inert rich gas can be pressurized up to a pressure of about 1,500 to 2,000 psig before being passed to the drilling region, however, other pressures can also be used. - An average drilling operation can take about five days to two weeks, although difficult geologic formations may require several months of drilling. The inert rich gas delivery system is designed for continuous operation and all of the inert rich gas is generated on-site without the need for external nitrogen replenishment required for cryogenically produced liquid nitrogen delivery systems.
- In a typical underbalanced drilling operation, 500 to 800 scfm (standard cubic feet per minute) of an inert rich gas is commingled with drilling mud to reduce the hydrostatic weight of the drilling fluid in the downhole region of a well. This reduces or prevents an overbalanced condition where drilling fluid enters the formation, or mud circulation is lost altogether. Carefully adjusting the weight of the drilling fluid will keep the formation underbalanced, resulting in a net inflow of gas and/or oil into the well.
- If a drill string becomes stuck due to high differential pressure caused by combined hydrostatic and well pressure conditions, an inert rich gas at 1500-3000 scfm at pressures of 1000-2000 psig can be injected down the drill string to force the fluid up the annulus to the surface. The reduced weight and pressure will help free the stuck pipe. In this case, the inert rich gas is used as a displacement gas.
- A naturally producing reservoir loses pressure (depletes) over time with a resulting loss in recoverable oil and/or gas reserves. Injection of nitrogen at 1500 scfm or greater at various locations or injection sites will keep the reservoir pressurized to extend its production life. In gas condensate reservoirs, the pressure is kept high enough to prevent gas condensation or liquefaction, which is difficult to remove once liquefied.
- The inert rich gas can be introduced into the producing wells by means of special valves in the production casing positioned in the downhole region of the well. The lifting action of the inert rich gas is one form of artificial gas lift as shown best in
FIG. 5 . - With reference to
FIG. 6A , the mobile inertgas separation system 200 can include apropulsion device 206 and asuspension device 208 supporting an inertgas separation system 210. - The
propulsion device 206 can be in the form of any type of propulsion device, including, for example, but without limitation, a truck designed for towing on highway or off-road. Thesuspension device 208 can be in the form of a trailer configured to be towed by thepropulsion device 206. Optionally, thepropulsion device 206 and thesuspension device 208 can be integrally formed in a rigid frame, fixed wheel base truck. However, these are merely examples ofpropulsion devices 206 andsuspension devices 208 that can be used to allow the inertgas separation system 210 to be mobile. Other arrangements can also be used. -
FIG. 7 illustrates one embodiment of an inertgas generation system 210 that can provide a supply of inert gas. Thesystem 210 can produce inert gas of suitable quality for use, for example, in drilling operations as described above. The inertgas generation system 210 preferably includes aflow source 212, aconditioning system 214, and anoutput 216 of theconditioning system 214. - The
flow source 212 provides an output of fluid to theconditioning system 214. Theflow source 212 can be configured to output any type of fluid having a reduced amount of oxygen and an inert portion. In the illustrated embodiment, the output of theflow source 212 is exhaust gas from a combustion process. However, as noted above, output of theflow source 212 can be compressed atmospheric air. - An output of the
flow source 212 is connected to theconditioning system 214. Theconditioning system 214 can be configured to treat and/or condition the output to achieve desired flow characteristics of the flow passing out ofoutput 216. For example, theconditioning system 214 can be configured to convert the output of thesource 212 into a fluid with suitable pressure, purity, temperature, volumetric flow rate, and/or any other desirable characteristic depending on, for example, the end use of the output flow. - In one non-limiting embodiment, the inert
gas generation system 210 is configured to produce a flow that comprises an inert gas. The inert gas can be a highly pure inert gas, such as Nitrogen gas. In one embodiment, the inert gas comprises mostly Nitrogen gas but can include other substances, such as Oxygen and particulates. - In the illustrated embodiment, the
flow source 212 can comprise an air/fuel engine 220. The air/fuel engine 220 can comprise any type of air/fuel combustion engine, including open-system combustion engines such as, but without limitation, turbine engines, as well as internal combustion engines, including, but without limitation diesel, gasoline, four-stroke, two-stroke, rotary engine, and the like. In some embodiments, the air/fuel engine 220 can be configured to provide propulsion power for transporting the entiremobile separation system 200. - In an exemplary but non-limiting embodiment, the
engine 220 is a diesel engine. Theengine 220 can be normally aspirated, turbo-charged, super-charged, and the like. The construction and operation of such engines are well known in the art. Thus, a further description of the construction and operation of theengine 220 is not repeated herein. - In an exemplary but non-limiting embodiment, the
engine 220 is configured to produce an output of about 400-650 horsepower (hp). In another exemplary but non-limiting embodiment, theengine 220 is configured to produce an output of about 550 hp. Optionally, theflow source 212 can comprise a plurality of similar ordifferent engines 220. In one exemplary but non-limiting embodiment, theflow source 212 comprises one or more diesel engines and/or one or more gasoline engines. In another embodiment, theflow source 212 comprises a plurality of diesel engines. - The output from the
engine 220 can contain various products of combustion. The exhaust produced by theengine 220 can include gases, liquids, and particles. For example, the output can comprise gases such as argon, hydrogen (H2), nitrogen (N2), oxides of Nitrogen (NOx), carbon oxide (e.g., carbon monoxide (CO) and carbon dioxide (CO2)), hydrocarbons, and/or other gases. The output can also comprise fluid such as water (H2O) and oil. The output can also comprise particles such as diesel particulate matter, if theengine 220 is a diesel engine. Of course, the output of theflow source 212 will have different components depending on the type offlow source 212 that is employed. - The
engine 220 can draw in ambient air through anair intake 221 and can produce exhaust containing both inert and non-inert gas. Preferably, the volume percentage of the inert gas output from theengine 220 is generally greater than the volume percentage of the inert gas typically present in ambient air. - In some embodiments, the volume percentage of the inert rich gas of the exhaust fluid produced by the
engine 220 is at least 5% greater than the volume percentage of inert gas typically present in ambient air. In yet another embodiment, the volume percentage of the inert rich gas of the exhaust fluid produced by theengine 220 is at least 10% greater than the volume percentage of inert gas typically present in ambient air. In some embodiments, the proportion of inert gas in the exhaust of theengine 220 can be increased by increasing the power output from theengine 220. - For example, diesel engines do not have a throttle valve. Thus, when a diesel engine is operating at a power output level that is below full power, the amount of fuel burned in the engine is not sufficient to burn all of the air in the engine. Thus, fuel is burned in a “lean” mixture, i.e., non-stoichiometric. Thus, the exhaust gas discharged from the
engine 220 contains some oxygen. However, when the power output of a diesel engine is raised, more fuel is injected, and thus, more oxygen is “burned”, thereby reducing the oxygen content of the exhaust. Thus, a further advantage is produced where theengine 220 used is sized such that during normal operation, theengine 220 is running under an elevated power output. For example, if theengine 220 is rated at about 550 horsepower and the engine is operated at about 225 horsepower, theengine 220 will burn a substantial portion of the oxygen in the ambient air drawn into theengine 220. Further advantages are achieved where theengine 220 is operated at near maximum power. For example, if theengine 220 is operated at about 450 horsepower, the engine will burn nearly all of the oxygen present in the air. One of ordinary skill in the art recognizes that gasoline-burning engines operate under different air/fuel principles, and thus, the proportion of oxygen present in gasoline-powered engines does not vary substantially with power output. - Normally, exhaust gas produced by the
engine 220 will contain less oxygen than ambient air. In one-embodiment, the exhaust gas can contains less than about 10% by volume of oxygen gas, depending on the air fuel ratio of a mixture combusted therein and operating load of theengine 220. As noted above, as the fuel injection rate of a diesel engine is increased, more oxygen is consumed, and thus, the oxygen content of the exhaust gas is similarly decreased. Preferably, the exhaust gas from theengine 220 comprises less than about 7% by volume oxygen. In another embodiment, the exhaust gas from theengine 220 contains less than about 5% by volume of oxygen gas. In another embodiment, the exhaust gas from theengine 220 comprises less than about 3% by volume of oxygen gas. - The low levels of oxygen gas contained in the exhaust gas can increase the inert gas purity of the gas discharged from the
conditioning system output 216 of theconditioning system 214. Additionally, theconditioning system 214 can produce high purity inert gas even though the working pressure of theconditioning system 214 is very low. It is contemplated the type ofengine 220 employed and the power output of theengine 220 can be varied by one of ordinary skill in the art to achieve the desired purity of the gas outputted from theengine 220. The operating conditions of the engine can also be controlled so as to produce the desired flow characteristics (e.g., volumetric flow rate, pressure, purity, and the like). - For example, in embodiments where the
engine 220 is a diesel engine, the volumetric flow rate of exhaust gases out of theengine 220 can be controlled by controlling the speed of theengine 220. This is because diesel engines do not operate with a “throttle valve.” Rather, diesel engines always displace the same volume of gas regardless of the power output of theengine 220. For example, a 13 liter engine (wherein 13 liters refers to the total volume swept by the pistons of the cylinders during operation) displaces about 13 liters of air for each two revolutions of the crank shaft (where theengine 220 is a 4-stroke engine). As noted above, the power output from theengine 220 depends on the amount of fuel injected into the combustion chambers of the engine. - During operation, diesel engines can operate over a range of different engine speeds. Additionally, diesel engines generally can output a significant amount of power or torque over a range of different speeds. Thus, in some applications, it may be desirable to set the engine to operate at a fixed speed and allow the engine controller to control fuel injection to maintain the speed of the engine by varying the power output. Thus, if it is desired to cause the
engine 220 to output a relatively lower volumetric flow rate of exhaust gas, theengine 220 can be set to operate between idle speed and low engine speeds, for example, between 500 and 1,200 rpm. If higher volumetric flow rates are desired, theengine 220 can be set to operate at speeds above 1,200 rpm. However, other techniques can also be used to vary the volumetric flow rate of exhaust gas out of theengine 220. - An
exhaust conduit 226 connects thesource 212 with theconditioning system 214. In the illustrated embodiment, theexhaust conduit 226 connects theengine 220 to amixing plenum 228 of theconditioning system 214. The output of theengine 220 is exhaust flow or fluid that is passed through theexhaust conduit 226 and is fed into the mixingplenum 228. - Optionally, the inert
gas generation system 210 can include atemperature control system 236 for controlling the temperature of the exhaust fluid before the exhaust fluid enters the mixingplenum 228. For example, thetemperature control system 236 can include a heat exchanger configured to maintain the temperature of the exhaust fluid at a desired temperature. - In the some embodiments, the
temperature control system 236 can increase or decrease the temperature of the exhaust fluid as it flows down theexhaust conduit 226. By removing heat from the exhaust fluid flowing through theexhaust conduit 226, a further advantage is provided in preventing undesirable effects, such as overheating, of downstream devices. Although not illustrated, thetemperature control system 236 can include temperature sensors, pressure sensors, flow meters, or the like. - Preferably, the mixing
plenum 228 is configured and sized to receive a continuous flow of exhaust fluid from theexhaust conduit 226. However, the mixingplenum 228 can be configured and sized to receive an intermittent flow or any type of flow of exhaust fluid. Additionally, the mixingplenum 228 can be adapted to receive the exhaust flow at various volumetric flow rates. - In an exemplary but non-limiting embodiment, the mixing
plenum 228 includes aenlarged chamber 229. Thechamber 229 can comprise a plurality of channels or tubes that are configured to mix the exhaust fluid with one or more other gases. For example, in some embodiments, the mixingplenum 228 can include theair intake 230 that draws in ambient air surrounding the mixingplenum 228 into the channels within the mixingplenum 228. The mixingplenum 228 can combine and mix the ambient air with the exhaust fluid to output a generally homogeneous or heterogeneous fluid to downstream sections of theconditioning system 214. In other embodiments, the mixing chamber is substantially sealed from ambient air. - Optionally, the mixing
plenum 228 can have acontroller 232 configured to selectively determine the mixture and content of the output flow from the mixing plenum. For example, thecontroller 232 can include a device (e.g., a motor) configured to agitate and mix the fluids contained within mixingplenum 228. - Optionally, a
feedback device 240 can be configured to control the total level of inert and non-inert gases within the mixingplenum 228. For example, thefeedback device 240 can include acontroller 242 for controlling the proportion of exhaust fluid from theexhaust conduit 226 to the amount of ambient air from theair intake 230 contained within the mixingplenum 228. In some embodiments, thefeedback device 240 can be configured to reduce the amount of air flowing into theair intake 230 so as to increase the purity of the downstream inert gas, described in greater detail below. Thefeedback device 240 can also be configured to increase the amount of ambient air flowing into theair intake 230 and into the mixingplenum 228 so as to reduce the purity of the downstream inert gas. Thus, thefeedback device 240 can selectively increase and/or decrease the content and purity of the downstream fluid in theconditioning system 214. - Although not illustrated, the
feedback device 240 can include one or more sensors configured to detect, for example, the level of the constituents within the mixingplenum 228 and/or within theexhaust conduit 226, the flow parameters (e.g., temperature, flow rate, pressure) of the exhaust fluid passing through theexhaust conduit 226, and the like. Thefeedback device 240 can be an open or closed loop system for controlling the flow of substances passing through theconditioning system 214. - For example, the
feedback device 240 can be an open system that commands thetemperature control system 236 wherein an operator can determine and set the temperature of the exhaust fluid fed into the mixingplenum 228. In another embodiment, thefeedback device 240 can be a closed loop system and be configured to command thetemperature control system 236 to dynamically change the temperature of the fluid passing through theconditioning system 214 depending on, for example, the temperature of the fluid passing out of theconditioning system output 216. - Optionally, the
system 210 can include a backpressure control device 233 configured to control a back pressure in themixing plenum 228. For example, the backpressure control device 233 can be a throttle device having an orifice and a valve, such as a butterfly-type valve, or any other kind of valve, for metering the flow rate out of themixing plenum 228 into theconduit 244. Thisrestriction device 233 can also be used to control a pressure of the gases discharged from the mixingplenum 228 into theconduit 244. Optionally, an electronic controller (not shown) can be incorporated into thedevice 233 to allow for electronic control of the back pressure generated by thedevice 233 - Additionally, the
device 233 can also be used to affect the oxygen concentration of the exhaust gases discharged from theengine 220. For example, as is well known in the art, as a back pressure in the exhaust system of an engine, such as theengine 220, is raised, the load on the engine increases. Thus, by increasing the restriction or the back pressure in the exhaust system of theengine 220, the load on the engine will increase. If the engine is set to operate at a constant speed, then the engine controller will increase the amount of fuel injected into the combustion chambers of the engine and thereby combust more of the oxygen of the air flowing into theengine 220. Thus, the oxygen content of the exhaust gas leaving theengine 220 will be lower. - Optionally, gas analysis can be performed on the fluid from the
source 212 to ensure the gas compositions are within desired levels. Such an analysis can be incorporated into a process controller (not shown) integrated with theconditioning system 214, or any other part of thesystem 210. In some embodiments, the process controller is integrated with thecontroller 242. However, other components of theconditioning system 214 can have one or more process controllers for determining the composition of the fluid passing through thesystem 214 to control the composition of the output gas passing out of theconditioning system output 216. - The
conditioning system 214 can also include aplenum conduit 244 that extends from the mixingplenum 228 to acompressor 246. Thus, fluid from the mixingplenum 228 can pass through theplenum conduit 244 and into thecompressor 246. - In one non-limiting embodiment, the
compressor 246 is configured to draw fluid from the mixingplenum 228 and increase the pressure thereof. For example, thecompressor 246 can be configured to raise the pressure of the fluid from the mixingplenum 228 to pressures from about 100 psig to about 600 psig. - The
compressor 246 can be any type of compressor. Preferably, thecompressor 246 is a rotary screw type compressor. However, thecompressor 246 can be a pump with fixed or variable displacement that causes an increased downstream fluid pressure. It is contemplated that one of ordinary skill in the art can determine the type of compressor to achieve the desired pressure increase of the fluid. For example, in one embodiment thecompressor 246 is a booster compressor. Although not illustrated, the inertgas generation system 210 can have a plurality of compressors configured to draw fluid from the mixing plenum. - The compression process performed by the
compressor 246 can be used to remove constituents from the exhaust fluid it receives from theplenum conduit 244. For example, the mixingplenum 228 can feed exhaust fluid that comprises water into theplenum conduit 244. Theplenum conduit 244 then delivers the fluid to thecompressor 246. The compression process of thecompressor 246 can remove an amount, preferably a significant amount, of water from the fluid. In one exemplary non-limiting embodiment, a water knock out vessel is included in thecompressor 246 to collect water removed from the fluid. Additionally, a coalescent filter (not shown) can be provided to remove additional entrained water and oil carryover that may be present in the output fluid. - The
conditioning system 214 can also include acompressor conduit 250 that extends from thecompressor 246 to afiltration unit 251. - The
filtration unit 251 can include one or more devices to remove components from the fluid delivered by thecompressor conduit 250. In the illustrated embodiment, thefiltration unit 251 includes afiltration system 252 and aparticulate filter 260. In one non-limiting exemplary embodiment, fluid delivered from thecompressor 246 can pass through thecompressor conduit 250 and into thefiltration unit 251. - Optionally, the
conditioning system 214 can also include atemperature control system 256 configured to adjust the temperature of fluid passing through thecompressor conduit 250. Preferably, thetemperature control system 256 is configured to lower the temperature of the fluid proceeding along thecompressor conduit 250 to a desired temperature. - For example, the
temperature control system 256 and thecompressor 246 can work in combination to adjust the temperature of the fluid passing therethrough to a desired temperature to prevent, for example, overheating of downstream components (e.g., the filtration unit 251). In at least one embodiment, thecompressor 246 can provide fluid tocompressor conduit 250 at a predetermined pressure. Thetemperature control system 256 can be configured to increase or decrease the temperature of the fluid to adjust the pressure of the fluid. For example, thetemperature control system 256 can reduce the temperature of the fluid passing through thecompressor conduit 250 to reduce the pressure of the fluid delivered to thefiltration unit 251. Alternatively, thetemperature control system 256 can increase the temperature of the fluid passing through thecompressor conduit 250 to increase the pressure of the fluid delivered to thefiltration unit 251. - The
temperature control system 256 can be different or similar to thetemperature control system 236. In at least one embodiment, thetemperature control system 256 is a heat exchanger that can rapidly change the temperature of the fluid that passes along thecompressor conduit 250. Similar to thetemperature control system 236, thetemperature control system 256 can be part of an open or closed loop system. - The
filtration unit 251 can be configured to capture and remove undesirable substances from the exhaust fluid. Thefiltration unit 251 can include afiltration system 252 configured to remove undesired substances that may be present in the exhaust fluid. For example, thefiltration system 252 can be configured to capture selected gas impurities. In one embodiment, thefiltration system 252 can capture carbon oxides, hydrocarbons, aldehydes, nitrogen oxides (e.g., typically nitric oxide and a small fraction of nitrogen dioxide), sulfur dioxide, and/or other particulate that may be in the exhaust fluid. Thefiltration system 252 can comprise one or more absorption/adsorption filters and/or vessels that are suitable for removing one or more undesirable substances. Optionally, thefiltration system 252 can include a catalytic converter commonly used in the automotive industry. - With continued reference to
FIG. 7 , thefiltration unit 251 of theconditioning system 214 can also include afiltration system conduit 254 that extends from thefiltration system 252 to theparticulate filter 260. Such aparticulate filter 260 can comprise of one or more absorption filters and/or vessels. Theparticulate filter 260 can be configured to remove particulates that may undesirably adversely affect, for example, the performance of downstream components of theconditioning system 214 or purity of the gas produced by theconditioning system 214. If theengine 220 is a diesel engine, theparticulate filter 260 is preferably a filter that captures and removes diesel particulate matter from the fluid passing therethrough. In one embodiment, theparticulate filter 260 removes a substantial portion of the particulate matter from the fluid. - The
system 210 can also include an additional heat exchanger downstream from theparticulate filter 260. The heat exchanger can be configured to adjust the temperature of the filtered fluid from theparticulate filter 260. Raising the temperature of the upstream fluid can be beneficial because such heating reduces the likelihood that any remaining water vapor will condense out and damage downstream components. Optionally, the additional heat exchanger can be provided with heat from upstream temperature control systems (e.g.,temperature control systems 236, 256). For example, thetemperature control system 236 can be a heat exchanger that cools the exhaust fluid produced by theengine 220. The heat removed by theheat exchanger 236 can be delivered to the additional downstream heat exchanger. The additional heat exchanger can then use that energy to heat the filtered fluid preferably at some point downstream of thefiltration unit 251. It is contemplated that at least one of the temperature control systems can provide energy (e.g., heat) to another temperature control system or heat exchanger. One of ordinary skill in the art can determine the type, location, and configuration of one or more temperature control systems to control the temperature of the exhaust fluid as desired. - The
system 210 can also include aparticulate conduit 262 which extends from theparticulate filter 260 to aseparation unit 266. - With reference to
FIGS. 7 and 7A , theconditioning system 214 can also include a device adapted for separating inert substances from non-inert substances. In the illustrated embodiment, theconditioning system 214 includes theseparation unit 266. In one embodiment, theseparation unit 266 is a membrane separation unit including achamber 268 and a separation membrane 270 (shown inFIG. 7A ) within thechamber 268. As shown inFIG. 7A , themembrane separation unit 266 has amembrane 270 that partitions thechamber 268 into a plurality of chambers. - In the illustrated embodiment, the
membrane 270 divides thechamber 268 into aninert chamber 276 and anon-inert chamber 278. Preferably, during operation of thesystem 210 at least a portion of theinert chamber 276 contains fluid that comprises mostly inert gas, and thenon-inert chamber 278 contains mostly non-inert gas that is separated from the exhaust fluid. Additionally, theseparation unit 266 can have aninlet 280 and anoutlet 281 that are located on the same side of themembrane 270. Both theinlet 280 and theoutlet 281 can be in fluid communication with theinert chamber 276. Preferably, theinlet 280 andoutlet 281 are in fluid communication with opposing portions of theinert chamber 276. - The
inert chamber 276 can be sized and configured to define a flow path between theinlet 280 and theoutlet 281. Thenon-inert chamber 278 can be sized and configured to define a flow path between themembrane 270 and thevent 294. Preferably, thevent 294 is located on one side of themembrane 270 and both theinlet 280 and theoutlet 281 are located on the other side of themembrane 270. - The
membrane 270 can be configured to allow certain substances to pass therethrough at a first flow rate and other substances to pass therethrough at a second flow rate different than the first flow rate. For example, suchmembrane separation units 266 can be provided with amembrane 270 that allows different gases to pass therethrough at different rates. The effect is that the retentate gas, i.e., gases that do not permeate through themembrane 270, remain on the inlet side of themembrane 270 within theinert chamber 276. These gases proceed along thechamber 276 towards, and eventually pass through, theoutlet 281. The permeate gases, preferably non-inert gas, of the fluid delivered through theinlet 280 pass through themembrane 270 and through thenon-inert chamber 278 and are discharged out of the vent oroutlet 294 into the atmosphere, or are further sequestered. - In an exemplary but non-limiting embodiment, the
membrane 270 is an elongated generally planar membrane extending across thechamber 268 and is configured to allow the migration of fluid (e.g., gas) therethrough. Fluid, preferably comprising gases, enters theinert chamber 276 through theinlet 280, some gases pass through themembrane 270 while others do not. In somemembrane separation units 266, themembrane 270 can be configured to allow non-inert gases (e.g., oxygen) to pass more readily through themembrane 270 and inert gas (e.g., nitrogen) to pass through themembrane 270 at a much lower rate. Themembrane 270 can thus be used to separate fluid passing in through theinlet 280 into an inert gas flow that passes out of theoutlet 281 and a non-inert gas flow that passes through themembrane 270 and out of thevent 294. - In one embodiment, fluid passing through the
inlet 280 and into theseparation unit 266 can include, for example but without limitation, nitrogen gas, oxygen gas, oxides of carbon, oxides of nitrogen, and oxide of sulfur, as well as other trace gases. Themembrane 270 can be configured to allow one or more of the non-inert gases, such as oxygen gas, to pass therethrough at a relatively higher rate than the rate at which inert gas, such as nitrogen gas, can pass therethrough. Other gases such as carbon dioxide, oxides of nitrogen, oxides of sulfur, and other trace gases may also pass at a higher rate through themembrane 270 than the rate at which nitrogen gas passes through themembrane 270. The inert gases are thus captured in theinert chamber 276 and the non-inert gases pass through themembrane 270 and into thenon-inert chamber 278. The result is that the gas remaining in theinert chamber 276 has a high concentration of inert gases. Of course, the concentration of the inert gas in theinert chamber 276 can vary along theinert chamber 276 in the downstream direction. Preferably, the gas in theinert chamber 276 and proximate to theoutlet 281 comprises substantially inert gas. - In the present exemplary but non-limiting embodiment, the fluid within the
inert chamber 276 can be largely nitrogen gas and may include other inert gases. For example, theinert chamber 276 can contain inert gases such as, for example, without limitation, argon, carbon monoxide, and hydrocarbons. Preferably, most of the hydrocarbons have been filtered out of the exhaust fluid produced by theengine 220 by thefiltration unit 251. Optionally, themembrane 270 can be configured to allow water vapor to pass therethrough at a higher rate than the rate at which nitrogen gas can pass therethrough. Thus, theseparation unit 266 can receive fluid having water, inert gases, and non-inert gases. Theseparation unit 266 can produce a first flow of mostly inert gas flow and a second flow of non-inert gas and water. The first flow passes through theinert chamber 276 and out of theoutlet 281 and the second flow passes through themembrane 270 and then through thenon-inert chamber 278 and out of thevent 294. -
FIG. 7B illustrates an embodiment of a membrane that can be employed by theseparation unit 266 to separate fluid. The components of thesystem 266 have been identified with the same reference numerals as those used to identify corresponding components of thesystem 210, except that “′” has been used. - In one exemplary but non-limiting embodiment, the
membrane 270′ can be a hollow fiber, semi-permeable membrane. Abody 302 of themembrane 270′ can allow certain substances to pass therethrough at a first flow rate and other substances to pass therethrough at a second flow rate different than the first flow rate. Although not illustrated, thehollow fiber membrane 270′ can be disposed in thechamber 268 of theunit 266 shown inFIG. 7A . The construction of this type of membrane separation unit is well-known in the art, and thus, a further detailed description of thesystem 266 is not included herein. - The
hollow fiber membrane 270′ can include aninlet 300, thebody 302, acentral chamber 310, and anoutlet 304. Thehollow fiber membrane 270′ can separate the fluid provided by the conduit 262 (FIG. 7 ) into a purified inert gas flow and a non-inert gas flow. In some embodiments, with reference toFIG. 7B , fluid passing through theconduit 262 can pass into theseparation unit 266 and into theinlet 300 of themembrane 270′ in the direction indicated by thearrow 308. The fluid entering themembrane 270′ can include nitrogen gas, oxygen gas, carbon dioxide, oxides of nitrogen, and oxides of sulfur, as well as other trace gases. As the fluid flows through thecentral chamber 310 defined by thebody 302, the fluid is separated into its component gases and the more permeable gases migrate through thebody 302. Preferably, themembrane 270′ separates the fluid it receives into a first stream of mostly inert fluid that passes through thechamber 310 and out of theoutlet 304 and another stream of fluid that passes through thebody 302 of themembrane 270′ in the direction indicated byarrows 311. That is, a stream of inert gases passes through thechamber 310 and out of theoutlet 304. Theseparation unit 266 then delivers those inert gases to the conduit 290 (seeFIG. 7 ). The non-inert gases which pass through thebody 302 of themembrane 270′ can be directed to thevent 294 of theunit 266 and discharged into the atmosphere, or further sequestered. - Although not illustrated, the
separation unit 266 can include any suitable number ofmembranes 270′. Themembrane separation 266 may have an increased or reduced number ofmembranes 270′ for an increased or reduced, respectively, separation capacity of theseparation unit 266. For example, theseparation unit 266 can include thousands or millions of the hollow fibersemi-permeable membranes 270′ that are bundled or packed together. Theseparation unit 266 can therefore have an extremely large membrane surface area capable of separating non-inert gas from the fluid passing through theconditioning system 214. Of course, the length of themembrane 270′ can be varied to achieve the desired membrane surface area and pressure drop across theseparation unit 266. - The
separation unit 266 can receive exhaust fluid from theconduit 262 and remove at least a portion of the non-inert component of the exhaust fluid. Theseparation unit 266 can then output an inert rich gas. In one exemplary embodiment, theseparation unit 266 can produce inert rich gas that comprises at least 96% by volume of inert gas. In one exemplary embodiment, theseparation unit 266 can produce inert rich gas that comprises about 98% by volume of inert gas. In another embodiment, the inert rich gas comprises about 99% by volume of inert gas. In yet another embodiment, the inert rich gas comprises about 99.9% by volume of inert gas. Advantageously, because theseparation unit 266 only has to remove a low amount of non-inert gas from the exhaust fluid provided by theconduit 262, theseparation unit 266 can produce highly pure inert rich gas at high volumetric flow rates. Theseparation unit 266 can therefore rapidly separate the exhaust flow into non-inert rich gas and an inert rich flow. In one embodiment, theseparation unit 266 removes less than about 10% by volume of the fluid and discharges highly pure inert rich gas. - Optionally, the
conditioning system 214 can comprise a plurality ofseparation units 266. Each ofseparation units 266 can include one ormore membranes 270′, ormembrane 270. Thus, each of themembrane separation units 266 can comprise one or more similar or dissimilar membranes. It is contemplated that a plurality ofseparation units 266 of theconditioning system 214 can be in a parallel configuration or in a series configuration. For example, a plurality ofmembrane separation units 266 can be in series along theconditioning system 214 to provide an extremely pure inert fluid, preferably a gas, out of theconditioning system output 216. Each of theseparation units 266 can increase the purity of the inert gas passing through theconditioning system 214. - In one exemplary but non-limiting embodiment of
FIG. 7C , theseparation unit 266 is a pressure swing adsorption system (PSA) that preferably produces a purified inert gas. ThePSA 266 may comprise a plurality of beds for producing inert rich gas. Preferably, each of the beds includes an adsorption material (e.g., carbon molecular sieve or silica gel) adapted to adsorb a non-inert component at a faster rate than the rate of absorption of inert components. In one non-limiting embodiment, thePSA 266 includes a pair ofbeds bed beds PSA 266 can be increased or decreased to increase or decrease, respectively, the flow rate at which gases pass through thebeds PSA 266 can be increased or decreased by decreasing or increasing, respectively, the upstream pressure. - During a first production cycle, the
valves conduit 262 flows through theconduits bed 360. The adsorption material in thebed 360 captures the non-inert substances in the fluid flow and allows fluid comprising a high proportion of inert substances (e.g., nitrogen gas) to non-inert substances to pass therethrough. The inert substance, preferably inert fluid (e.g., an inert rich gas), then passes out of thebed 360 and into theconduits conduit 324 can then deliver the inert rich gas to the conduit 290 (FIG. 7 ). - While fluid flows through the
bed 360, thebed 362 can optionally undergo depressurization and can be purged by, for example, nitrogen rich fluid to remove non-inert substances, such as oxygen, that has accumulated in thebed 362. The separating capacity of thebed 362 is thus increased due to the removal of substances from the bed. For example, thevalves bed 360 pass through theconduits bed 362 to purge thebed 362. Optionally,valve 369 can be left open during this stage. The purge fluid can pass out of thebed 362 and into theconduits separation system 266 can have a purge container that contains a fluid that can be used to purge thebeds - During a second cycle, the
valves valves conduit 262 passes through theconduit 379 and into theconduit 375 and through thebed 362. Thebed 362 can capture non-inert components of the fluid and permit inert components to flow into theconduits bed 362, thebed 360 can optionally undergo depressurization and can be purged by some, for example, nitrogen rich fluid to remove oxygen that has accumulated in thebed 360. For example, thevalves valve 370 can be opened so that fluid from thebed 362 passes through theconduits - In the illustrated embodiment, the first cycle can be performed until the
bed 360 has reached a predetermined saturation level. For example, the first cycle can be performed until thebed 360 is generally completely saturated. After thebed 360 is saturated, thebed 360 can be purged so that the non-inert substances captured by thebed 360 are discharged. After the first cycle, the second cycle can be performed until thebed 362 likewise reaches a predetermined saturation level. Thebed 362 and be subsequently purged to remove non-inert substances from thebed 362. These acts can be repeated to produce highly purified inert rich gas. - In some embodiments, such as that illustrated in
FIG. 7D , avacuum pump 381 can be used to increase the performance of thePSA 266. In this arrangement, the system can be referred to as a “Vacuum Swing Adsorption” (VSA) device. In such a device, thevacuum pump 381 is disposed on the outlet ends of thebeds - Embodiments incorporating a PSA or a PSA device can further include a buffer tank, such as the
buffer tank 365. In such embodiments, the buffer tank can be configured to store pressurized gas discharged from thebed 360, and thus provide a more continuous flow of gas from theseparation unit 266. In such embodiments, thebuffer tank 365 can be connected to thebed 360 with a discharge line 356A, which guides gas from thebed 360 to thebuffer tank 365. - A further advantage can be achieved where the buffer tank is also connected to a
valve 365C and areverse flow line 365B. In such embodiments, thebed 360 can also be connected to a vent line at its inlet end. As such, when the vent is opened, the gas in thebuffer tank 36 can be used to purge thebed 360 to perform the desorption process for thebed 360. In some embodiments, thebuffer tank 365 can be sized to be sufficiently large that thebuffer tank 365 can continue to supply gas to downstream components through theline 290 while, at the same time, purge thebed 360. As such, theseparation unit 266 can continue to operate while purging (i.e., the desorption process) even though it only has one tank. - With reference to
FIG. 7F , in some embodiments, theseparation unit 266 can include a plurality of separation devices comprising at least one of an adsorption device and a membrane separation device. For example, in some embodiment, theseparation unit 266 can include, at its upstream end, anadsorption device 266A. Theadsorption device 266A can be any type of adsorption device, including but without limitation, any of the adsorption devices disclosed herein such as the PSA shown inFIG. 7C , the VSA shown inFIG. 7D , or the buffer tank type system shown inFIG. 7E . - The outlet of the
adsorption device 266A can be connected to the inlet of yet another separation device. In the illustrated embodiment, the outlet of theadsorption device 266A is connected to the inlet of amembrane device 266B. Themembrane device 266B can be any type of membrane separation device, including but without limitation, any of the membrane separation devices disclosed herein such as those described with reference toFIGS. 7A and 7B , or any other known membrane separation device. - In this configuration, the gas discharged from the
adsorption device 266A is further purified by themembrane device 266B. In some embodiment, the order of the devices can be reversed. For example, thedevices membrane device 266B is further purified by theadsorption device 266A. - In some embodiments, the
separation unit 266 can comprise a series ofmembrane separation units FIG. 7G . In this arrangement, the feed gas first enters thefirst membrane device 271A. The permeate from thisfirst unit 271A is more likely to be highly contaminated. Thus, the permeate from themembrane unit 271A can be vented out of the system. The retentate, on the other hand, is discharged to the inlet of thesecond membrane device 271B. - The permeate from the
second membrane device 271B will be less contaminated than the permeate from thefirst membrane unit 271A. Thus, in some embodiments, the permeate from thesecond membrane unit 271B can be returned to the system at a point upstream from the second membrane unit, such as the inlet of thefirst membrane device 271A, or another location. For example, but without limitation, the permeate from thesecond membrane unit 271B can be returned to the system at the inlet to thecompressor 246, and thus eventually returns to the inlet of thefirst membrane device 271A. - In some embodiments, the
separation unit 266 can include more than two membrane separation devices. Further, in such embodiments, the permeates from each of the membrane devices downstream from thefirst membrane device 271A can be returned to the system at a point upstream of thefirst separation unit 271A, such as to the inlet of thecompressor 246, although these permeates can be returned to the system at other points. In some embodiments, the membrane separation units can be configured to operate at different pressures, can include membranes with different pore sizes for separating different compounds, and/or can have other differences. - These types of arrangements can provide further advantages. For example, exhaust gas from an internal combustion engine can include many different compounds. Thus, using multiple separation devices can better remove numerous compounds that exist in internal combustion engine exhaust gas that may not be desired. Further, different separation devices, such as PSA, VSA, and membrane-type devices can have different performance characteristics in terms of rate at which they can separate certain compounds out of a feed stream of gas. Thus, by combining different types of separation devices, the
separation unit 266 can achieve better performance, particularly in the environment of use where it is desired to separate certain compounds out of exhaust gas of an internal combustion engine or other environments of use. - Optionally, the conditioning system 214 (
FIG. 7 ) can also include apurity control system 320 for controlling the purity of the fluid passing out of theconditioning system output 216. Thepurity control system 320 can selectively determine the purity of the fluid passing to theconditioning system output 216. In one embodiment, thepurity control system 320 can comprise one or more valves for restricting the flow of fluid from theseparation unit 266 and may have one or more sensors for measuring the contents of the fluid flow produced by theseparation unit 266. - In an exemplary but non-limiting embodiment, the
purity control system 320 includes avalve 322 for restricting the flow of fluid from theseparation unit 266, preferably a membrane separation unit. When the inert gas concentration from theseparation unit 266 is below a predetermined amount, thevalve 322 can selectively restrict the flow through theconduit 324 so as to raise the pressure in themembrane separation unit 266. In the illustrated embodiment ofFIGS. 7 and 7A , when thevalve 322 inhibits the flow through theconduit 324 which extends from theconduit 290 to acompressor 330, the pressure within theinert chamber 276 is increased. By raising the pressure in theinert chamber 276, the volumetric flow rate of gas passing through themembrane 270 and into thenon-inert chamber 278 is increased. Thus, because a greater amount of permeate gas passes through the membrane, there is increased concentration of the inert gas discharged from themembrane separation unit 266. Of course, the increased upstream pressure may reduce the volumetric flow rate of the fluid passing out theoutput 216. - When the
separation unit 266 produces an inert gas concentration above a predetermined amount, thevalve 322 can be opened so as to increase the flow rate of fluid through theconduit 324. By opening thevalve 322, the upstream pressure can be reduced in theconditioning system 214 while providing an increased output from theoutput 216. For example, by reducing the pressure in theseparation unit 266 having a membrane, the volumetric flow rate of gas passing from theinert chamber 276 through the membrane 270 (FIG. 7A ) and into thenon-inert chamber 278 may be reduced. Thus, a reduced amount of permeate gas may pass through the membrane. In this manner, the proportion of the inert gas to non-inert gas of the fluid discharged from theseparation unit 266 into theconduit 290 may be reduced. Thus, thevalve 322 can be operated to determine the volumetric flow rate and/or the purity of the fluid outputted from theconditioning system 214. One of ordinary skill in the art can determine the desired purity of the gas flowing from theconditioning system 214 and the desired volumetric flow rate based on the use of the gas. - With reference to
FIG. 7 , thepurity control system 320 can also include aninert gas sensor 334 that is configured to detect flow parameters (e.g., the concentration of inert gases of the fluid, the amount of fluid emanating from theseparation unit 266, and the like). The measurements from theinert gas sensor 334 can be used to adjust the amount of fluid that flows through theconduit 324 by operating thevalve 322. It is contemplated that thepurity control system 320 can be an open or closed loop system. - Optionally, the
conditioning system 214 can also include a compressor 330 (e.g., a booster pump) that can be used to raise the pressure of the gas discharged from theseparation unit 266 to a desired pressure. In some embodiments, thebooster compressor 330 can be configured to raise the pressure of gas to about 1000 psig. In one embodiment, thebooster compressor 330 can increase the pressure of the inert rich gas from about 200 psig to about 4000 psig. For example, thebooster compressor 330 can increase the pressure of the exhaust fluid up to about 2000 psig. Optionally, thebooster compressor 330 can be configured to increase the pressure of the exhaust fluid up to about 5000 psig. However, thebooster compressor 330 can increase the pressure to any suitable pressure depending on the use of the inert rich gas. Inert gas from thebooster compressor 330 can be passed through aconduit 344 and out of theconditioning system output 216 to theupper portion 348 of adrill stem arrangement 18, as illustrated inFIG. 1 . The gas can continue to flow until it reaches thedrill stem assembly 20 as described above. Thus, thecompressor 330 can be selectively configured to raise the pressure of the gas to various pressure levels depending on the desired flow characteristic of the gas passing through thedrill stem arrangement 18. - The
engine 220 can be selected and configured to provide sufficient flow of exhaust fluid for generating the desired amount of inert gas outputted from theconditioning system 214 for any of the uses of inert gas described herein. That is, theengine 220 can be selected to output different levels of purity and different gas flow rates. Additionally, the operating speed of theengine 220 can be controlled to ensure further that the desired amount of exhaust fluid is delivered to theconditioning system 214. Theconditioning system 214 is preferably configured to produce and deliver generally highly pure inert gas which is then, in turn, used by, for example but without limitation, a drilling operation. It is contemplated that various components can be removed from or added to theconditioning system 214 to achieved the desired flow characteristics of the output fluid flow. For example, thecompressor 246 and thebooster compressor 330 can be configured so that theconditioning system output 216 discharges inert fluid at a sufficient pressure and volumetric flow rate for any of the uses disclosed herein. Additionally, thefiltration system 252 and theparticulate filter 260 can be configured to remove any undesirable substance in the exhaust fluid produced by theengine 220. Optionally, one or more components of theconditioning system 214 can be removed or not used during a production cycle. For example, during an operation cycle, thefiltration system 252 and theparticulate filter 260 can be off-line if some substances do not need to be filtered out of the exhaust fluid. In another operation cycle, thefiltration system 252 and theparticulate filter 260 can be online such that the inertgas generating system 210 provides an extremely pure inert gas from theconditioning system output 216. - In an exemplary but non-limiting embodiment, the
conditioning system 214 may have abypass system 350 for controlling the mixture of the fluid flow flowing out of theconditioning system output 216. For example, thebypass system 350 can include abypass system conduit 352 which extends from a location upstream from theunit 266 to a location of theconditioning system 214 downstream from theunit 266. In the illustrated embodiment, thebypass system conduit 352 extends from theparticulate conduit 262 to theconduit 344. However, thebypass system conduit 352 can extend from any point along theconditioning system 214 upstream from theseparation unit 266 to any point of theconditioning system 244 downstream from theseparation unit 266. - In the illustrated embodiment, the flow passing through the
conduit 262 can be separated into a first flow flowing into theseparation unit 266 and a second flow flowing into thebypass system conduit 352. An amount of the first flow can pass through theseparation unit 266 and through theconduits compressor 330, and theconduit 344. Of course, theseparation unit 266 can filter out non-inert portions of the first flow. The concentrated inert gas flow produced by theseparation unit 266 can be combined with the second gas flow passing through theconduit 352 at the junction of theconduits conditioning system 214 is below a predetermined amount, thebypass system 350 can reduce, or stop, the flow of fluid through theconduit 352. By reducing the flow of the fluid through theconduit 352, the purity of gas discharged from theconditioning system output 216 can be increased. - Alternatively, when the concentration of inert gas produced by the
conditioning system 214 is above a predetermined amount, thebypass system 350 can increase the amount of fluid flowing through theconduit 352, which is then combined with the inert fluid flow produced by theseparation unit 266. In this manner, the concentration of inert gas outputted from theconditioning system output 216 can be reduced. Thebypass system 350 can therefore be operated to control selectively and determine the purity of the inert gas produced and delivered out of theconditioning system 214. Optionally, of course, the operating speed of theengine 220 can be varied to control the purity and the amount of gas discharged from the conditioning system. - Optionally, the
bypass system 350 can include avalve 354 that can be used to control selectively the flow rate of the fluid passing through theconduit 352. Those skilled in the art recognize that the valves of theconditioning system 214 may be manually or automatically controlled and may comprise sensors. - Optionally, a further advantage can be achieved wherein one or more of the components of the
conditioning system 214 can be powered by theengine 220. This provides the advantage that the source of the exhaust fluid can also be used to provide power to various components of theconditioning system 214. Preferably,engine 220 can provide sufficient power to operate one or more of the components of theconditioning system 214. Thus, those components may not require any additional power from another power source. - In some embodiments,
engine 220 can produce exhaust fluid and a another secondary output, such electrical power. For example, theengine 220 can be a generation system (e.g., a generator) that generates power in the form of electricity. The electricity can be passed through anelectrical line 348 and can be delivered to a motor of thecompressor 246. The electricity generated from theengine 220 can therefore be used to power thecompressor 246. Theengine 220 advantageously provides exhaust fluid that can be treated by theconditioning system 214 to produce a highly pure inert gas and can be used to power thecompressor 246. It is contemplated that one of ordinary skill in the art can determine the appropriatesized engine 220 to provide the desired power suitable for driving one or more of the components, such ascompressor 246. - Although not illustrated, the
engine 220 can be in communication with other components of theconditioning system 214. For example, theengine 220 can be in communication with thebooster 330. An electric power line can provide electrical communication between theengine 220 and thebooster 330. Additionally, theengine 220 can provide power to thecompressor 246 and thebooster 330 simultaneously, or independently. - Optionally, the
engine 220 can be in communication with one or more of the temperature control systems of theconditioning system 214. For example, theengine 220 can provide power in the form of electricity to a temperature control system that can increase the temperature of the fluid passing through theconditioning system 214. Optionally, thevalves engine 220. Thevalves engine 220. - The
engine 220 can be in communication with one or more of the feedback devices of theconditioning system 214. Although not illustrated, theengine 220 can have a communication line connected, for example but without limitation, to thefeedback device 240 and also theinert gas sensor 334. The feedback devices may selectively control the operating speed of theengine 220. For example, if the exhaust fluid flow reaches a predetermined volumetric flow rate, a feedback device may reduce the engine's operating speed. Additionally, the operating speed of theengine 220 may be selectively controlled to determine the amount of power produced by theengine 220. In one embodiment, the operating speed of theengine 220 can be increased or decreased to increase or decrease, respectively, the amount of electricity produced by theengine 220. - Optionally, a further advantage can be achieved where the
engine 220 can provide mechanical power to one or more components of theconditioning system 214. In an exemplary but non-limiting embodiment, theengine 220 has amechanical output system 351 in the form of anoutput shaft 352 that can be connected to one or more of the components of theconditioning system 214. For example, theoutput shaft 352 in the illustrated embodiment is connected to themixing plenum 228. As theengine 220 operates, theoutput shaft 352 rotates. The rotation of theoutput shaft 352 can be used to agitate the fluid contained in themixing plenum 228. In one embodiment, the rotational movement of theoutput shaft 352 is translated into linear movement of at least one plenum within the mixingplenum 228. The movement of the plenum can agitate fluid comprising the exhaust fluid and the air drawn through theair intake 230. Although not illustrated, a further advantage is achieved where theoutput shaft 352 is connected to thecompressor 246 to as to drive thecompressor 246. In thesystem 210, thecompressor 246 can require substantial power to compress the gases flowing therethrough. Thus, by driving the compressor with a shaft from theengine 220, thecompressor 246 can be driven more efficiently. For example, a direct shaft drive connection between theengine 220 and thecompressor 246 avoids the losses generated by converting shaft power from theengine 220 into electricity, then back to shaft power with an electric motor at thecompressor 246. Further, theentire system 210 can be made lighter and more easily portable. For example, a mechanical connection between theengine 220 and thecompressor 246 can eliminate the need for an electric motor for driving thecompressor 246. - Optionally, a further advantage can be achieved where at least one or more devices of the drilling operation uses inert gas and/or power produced by the
engine 220. For example, various components of the drill stem arrangement 18 (FIG. 1 ) can use inert rich gas produced by theconditioning system 214 and can be operated by power generated by theengine 220. Many devices, such as lights, fans, blowers, venting systems, and/or other electrical devices, can receive power generated by theengine 220. For example, in one non-limiting embodiment, theengine 220 generates power that operates thecompressor 246, thebooster 330, lights proximate to thegeneration system 210, a fan which blows across the inertgas generating system 210, and/or a plurality of lights that illuminate the area surrounding the drilling operation. - The
engine 220 can also provide power to a battery or storage device. For example, theengine 220 can operate and can deliver power in the form of electricity to a battery which, in turn, stores the power. The battery can then deliver power to one or more components of theconditioning system 214 or the drilling operation. - In operation generally, the
engine 220 can be operated to generate exhaust fluid. The exhaust fluid can pass through theexhaust conduit 226 and into the mixingplenum 228. The exhaust fluid can be discharged from the mixingplenum 228 and through theplenum conduit 244 and into thecompressor 246. Thecompressor 246 can increase the pressure of the exhaust gas and deliver the exhaust gas through theconduit 250 to thefiltration unit 251. Thefiltration unit 251 can remove various substances from the exhaust fluid, which is then passed through theseparation unit 266. Theseparation unit 266 can receive fluid having a first concentration of inert gas and output a fluid having a second concentration of inert gas higher than the first concentration. The inert gas can then be passed through theconduits booster compressor 330. Thebooster compressor 330 can increase the pressure of the fluid and discharge the fluid to theconduit 344 which, in turn, delivers the fluid out of theoutput 216. - With reference to
FIG. 7H , a further modification of the separation unit is illustrated therein and is identified generally by thereference numeral 266′ In this arrangement, theseparation unit 266 can include a plurality of separation devices, for example,separation devices - Each of the
separation devices separation unit 266. Thus, while theseparation device 266 may be any one of a membrane, pressure screen adsorption, or a hybrid separation device. Theseparation devices 266 a, 266 b can be the same as theunit 266, or have a different arrangement than theunit 266. - In some embodiments, the
separation unit 266′ can be configured to allow for the selective activation or deactivation of the plurality ofseparation units separation unit 266′. For example, the inlet side of theseparation unit 266 can include anintake manifold 267 connecting each of theseparation units conduit 262. Additionally, theseparation unit 266′ can include adischarge manifold 269 connecting the outlets of theseparation devices - The
separation unit 266′ can include a plurality of inlet and outlet valves configured to allow each of theseparation units discharge manifolds intake valves separation devices intake manifold 267. Similarly,valves separation devices discharge manifold 269. - Thus, by selectively opening or closing the
valves devices devices intake manifold 267 anddischarge manifold 269, independently. - Optionally, the
system 210 can include a CO2 scrubber 340 configured to remove carbon dioxide discharged from thebooster compressor 330 through theconduit 344.Additional valves 382 can be arranged to guide all or some of the gas discharged through theconduit 344 into thecarbon dioxide scrubber 380. The carbondioxide removal device 380 can be any type of such device. - Optionally, the
system 210 can also include abypass inlet line 386 having aninput port 388 configured to allow a gas to be input into thesystem 210 at a point downstream from thecompressor 246. However, theinlet conduit 386 can be connected to any portion of thesystem 210. - In the illustrated embodiment, the
inlet conduit 386 allows a gas, such as compressed air, to be input into thesystem 210 bypassing theflow source 212. For example, theinlet conduit 386 can be connected to theconduit 351 so as to be downstream from theengine 220. Optionally, theinput conduit 386 can be connected to theconduit 244 upstream from thecompressor 246, and thus ambient air can be allowed to flow into theinput conduit 386 and thereafter be compressed by thefeed air compressor 246. However, in yet other embodiments, theinput conduit 386 can be connected downstream of theconditioning system 214, as illustrated inFIG. 7 . - In such arrangements, the
input conduit 386 allows a gas to be introduced into thesystem 210. This can be advantageous if a portion or all of theflow source 212 or a portion or all of theconditioning system 214 are inoperative. - For example, an
alternative source 390 can be connected to theinput port 388 and thus supply fluid to thesystem 210 bypassing theflow source 212 and/or theconditioning system 214. In some embodiments, thesource 390 can be an air compressor configured to discharge compressed air into theinput conduit 386. As such, the remainder of thesystem 210, i.e., the portion of thesystem 210 downstream from theflow source 212 and theconditioning system 214, can operate on compressed atmospheric air, or any other source fluid. This provides an advantage that if theengine 220 is inoperative, and/or if thecompressor 246 is inoperative, pressurized fluid can be introduced into thesystem 210 and be treated by the downstream components. - In yet other embodiments, the
source 390 can be in the form of a flue gas supply. For example, in applications where thesystem 210 is used in the vicinity of a supply of a sufficient flow rate of exhaust gas, or another type of gas with a reduced concentration of oxygen, such gas can be introduced into thesystem 210 through theinlet conduit 386. In some embodiments, thesource 390 can be the exhaust system of the engine driving a ship, or other kind of vehicle. - In embodiments where the
source 390 is the exhaust system of a ship engine, such flue gas is generally at a low pressure, near atmospheric pressure. However, this will depend on the point in the exhaust system at which the flue gas is bled from the exhaust system. Thus, as noted above, thesource 390 can be connected to thesystem 210 up or downstream from thecompressor 246, depending on the desired pressure. In other embodiments, an additional compressor (not shown) can be used to deliver pressurized flue gas from the exhaust system into theinlet conduit 386. - Optionally, the
system 210 can also include areheat bypass arrangement 392. In some embodiments, thereheat bypass 392 can be configured to direct gases from the downstream end of thesystem 210, for example, gases comprised of mainly nitrogen gas, to an additional heating device. - For example, the
reheat bypass 392 can include aninlet end arrangement 393 configured to draw gas from aninlet conduit 394 connected to a point in thedischarge line 324 upstream from thebooster compressor 330, aninlet line 395 connected to a part of thesystem 210 downstream from thebooster compressor 330, or aninlet line 396 connected to an output of the carbondioxide removal device 380. - The downstream end of the
bypass 392 can be connected to aheat transfer device 397 configured to transfer heat from the exhaust gas of theengine 220 to the gas flowing through thebypass 392. For example, theheat exchange device 397 can include aheat input portion 398 and aheat output portion 399. In the illustrated embodiment, theheat input portion 398 is a portion of theheat exchanger device 397 through which the exhaust gas from theengine 220 is directed. The heat from the exhaust gas is thereby transferred to the gas directed through thereheat bypass 392, as it flows through theheat output portion 399. As such, gases discharged from the downstream end of thesystem 210 can be reheated through theheat transfer device 397, such that the gas eventually discharged from thesystem 210 is at a desired temperature and/or humidity for the desired application. -
FIG. 8 illustrates a modified generation system and is identified generally by thereference numeral 210′. The components of thesystem 210′ have been identified with the same reference numerals as those used to identify corresponding components of thesystem 210, except that “′” has been used. Thus, the descriptions of those components are not repeated herein. - In the illustrated embodiment, the
conduit 226′ extends from theengine 220′ to a filtration unit, such as acatalytic converter 400. Thecatalytic converter 400 can remove many of the components of the exhaust fluid passing through theconduit 226′. In an exemplary but non-limiting embodiment, thecatalytic converter 400 can be configured to remove non-inert components of the exhaust fluid, such as carbon monoxide, hydrocarbons, volatile organic compounds, and/or nitrogen oxides (nitrogen oxide or nitrogen dioxide) to increase the purity of the inert gas of the exhaust fluid. - In an exemplary but non-limiting embodiment, the
catalytic converter 400 of theconditioning system 214′ comprises a reduction catalyst and oxidation catalyst that operate to take non-inert components out of the exhaust fluid. It is contemplated that the catalytic converter can be an oxidation or three way type catalytic converter depending on the desired removal of the non-inert components of the exhaust fluid. The construction and operation of such catalytic converter is well known in the art and thus further description of the construction and operation is not repeated herein. - A
catalytic converter conduit 406 extends between thecatalytic converter 400 and afluid separation unit 408. Preferably, thefluid separation unit 408 includes a high temperature membrane configured to remove the water from the exhaust fluid passing therethrough. - For example, the
engine 220′ can output exhaust fluid comprising various gases and a liquid, such as water. Thefluid separation unit 408 can remove the water from the exhaust fluid as the fluid passes through theunit 408. In one embodiment, thefluid separation unit 408 has a membrane (not shown) that is configured to allow gases to pass therethrough without permitting the passage of water. In other words, the gas component of the exhaust fluid can flow into and out of thefluid separation unit 408 and into theconduit 412. The membrane of thefluid separation unit 408 can remove water from the exhaust fluid and deliver it to a water knock out vessel in theunit 408. The water knock out vessel can be periodically removed from theunit 408 and emptied. Additionally, a coalescing filter (not shown) can be provided to remove oil carryover that may be present in the exhaust fluid. - Optionally, the
fluid separation unit 408 can have a heat exchanger to increase the temperature of the fluid delivered by theconduit 406. The heat exchanger can increase the temperature of the liquid component of the exhaust fluid for easy removal of the liquid. - The
conditioning system 214′ can also include atemperature control system 416 that is connected to thefluid separation conduit 412. Thetemperature control system 416 can be configured to increase or reduce the temperature of the exhaust fluid fed from thefluid separation conduit 412. Because thefluid separation unit 408 may have features, such as a heat exchanger, to raise the temperature of the exhaust fluid, thetemperature control system 416 can be configured to reduce the temperature of the exhaust fluid to desirable temperatures for feeding the exhaust through the temperaturecontrol system conduit 420 and into thecompressor 246′. - The
conditioning system 214′ can have acompressor 246′ which raises the pressure of the exhaust fluid. Thecompressor 246′ then delivers the fluid to acompressor conduit 250′, which, in turn, feeds the exhaust fluid to afiltration unit 424. Thatfiltration unit 424 can be configured to capture and remove undesired substances that may be present in the exhaust fluid. Thefiltration unit 424 can be can similar or different than thefiltration unit 251. - The exhaust fluid from the
filtration system 424 can pass through theconduit 262′ and into theseparation unit 266′. Theseparation unit 266′ can be similar or different that the units illustrated inFIGS. 7A , 7B, 7C, 7D, 7E, 7F, 7G, and 7H. Theseparation unit 266′ can receive exhaust fluid and can remove at least a portion of the non-inert component of the exhaust fluid and pass inert rich gas into theconduit 324′. The inert fluid can then be fed into thebooster pump 330′. Thebooster pump 330′ can increase or decrease the pressure of the fluid and can pass the fluid into theconduit 344′ and out of theconduit system output 216′. - The
engine 220′, of course, can generate and provide power to one or more components of theconditioning system 214′. For example, theengine 220′ can be in electrical communication with at least one of thecompressors 246′, 330′. Theengine 220′ can therefore power one or more of the compressors which can provide a pressure increase in theconditioning system 214. Optionally, theengine 220′ can provide power to any other type of power consumption device. - Optionally, a further advantage can be achieved where the inert
gas generation systems systems gas generation system - The
generation systems generation systems - With reference to
FIGS. 9A and 9B , any of the embodiments disclosed above with reference to either of thegeneration systems mobile separation system 200 illustrated inFIG. 6A . -
FIGS. 9A-37 illustrate exemplary but non-limiting embodiments ofmobile separation units 200A (FIGS. 9A and 9B ) and 200B (FIG. 32 ). In each of theseembodiments separation systems mobile separation units separation systems - Additionally,
FIGS. 9A-36 include dimensions, sizes, material thicknesses, model numbers, voltages, etc. However, these values are merely disclosed for purposes of providing exemplary embodiments of at least some of the inventions disclosed herein. These values do not limit the inventions disclosed herein. - With reference to
FIGS. 9A-30 , components of themobile separation unit 200A that are the same or similar components as themobile separation unit 200 have been identified with the same reference numerals, except that that a “A” has been added thereto. Additionally, because theseparation system 210A of themobile separation unit 200A can be any of the above-described embodiments of theseparation systems separation system 210A are not repeated below. - Additionally, it is to be noted that
FIGS. 9A-37 include reference numerals set off by parenthesis. The reference numerals contained within the parenthesis in these figures do not correspond to the reference numerals used in the text of this specification. Rather, the text of this specification uses reference numerals that are not set off in parenthesis in the figures. - The
mobile separation unit 200A can include acontrol cab 205 and asuspension device 208A. Thecontrol cab 205 can include a plurality of control panels and devices for controlling the various parts of theseparation system 210A. Additionally, thecontrol cab 205 can include all of its own dedicated control panels in aNEMA 4 enclosure. Compressor controls can indicate critical oil temperatures and pressures, as well as exhaust gas pressures and temperatures. The membrane control system can also provide instantaneous and cumulative nitrogen flow information, as well as nitrogen purity pressure, pure pressures, and temperatures. -
FIGS. 33-37 include various schematic diagrams of control panels in units that can be disposed within thecontrol cab 205 for remotely controlling the various corresponding devices within theseparation system 210A. - For example, as is illustrated in many of the following schematic diagrams, the components of the
separation system 210A can be controlled with electronics, including electronically controlled pneumatic actuators. Thus, with reference to these schematic diagrams, one of ordinary skill in the art can determine how to connect the various components of theseparation systems 210A with control devices disposed within the control cab 206A. - The
suspension device 208A can be in the form of a trailer, such as those commonly designed to be pulled by a towing vehicle referred to as a “tractor,” for on-highway transportation. The design, suspension, wheels, etc. of thesuspension unit 208A can be determined based on the total weight of theunit 200A. In the illustrated embodiment, thesuspension device 208A includes three axels at its rear end, and is configured to be towed as a “fifth wheel trailer.” However, other configurations can also be used. - As noted above, the
separation system 210A can be in the form of any of the above-identified embodiments and modifications of theseparation system separation system 210A is merely an exemplary but non-limiting embodiment of the features, devices, and methods of operation of theseparation systems - As shown in
FIGS. 9A , 9B, themobile separation unit 200A includes aflow source 212A, aconditioning system 214A, and anoutput 216A. In the illustrated embodiment, theflow source 212A is in the form of afeed air compressor 246A configured to draw in atmospheric air, compress the air, and deliver it to theconditioning system 214A. Theconditioning system 214A can include afiltration unit 251A and aseparation unit 266A. - The gases leaving the
conditioning system 214A are guided to theoutput 216A. In some embodiments, theoutput 216A is a booster compressor configured to raise the pressure of the gases discharged from theconditioning system 214A. - With reference to
FIG. 10 , thefeed air compressor 246A can include anengine 220A, acompressor 246A, and anoutlet conduit 250A. During operation, theengine 220A can drive thecompressor 246A, and thereby pressurize atmospheric air and discharge it through theoutput 250A. - However, the
feed air compressor 246A can include many other devices and features that are optional. Many of these optional features are illustrated inFIG. 10 . Set forth below is a description of some of the optional features. The features that are illustrated inFIG. 10 but not described below can be readily implemented by those of ordinary skill in the art. - With continued reference to
FIG. 10 , thefeed air compressor 246A can include anintake filter unit 500, anoil separator 502, apressure loading device 504, an after cooler 506, and a water separator 508, as well as other features. - For example, but without limitation, the
feed air compressor 246A can also include engine coolant input andoutput ports feed air compressor 246A can include compressor oil input andoutput ports compressor 246A to be circulated through a heater, described in greater detail below. - During operation, the separation process can be commenced by starting the
flow source 212A. For example, theengine 220A can be started. After a delay, for example, to allow theengine 220A to warm up, thefeed air compressor 246A can be started. For example, aclutch mechanism 518 can be selectively engaged to allow theengine 220A to selectively drive thefeed air compressor 246A. - After the
feed air compressor 246A begins to turn, ambient air begins to enter the system through the inlet andfilter device 500. As such, pressure begins to build in theoil separator 502. - While the
engine 220A is idling or operating at a low engine speed, thesystem 210A can be unloaded. For example, thepressure loading device 504 can be “open” so as to allow pressurized air from thefeed air compressor 246A to be vented. However, other techniques can also be used to allow the system to remain unloaded while theengine 220A is idling or operating at low engine speed. - In some embodiments, the
flow source 212A is substantially unloaded so that the maximum pressure reached in theflow source 212A is only about 40-60 psig. However, theseparation flow source 212A can be designed to reach other maximum pressures when theengine 220A is idling or running at low speeds, depending on the application. When theengine 220A is idling or operating at low speed, very little or substantially no air is flowing through theflow source 212A or theconditioning system 214A. - As the
flow source 212A is loaded, theengine 220A can be adjusted to run at a target operating speed (e.g., 1800 to 2100 rpm), and thepressure loading device 504 can be controlled to load thecompressor 246A to increase the pressure up to a target pressure. As noted above, thepressure loading device 504 is configured to operate from a remote location. For example, thepressure loading device 504 can include electrically controlled pneumatic actuators for operating the various valves and devices within thepressure loading device 504. - When the
flow source 212A is loaded, theengine 220A can operate at normal operating speeds. In some embodiments, the pressure can be increased to about 350 psig (2.4 MPa). At this point, thecompressor 246A can deliver air to the aftercooler device 506 where the air can be cooled. - For example, but without limitation, the after
cooler device 506 can be configured to bring the temperature of the compressed air down to within about 15° F. of the ambient temperature. After the aftercooler device 506, the compressed air can be guided to the water separator device 508 and then out of theoutput 250A to theconditioning system 214A. - In some embodiments, the
engine 220A can be a high performance diesel engine. For example, but without limitation, theengine 220A can be a Caterpillar C-16 ATAAC high performance engine rated at about 630 bhp at 1800 rpm or equivalent. The engine can be cooled by a radiator that incorporates an air charge cooler and a fuel cooler. The fan for the heat exchanger can be driven off of the front of the engine via a pulley arrangement. Theengine 220A can also be equipped with electronic engine controls to ensure low emissions and improved fuel economy. Any number of various types of engines can also be employed. - In some embodiments, the
feed air compressor 246A can be a Sullair two-stage oil flooded rotary screw compressor or another type of a compressor, configured to couple, directly or indirectly, for example, through theclutch mechanism 518, to theengine 220A. Theair filter 500 can be a heavy duty air filter configured to remove larger particles from the incoming air. Thecompressor 246A can be fitted with an unloadingvalve 519 on its inlet end. - The unloading
valve 519 can be part of thepressure loading device 504, and can be configured to modulate the inlet flow into thecompressor 246A to control the capacity of the compressor, and as may be desired or required by system operating conditions. The air from thecompressor 246A can flow directly to theoil separator 502 where oil can be removed from the air stream down to about 2-3 parts per million. The air and oil can then each be directed to their own section of an air cooled heat exchanger assembly (not shown) which can be combined with the radiator of theengine 220A. However, other configurations can also be used. By cooling the compressed air, water vapor in the compressed air is condensed and becomes liquid which can be removed by the water separator 508. - With continued reference to
FIG. 10 , although the after cooler 506 is illustrated as a single device, the after cooler 506 can be in the form of a plurality of heat exchangers. For example, the after cooler 506 can be in the form of a main heat exchanger and a second heat exchanger. The main heat exchanger can contain one or more of the following: the radiator of theengine 220A, an engine air charge cooler, an engine diesel fuel cooler, a compressor oil cooler, and a compressed air after cooler. - In some embodiments, the main heat exchanger can be located on the front of the
engine 220A, although the main heat exchanger can be positioned at other suitable locations. The second heat exchanger can be a compressed air reheater and can use hot compressor oil to heat the cooled and dried feed air up to a desired operating temperature, for example, for more ideal operation of the membrane separation process. The reheater can be located next to the compressor oil separator or on the membrane tower. - The water separator device 508 can be any known type of water separator device. In some embodiments, the water separator device 508 is a centrifugal-type water separator device disposed on the discharge side of the after
cooler device 506. Such a centrifugal water separator device can remove the bulk of liquid water from the compressed air. As noted above, the pressurized air is discharged from theflow source 212A from theoutlet 250A. - With reference to
FIG. 11 , thefiltration unit 251A can receive the compressed air from theflow source 212A at itsinlet 520. Thefiltration unit 251A can include a plurality of filtering devices. In the illustrated embodiment, thefiltration unit 251A includes four coalescingfilters - The coalescing filters 522, 524, 526 can each include an
auto drain system 530 configured to drain liquids out of thefilters common drain discharge 532. Although not illustrated, the coalescingfilter 528 can also include an auto drain system. - Additionally, in the illustrated embodiment, the
filtration unit 251A includes acarbon tower unit 534. However, other configurations can also be used. - Filtered air is discharged from the
filtration unit 251A through itsdischarge 534. Optionally, thefiltration unit 251A can include a feedair heater system 540. The feedair heater system 540 can include any type of heating device configured to heat the air traveling through thefiltration unit 251A. - In the illustrated embodiment, the feed
air heater device 540 includes a heat transfer device 542 (FIGS. 11 and 20 ) disposed between the initial three coalescingfilters carbon tower 534. However, other configurations can also be used. In the illustrated embodiment, theheat transfer device 542 is supported on amembrane tower 620, described in greater detail below. - The feed
air heater assembly 540 can also include a plurality ofvalves 544 configured to allow air from the upstream side of theheating device 540 to be passed through theheat transfer device 542 or to bypass theheat transfer device 542. By operating thevalves 544 in an appropriate manner, the temperature of the air discharged from theheater 540 can be controlled even where theheat transfer device 542 is operated continuously or non-continuously or with uniform or changing internal temperatures. - The coalescing filters 522, 524, 526 can have the same or different designs. For example, the
filter 522 can be configured to remove condensate. For example, but without limitation, thefilter device 522 can be a device configured to form a water separator and a moisture separator filter configured to remove at least about 99% of condensate along with larger particulates. The removed condensate can be collected in the collector within thefilter unit 522. For example, thefilter unit 522 can include a condensate drain bowl or other suitable device. When the drain bowl is full, the drain bowl automatically opens, with the operation of theauto drain devices 530, and thus dumps the condensate into thedrain 532. - The partially dry air can then enter coalescing
filters filters filters auto drain devices 530 for dumping condensates to thedrain 532. - As noted above, the feed
air heater device 540 can be used to control the temperature of the air flowing through thefiltration unit 251A. For example, the dried compressed air from thefilters carbon tower 534. - In some embodiments, the heat added to the compressed air flowing through the
heating device 540 can be transferred to theheat transfer device 542 from the compressor oil of thecompressor 246A (FIG. 10 ). As shown inFIG. 11 , the feedair heating device 540 can include fluid input andoutput ports ports FIG. 10 ) to enter the input port 550 (FIG. 11 ). - As such, the hot compressor oil can travel through the
heat transfer device 542 and thereby impart heat into the compressed air flowing through thefeed air heater 540. After passing through theheat transfer device 542, the compressor oil can return to thecompressor 246 by being discharged through theoutput port 552 and reintroduced through the input port 514 (FIG. 10 ). This design provides additional efficiency in that the heat contained within the circulating compressor oil from thecompressor 246A would normally be discharged as waste heat. Thus, this waste heat can be utilized for improving the performance of thefiltration unit 251A without the need for additional energy input. However, other designs can also be used. - The
valves 544, as noted above, can be used to adjust the temperature of the compressed air ultimately discharged from the feedair heater device 540. For example, the air flowing through the feedair heater device 540 can be modulated to either flow through theheat transfer device 542 or to by-pass theheat transfer device 542. Thevalves 544, as noted above, can be electronically actuated pneumatic valves. Thus, a control device (not shown) can be configured to utilize the output fromtemperature sensors valves 544 and to thereby adjust the temperature of the compressed air ultimately discharged from the feedair heater device 540. - More specifically, the heating process performed by the feed
air heater device 540 can be controlled by thevalves 544 that are controlled to open and close based on the measurement of the temperatures by thetemperature sensors temperature sensors valves 544. In some non-limiting embodiments, the temperature of the compressed air discharged from the feedair heat device 540 can be set at approximately 120-130° F. (49° C.-54° C.). The reheating of the air as such keeps the air temperature substantially above the dew point temperature of the air. As such, little or no condensate forms as the air travels through the carbon absorber of thecarbon tower 534, and thus proceeds to the membrane separator. Any suitable type of heat exchangers can be used to control the temperature of the air. Exemplary heaters include, but are not limited to, resistance heater, double pipe heat exchangers, and the like. - As noted above, the reheated air enters the
carbon tower 534. Thecarbon tower 534 can be configured to remove substances to increase the operating life of downstream equipment. In some embodiments, the carbon tower can be configured to remove hydrocarbon vapors from the compressed air. In some embodiments, the compressed air or gases exit thecarbon tower 534 with less than 5 parts per billion (ppb) of hydrocarbon vapors (excluding methane). This low concentration of hydrocarbon vapor can maximize nitrogen membrane operating life. Other types of filters can also be used to remove undesirable substances from the compressed air or other gases. - With reference to
FIGS. 12-14 , thefilters integral filter unit 560. This provides a unique and compact arrangement. In some embodiments, because thefilters FIGS. 12-14 . - The filter stand 560 includes a
base portion 562 configured to support theassembly 560 on an upper surface of thesuspension device 208A (FIGS. 9A , 9B). Theassembly 560 can also include at least oneupright member 564 to which thefilters FIGS. 12-14 , theassembly 560 includes a plurality ofcross members filters - This space saving arrangement can be accomplished even though, in the direction of air flow through the perspective filters, the
carbon tower 534 is disposed between thefilter filter 526 to thefeed air heater 540 and thecarbon tower 534 and additional plumbing to connect the output side of thecarbon tower 534 to the input side of thefilter 528, the structural similarities of thefilter devices -
FIGS. 15-18 illustrate an exemplary embodiment of thecarbon tower 534. As shown inFIGS. 15-18 , thecarbon tower 534 is included within acarbon tower assembly 570. Thecarbon tower assembly 570 can include abase 572 and a plurality ofupright support members 574 configured to support thecarbon tower 534 in a generally upright configuration. - In this configuration, the
carbon tower 534 includes aninlet 576 at its upper end and anoutlet 578 at its lower end. Theinlet 576 is connected to the feedair heater device 540 and theoutlet 578 is connected to the inlet side of the filter 528 (FIG. 12 ). - With reference to
FIG. 9A , the arrangement of thefilter unit 560 and thecarbon tower unit 570 provides a compact arrangement enhancing the overall space efficiency of thesystem 210A, and thus allowing the overall size of thesuspension unit 208A to be made as small as possible. - With reference to
FIG. 19 , theseparation unit 266A can be configured and constructed in accordance with any of the above-describedseparation devices separation unit 266A that correspond to the above-describedseparation units - The
separation unit 266A can include aninlet 262A and anoutlet 290A. In the illustrated embodiment, theseparation unit 266A includes an array ofmembrane separation devices 266 a, 266 b, etc. arranged in parallel with each other, such as the arrangement partially illustrated inFIG. 7H . - During operation, the filter gases discharged from the output 534 (
FIG. 11 ) of thefiltration unit 251A are guided to theinlet 262A of theseparation device 266A. The illustratedseparation unit 266A includes a pair of bundles, each comprising a plurality of membrane units (266 a, 266 b), which in the illustrated embodiment, are membrane separation units. Each of themembrane separation units 266 a, 266 b can be configured to separate one or more components of the gas input into theinput port 262A. - The
membrane separation units 266 a, 266 b can allow certain substances to permeate therethrough. In some embodiments, the separation units comprise membranes in the form of a bundle of hollow fibers configured to separate the air flow, as described above. For example, the separation membranes can allow oxygen, water vapor, and carbon dioxide to permeate the walls of the hollow fibers, leaving a high pressure concentration of nitrogen on the inside of the hollow fibers. - During normal operation, in some exemplary but non-limiting embodiments, the pressure in the
membrane separation units 266 a, 266 b can be maintained at about 330-350 psig (2.3-2.4 MPa) through the use of a flowcontrol valve device 322A. The nitrogen can be collected in a manifold, identified generally by thereference numeral 600, and can be directed through theflow control valve 322A. - In some embodiments, a
product isolation valve 602 can be used to vent the flow of some of the nitrogen overboard during that portion of the production cycle. In some embodiments, theproduct isolation valve 602 can be opened to vent the flow of nitrogen out of the system during warm-up until the nitrogen purity reaches the minimum desired level. Once the flow of nitrogen reaches the target purity, theproduct isolation valve 602 can be closed. Exemplary membrane separation units can be used to separate any desired gas (e.g., inert gases) from a feed gas. As such, an output gas of a particular desired purity can be produced. - With reference to
FIGS. 20-23 , theseparation unit 266A can be assembled into a singleintegral membrane tower 620. As shown inFIGS. 20-23 , themembrane tower 620 can include an arrangement ofmembrane separation units 266 a, 266 b in two vertical stacks, although other numbers of stacks can also be used. This provides a high level of space efficiency due to the vertical stacking arrangement, and thus further enhances the ability of theseparation system 210A to be disposed on asuspension unit 208A for transportability. - In the illustrated embodiment, the
membrane tower 620 includes abase 622 and at least one vertical support configured to support the weight of the individualmembrane separation units 266 a, 266 b. In the illustrated embodiment, thetower 620 includes fourvertical members membrane separation devices 266 a, 266 b. However, other numbers of vertical supports and/or configurations can be used. - With reference to
FIG. 20 , each of the individualmembrane separation devices 266 a, 266 b are suspended from thevertical supports cross member devices 632. However, other configurations can also be used. - The
membrane tower 620 can include a plurality of intake anddischarge manifolds membrane separation devices 266 a, 266 b. As shown inFIG. 22 , all of theintake manifolds 640 are disposed at one end of thetower 620 and all of the discharge manifolds 642 are disposed at the opposite end. However, other configurations can also be used. - In some embodiments, the
intake manifold 640 is connected to theinlet 262A, and thus receives filtered air from thefilter unit 251A. Thedischarge manifold 642 can be connected to theoutlet 290A, and thus is used for discharging nitrogen from theseparation unit 266A. - A further advantage is achieved where the structural components of the
tower 620 are used both for providing structural support for thetower 620 as well as for fluid handling. In the illustrated embodiment, thevertical support permeate discharge manifolds membrane separation devices 266 a, 266 b so as to allow the permeate gases to flow into thepermeate manifolds vertical supports - The permeate entering the
vertical supports manifolds - Optionally, the
separation device 266A can include aflow meter 654. Additionally, as noted above, themembrane tower 620 supports theheat transfer device 542. As illustrated inFIGS. 21 and 23 , theheat transfer device 542 is supported by thevertical members heat transfer device 542 is similar in shape to themembrane devices 266 a, 266 b, etc., and thus can be supported by thetower 620 in a compact and space-saving configuration. For example, but without limitation, theheat transfer device 542 is nested with theother membrane devices 266 a, 266 b, etc. In other words, there is a vertical stack ofmembrane devices 266 a, 266 b, stacked above theheat transfer device 542 with both themembrane devices 266 a, 266 b, and theheat transfer device 542 supported by the same members, in this case, thevertical members additional membrane devices 266 a, 266 b. As such, the heat transfer device is compactly positioned between themembrane tower 620 and the filter stand 560 without the need for an additional separate mounting arrangement for supporting theheat transfer device 542 relative to the trailer. - Both the
filter unit 251A and theseparation unit 266A, including the above-described space efficient tower designs, as noted above, provide a particularly compact design that is helpful in arranging the components of theseparation system 210A into a configuration that will fit on an on-highway device, such as thesuspension device 208A. For example, with the arrangement of themobile separation system 200A described herein, all the components can be supported on a single 53 ft. long trailer or on a self-propelled unitary frame truck of about 41 ft. long. However, other size trailers and trucks can also be used. - As noted above, the
output 216A of thesystem 200A can include abooster compressor 330A. Thebooster compressor 330A can be configured to raise the pressure of the nitrogen gas discharged from theseparation device 266A to a desired pressure. - The
booster compressor 330A can include anengine 700 and acompressor device 702. Optionally, thebooster compressor 330A can include aclutch mechanism 704 for selectively engaging theengine 700 with thecompressor device 702. - The
booster compressor 330A can also include aninlet 706 connected to the outlet of themembrane separation unit 266A. - During operation, nitrogen gas flowing into the
inlet 706 can initially be received in anitrogen receiver device 708. The nitrogen can then enter a firststage booster compressor 710 of thecompressor device 702. Optionally, thecompressor device 702 can include second andthird stages - In some non-limiting exemplary embodiments, the pressure of the nitrogen can be increased up to about 600 psig (4.1 MPa) in the
first stage 710. The pressurized nitrogen can be discharged out of thecompressor device 702 and into a first stage of a highpressure heat exchanger 716. The highpressure heat exchanger 716 can be configured to cool the nitrogen compressed by thefirst stage 710. Optionally, the firststage heat exchanger 716 can have an output connected to an oil separator 718 configured to separate any compressor oil in the compressed nitrogen. - After leaving the oil separator device 718, the compressed nitrogen can be introduced into this
second stage compressor 712. After being compressed by thesecond stage compressor 712, the nitrogen can be further compressed by thethird stage compressor 714. After passing through each of the second andthird stage boosters - For example, pressurized nitrogen discharged from the
second stage 712 can be directed to a second stage high pressure heat exchanger configured to cool the pressurized gas and a second stageoil separation device 722 configured to separate oil out of the compressed nitrogen. Similarly, pressurized nitrogen discharged from thethird stage booster 714 can be directed through a thirdstage heat exchanger 724 and, optionally, an additional oil separator (not shown). - The flow of pressurized nitrogen can be controlled by a combination of inlet pressure variations to the
booster 702, e.g., by modulating the flow control valve 654 (FIG. 19 ) and/or by changing the speed at which thebooster compressor 702 is operated. For example, the speed of the crankshaft or theengine 700 can be changed by adjusting a “throttle” position of theengine 700. Changing the speed of theengine 700 also thus changes the speed of thecompressor 702. - Optionally, the flow of nitrogen can also be controlled by passing nitrogen from the final discharge 730 back to the
first stage 710 of thecompressor 702. For example, abypass line 732, which is connected to the discharge side of thethird stage compressor 714, can also be connected back to an inlet side of thefirst stage compressor 710. In some embodiments, as illustrated inFIG. 24 , thebypass line 732 is connected to thenitrogen receiver tank 708. From there, this highly pressurized nitrogen can then be again fed into thefirst stage compressor 710. - Optionally, a high
pressure control valve 734 can be used to control the flow of nitrogen through thebypass line 732. Nitrogen that is not bypassed through thebypass line 732 can be directed to the final discharge 730. Optionally, the final discharge 730 can also include acheck valve 740 and aplug valve 742 with an integral discharge port. However, other configurations can also be used. - In some embodiments, the
booster compressor 330A can be a hurricane model 6T-276-43B-4000 compressor, or an equivalent. Such a nitrogen booster can deliver high pressure nitrogen to about 5,000 psig (35 MPa). The booster can be a single stage or have a plurality of stages of compressors. - In the illustrated embodiment, the
booster compressor 330A includes threestages - The booster can be constructed with a water cooled reciprocating compressor engine having a suction pressure of about 320-350 psig (2.2-2.4 MPa). As noted above, the intercoolers can be provided between one or more of the stages to dissipate the heat of compression. Additionally, an air cooled aftercooler can also be provided to reduce the temperature to within about 20° F. (11.1° C.) of ambient temperatures.
- The
engine 700 of thebooster compressor 330A can be a diesel engine, or any other type of engine. Theengine 700 can be coupled directly or indirectly (perpendicular) to thebooster 702. Additionally, as noted above, aclutch mechanism 704 can optionally be used to selectively connect and disconnect theengine 700 from thebooster 702. - The
engine 700 can be, in an exemplary but non-limiting embodiment, a Caterpillar C9 diesel engine rated at 350 bhp at 1,800 rpm or an equivalent engine. Such an engine can have a 6-cylinder configuration with a total engine displacement of 732 cubic inches. If the booster is driven indirectly with a high tower and PTO drive (perpendicular) by a diesel engine from a self-propelled carrier or a tractor diesel engine that pulls the trailer mounted equipment, the engine can be rated at 500 bhp or greater. - With reference to
FIG. 25 , themobile separation system 200A can include asupplemental heater system 800. For example, where thesystem 200A will be operated in arctic-like conditions, thesupplemental heater system 800 can be configured to assist in start-up and operation of thesystem 200A. - In some embodiments, with continued reference to
FIG. 25 , thesupplemental heater system 800 can be configured to circulate engine coolant from theengines heating devices FIG. 10 , theengine 220A can include engine coolant input andoutput ports heater 802 via input andoutput ports - Similarly, the
engine 700 can include coolant input andoutput ports 750, 752 (FIG. 24 ) can be connected to coolant input andoutput ports 812, 814 (FIG. 25 ). As such, engine coolant from theengine 700 can be circulated through theheater device 804. As such, engine coolant from theengine 220A can be circulated through theheater 802. - The
heaters heaters heaters system 200A as well. For example, in some embodiments, thesupplemental heater system 800 can also be used to heat the batteries and fuel of each of theengines - In some embodiments, the
supplemental heater system 800 is formed in essentially two independent systems, one system heating the feed air compressor engine, batteries, control cabin heater, and the intake fuel line. The other independent system can be used to warm the engine of the booster compressor, the booster block itself, batteries, fuel tank, and intake fuel lines. - For example, with continued reference to FIGS. 25 and 28-30, the
heater 802 can be powered by the batteries of the feedair compressor device 212A, and can be configured to burn diesel fuel from the commondiesel fuel tank 820. Theheater 802 can include a pump (not shown) configured to pull engine coolant from theengine 220A and through the heater manifold device 822. The heater manifold device can be used to circulate heated engine coolant intoheat exchanger devices feed air compressor 212A. Similarly, the heat from theheater 802 can be used to provide heat to aheat exchanger device 828 configured to transfer heat to portions of the control cab. Similarly, heat from theheater 802 can be directed to aheat exchanger device 830 for heating fuel for theengine 220A. Theheater 804 can include similar plumbing for heating other devices. - As noted above, the complete
mobile separation system 200A can be operated from a central location, for example, thecontrol cabin 205. However, in other embodiments, such controls can be mounted within the sleeper portion section of a self-propelled carrier or another remote control box. - The control system can be configured to use a combination of PLC (Programmable Logic Controller) equipment (
FIGS. 35-37 ) and a touch screen arrangement (FIG. 33 ) for allowing an operator to operate and monitor thesystem 200A. The central operating location allows for functions, such as starting engines, controlling nitrogen purity, pressure, and flow rate. The central operation system also provides continuous feedback of the operating status of theseparation system 200A via the touch screen display. -
FIG. 26 illustrates an electrical schematic of the feed air module.FIG. 27 illustrates an electrical schematic of thebooster compressor module 330A. These two figures, 26, 27, show the electrical systems for operating engine driven components from one central location. -
FIG. 34 illustrates a power distribution system which can be provided at the central location to power the PLC monitoring system and other ancillary equipment, such as a cabin heater, fan, and lights. - As noted above,
FIG. 33 illustrates atouch screen device 840 and an Electronic Control Unit (ECU) 841. TheECU 841 can be in the form of any type of device that can accept input from sensors and provide output to actuators. For example, but without limitation, theECU 841 can be in the form of a hard-wired control circuit. Alternatively, theECU 841 can be constructed of a dedicated processor and a memory for storing a computer program configured to perform the functions of theECU 841 described herein. Additionally, theECU 841 can be constructed of a general purpose computer having a general purpose processor and the memory for storing the computer program for performing the functions of theECU 841 described above. - In the illustrated but non-limiting embodiment, the
ECU 841 is in the form of a programmable logic controller which has a plurality of Programmable Logic Controller (PLC)slots separation system operation 200A. ThePLC slot 804 can be used to connect the PLC system to a recording device (e.g., lap top computer) so that the separation system operations can be recorded for future use or comparison. -
FIG. 35 illustrates connections with the PLC slot identified as “Slot 0” which can be used to providedigital display devices Slot 5” (FIG. 33 ). -
FIGS. 36 and 37 illustrate optional uses for the PLC slots identified as “Slot 1”-“Slot 4,” and “Slot 6.” These connections illustrate how different operating data, such as feed air module pressure and temperature, filter and membrane module, pressures and temperatures, operate the automatic filter dump valves, nitrogen purity, nitrogen flow rate, and booster modules pressures and temperatures. However, other arrangements can also be used for displaying operating data of theseparation system 200A in case thetouch screen 840 is not operating correctly. This is a back-up monitoring system that can display all the data that the touch screen provides by selecting the parameter from the display selector shown inFIG. 36 . - With continued reference to
FIG. 32 , a modification of themobile separation system 200A is illustrated therein and identified generally by thereference numeral 200B. The components of themobile separation system 200B can be the same as those identified above with reference to theseparation system 200A, except as expressly indicated below. Thus, components of thesystem 200B corresponding to thesystem 200A that are similar or the same are identified with the same reference numeral, except that a “A” has been changed to a “B.” - As with the
system 200A, themobile separation system 200B can include a feed air compressor or aflow source 212B, aconditioning system 214B, and anoutput device 216B. - In this embodiment, the
output device 216B, which is in the form of abooster compressor 330B, is essentially the same as thebooster compressor 330A, except that thebooster compressor 330B does not include an engine that can provide the sole means for powering thebooster compressor unit 702B. Rather, thesystem 200B includes a PTO device configured to convert shaft power from anengine 900 disposed with thepropulsion device 206B to drive thecompressor unit 702B. - The
engine 900 can be any type of engine. In this embodiment, theengine 900 is configured to generate shaft power for driving one or a plurality of thefront wheels 902 and/or therear wheels 904 of thesystem 200B. ThePTO device 906 can be any type of known PTO device. - In the illustrated embodiment, the
PTO device 906 is configured to receive shaft power from, for example, afirst drive shaft 910 driven by theengine 900, and use that shaft power to drive a second vertical drive shaft (not shown) which is connected to thecompressor unit 702B. Additionally, athird drive shaft 912 can extend rearwardly from thePTO device 906 to the axle of one or more of therear wheels 904. - The
propulsion device 206B can include an internal control for changing the mode of operation of thePTO device 906. For example, the input device (not shown) can allow an operator of thepropulsion device 206B to change the operation of thePTO device 906 between two modes of operation, including, for example, but without limitation, a mode in which shaft power from theshaft 910 is directed only to thecompressor unit 702, and a second mode in which shaft power from theshaft 910 is only directed to thedrive shaft 912 for powering one or more of therear wheels 904. Such a type of input control and PTO device are well known in the art, and thus are not described in further detail. - Such an arrangement provides a substantial advantage in that the cost of an additional engine, such as an engine 700 (
FIG. 24 ), can be avoided. Rather, thebooster compressor 330B can utilize the shaft power from theengine 900, which, when thebooster compressor 330B is not being used, can be used to move thesystem 200B. This provides a significant savings in weight and in the cost of engines. In some embodiments, the PTO device can be configured to drive the feed air compressor 246B. - Further advantages can be achieved where exhaust from the
engine 900 is fed to the inlet of thefeed air compressor 212B. For example, as shown inFIG. 32 , theengine 900 can include anexhaust discharge 920 configured to guide exhaust gases from the combustion chambers within theengine 900 toward the atmosphere. Of course, as is widely known in the art, theengine 900 can also include pollution controls which reduce or eliminate certain contaminants that can be found in exhaust gases from internal combustion engines, such as diesel engines. - As explained above with reference to the
separation systems exhaust discharge 920, can be fed to theinlet 500B of thefeed air compressor 212B. As such, thesystem 200B can operate to separate nitrogen out of the exhaust gas discharge from theengine 900. This provides further advantages, as noted above, in that there is significantly less oxygen in the exhaust gas from an internal combustion engine than there is in ambient air. Thus, for some applications, theentire system 200B can be run at lower power settings because there is overall less oxygen to separate out of the gases being fed to theconditioning system 214B. - Additionally, with such a configuration, all of the equipment that can be disposed in the
control cab 205 can be contained in the cab of thepropulsion unit 206B. - As such, because the cabs of trucks are normally provided with sufficient light, heaters, and weather protection, it is not necessary to provide a separate control cab such as the control cab 205 (
FIGS. 9A , 9B). Thus, with all the control panels disposed within the cab of thepropulsion unit 206B, further savings are achieved. - Optionally, the
propulsion unit 206B can be provided with a “sleeper cab,” which can therefore provide more room for control panels and for the operator to operate such control panels, as well as room for a passenger in thepropulsion unit 206B. - With reference to
FIG. 38 , theECU 841, along with the various sensors, actuators, displays, and control devices noted above, can form anelectronic control system 860. It is to be noted that theelectronic control system 860 can be used with any of the above-described embodiments of themobile separation units mobile separation system 200A are referenced below with respect to certain features, functions or advantages, those of ordinary skill in the art will understand how the description of theelectronic control system 860 can be used with the othermobile separation systems - As reflected in the schematic of
FIG. 38 , at least some of the sensors and actuators of themobile separation system 200A can be grouped or organized based on the components of theseparation system 200A with which they operate. For example, as described above, theseparation system 200A can include afeed air compressor 246A, aseparation unit 266A, and an output, which can be in the form of abooster compressor 216A. As noted above, each of thesedevices - For example, the
feed air compressor 246A can include, as illustrated inFIG. 10 , a compressordischarge pressure sensor 900 and a compressoroutlet temperature sensor 902. Additionally, other sensors can also be considered as effecting or effected by the operation of thecompressor 246A, and thus, can be considered part of the compressor sensors. For example, but without limitation, the nitrogen flow rate, nitrogen purity, and booster inlet pressure, are all affected by the operation of thecompressor 246A. Thus, thecompressor sensor group 900 can be considered to also include the nitrogen flow meter 654 (FIG. 19 ) which, optionally, can also include anitrogen purity sensor 906. - Further, the
compressor sensors group 900 can also include a pressure sensor 908 (FIG. 19 ) which is disposed at an outlet of themembrane separation unit 266A. However, because it is at the outlet end of themembrane separation unit 266A, it can also be considered as providing the pressure at the inlet of thebooster 216A. - The
compressor 246A can also have a group ofactuators 910 associated with the operation of thefeed air compressor 246. For example, but without limitation, thefeed air compressor 246 can include a combustion air valve 912 (FIG. 10 ) for controlling the flow of air into theengine 220A, an engine speed control actuator 914 (FIG. 26 ), astarter switch 916, the unloading valve 519 (FIG. 10 ), and/or other actuators. - Similarly, the
membrane separation unit 266A can include amembrane sensors group 920 and amembrane actuator group 922. Themembrane sensors group 920 can include, similarly to thecompressor sensor group 900, sensors that are specifically dedicated to only themembrane separation unit 266A as well as sensors that are also considered part of other sensor groups. - For example, the
membrane sensors group 920 can include the compressoroutlet temperature sensor 902, thenitrogen purity sensor 906, thenitrogen flow sensor 654, thetemperature sensor 556 indicating the temperature at the outlet of theheater 542, thetemperature sensor 554 indicating the temperature at the inlet of theheater 542, a temperature sensor 922 (FIG. 11 ) configured to detect the temperature of the gases discharged from thefilter assembly 251A, or, in other words, flowing into themembrane system 266A, and one or plurality ofadditional temperature sensors membrane separation unit 266A. Themembrane actuator group 922 can include theflow control valve 322A (FIG. 19 ), adump valve 928 configured to vent all of the nitrogen gas from themembrane separation unit 266A, as well as other actuators. - Additionally, the
booster compressor 216A can include abooster sensors group 930 and abooster actuator group 932. Thebooster sensors group 930 can include thetemperature sensor 926 at the outlet of themembrane separation unit 266A (FIG. 19 ), thepressure sensor 908, apressure sensor 934 at the discharge end of thebooster compressor 216A, atemperature sensor 936 configured to detect the temperature at the outlet of the booster compressor, apressure sensor 938 configured to detect a pressure produced by the first stage of the booster compressor, apressure temperature sensor 940 configured to detect a temperature at the outlet of the first stage of the booster, apressure sensor 942 configured to detect a pressure at the outlet of the second stage of the booster compressor, a temperature sensor 944 configured to detect a temperature at the outlet of the second stage of the booster compressor, atemperature sensor 946 configured to detect the temperature at the discharge of the third stage of the booster compressor, a pressure sensor 948 configured to detect an oil pressure in the booster compressor, as well as other sensors. - The
booster actuator group 932 can include a plurality of actuators configured to allow an operator to operate thebooster compressor 216A. For example, thebooster actuators group 932 can include actuators (not shown) for starting, loading and controlling a pressure output from thebooster compressor 216A. - The
electronic control system 860 can also include other sensors and actuators, schematically represented by theother sensors group 960 andother actuators group 962. Those of ordinary skill in the art can readily determine what sensors and actuators may be used to provide further operability of the mobilegas separation system - Additionally, the
electronic control system 860 can also include anexternal sensors group 964 and anexternal actuators group 966. Theexternal sensors group 964 can include any other sensor that an operator or user may desire to use at a site of operation of themobile separation system electronic control system 860, as part of theexternal sensors group 964, can include one or a plurality of auxiliary sensors input ports configured to allow a sensor (not shown) external to themobile separation units ECU 841. As such, a user or operator can monitor the output of such an external sensor from the same location from which the output of the other sensors are monitored, or other locations. - Similarly, as part of the
external actuators group 966, theelectronic control system 860 can include connectors or output ports configured to allow other external actuators to be connected to theECU 841. As such, a user or operator of theelectronic control system 860 can operate other actuators from the same location that the above noted actuators are operated, or from another location. - As one exemplary but non-limiting embodiment, a sensor that can be considered part of the
external sensors group 964, in a well drilling operation, is a pressure sensor (not shown) that can be mounted at a gas discharge outlet so as to monitor the pressure at which a gas, originally supplied by thesystem 200A, is discharged from a well during the drilling operation. As such, the discharge pressure of thebooster 216A can easily be compared with the discharge pressure detected by such an external sensor. Those of ordinary skill in the art can determine other types of external sensors and/or actuators that can also be used. - As shown in
FIG. 38 , theelectronic control system 860 also includes acontrol panel 970, an exemplary but non-limiting embodiment of which is illustrated inFIG. 39 . With continued reference toFIG. 38 , thecontrol panel 970 can include a plurality ofindicators 972, and a plurality ofinput devices 974 configured to allow an operator or user to input commands into theECU 841. Additionally, thecontrol panel 970 can optionally include an input/output (IO)display 840, such as, for example, but without limitation, a “touch screen” device. - With reference to
FIG. 39 , thecontrol panel 970, including theindicators 972,input devices 974, and the I/O display 840, can be disposed in an control cabin 205 (FIG. 9B ), the cab of apropulsion device 206B (FIG. 32 ) or any other location. - As illustrated in
FIG. 39 , thecontrol panel 970 can be considered as including four different panels; a feedair compressor panel 980, a nitrogenflow control panel 982, abooster compressor panel 984, and adisplay panel 986. - The feed
air compressor panel 980 can include any number of various indicators and input devices for the convenience of an operator. In the illustrated but non-limiting embodiment, the feedair compressor panel 980 includes a plurality of warninglamps 988, including acheck engine lamp 990, awarning lamp 992, and a compressorhigh temperature lamp 994. These warninglamps control panel 970. - For example, the
check engine lamp 990 is illuminated by theECU 841 when the controller of theengine 220A issues a check engine warning. Thewarning lamp 992 can be configured to be illuminated when voltage of the battery of theengine 220A is too low. Additionally, the compressorhigh temperature lamp 994 can be configured to be illuminated when the temperature detected by the temperature sensor detected by the temperature sensor 904 (FIG. 10 ) is over a temperature threshold. - The feed
air compressor panel 980 can also include anengine monitor system 996 which can include a plurality of additional warning lamps and a generic display device that can be adjusted to display a number of operating parameters of theengine 220A. Such monitoring devices are well known and commercially available. In an exemplary but non-limiting embodiment, theengine 220A is a diesel engine made by the Caterpillar Corporation. Themonitoring system 996 illustrated inFIG. 39 is available from the Caterpillar Corporation. Additionally, thepanel 980 can include avoltage meter 998 configured to continuously display a voltage of a battery of theengine 220A. - The
panel 980 can also include a warm upcontrol knob 1000, a high-low pressurevalve control knob 1002 and anengine control switch 1004. The warm-up control knob 1000 (FIG. 39 ) can be configured to control a pressure loading device 504 (FIG. 10 ) which can provide for cold weather starting. When placed in the “Start” position, the warm-up control valve cuts off the pressure signal to the pressure regulating valve causing the inlet valve 519 (FIG. 10 ) to remain closed. This will allow theengine 220A (FIG. 10 ) to run unloaded until it is properly warmed up at which time the warm-up control knob 1000 (FIG. 39) can be set in the “Run” position which can open the inlet valve 519 (FIG. 10 ) and cause thefeed air compressor 246A (FIG. 10 ) to start producing air flow. - The
control knob 1002 can be configured to allow thefeed air compressor 246A to operate under a high or low pressure mode, the low pressure mode being used during start-up. For example, The High-Low pressure control knob 1002 (FIG. 39 ) can be configured to allow thefeed air compressor 246A (FIG. 10 ) to operate under rated pressure or forces the compressor to a lower standby pressure. - Finally, The engine control knob 1002 (
FIG. 39 ) can be configured to de-energize the control power and shut theengine 220A (FIG. 10 ) off by moving to the OFF position. In the Start position, control power is energized and the engine start will start theengine 220A (FIG. 10 ). After theengine 220A (FIG. 10 ) is started, the control knob can be released and the knob will return to the Run condition. - The
control panel 970 can include a plurality of heat control switches 1006. For example, theheater control switches 1006 can include a mainheater toggle switch 1008, a filterheater toggle switch 1010 and acab heater switch 1012. However, these are merely optional switches and controls that can be used, other controls can also be used. - The
nitrogen flow panel 982 can include a nitrogen gasflow control knob 1014, atotalizer reset knob 1016, afilter dump control 1018, amain power knob 1020 and anemergency stop button 1022. The nitrogenflow control knob 1014 can be connected, through theECU 841, to the nitrogenflow control valve 322A. In some embodiments, thecontrol 1014 is used only during low pressure operation. Thetotalizer reset 1016 can be configured to signal theECU 841 to reset a counter that can be configured to cumulatively calculate the total amount of nitrogen gas delivered by the correspondingsystem - The
filter dump control 1018 can be configured to operate thevalve 928. For example, if desired, thevalve 928 can be opened to depressurize and thus discharge the nitrogen gas out of thenitrogen separation unit 266A. - The
power actuator 1020 can be configured to control power to thecontrol panel 970. Finally, theemergency stop actuator 1022 can be configured to shut off the engines of both thefeed air compressor 246A and thebooster compressor 216A. Thenitrogen control panel 982 could also include other controls. - The
booster compressor panel 984 can include controls similar to that of the feedair compressor panel 980. For example, thebooster compressor panel 984 can include anengine monitoring device 1030 configured to display various operating parameters of the engine 700 (FIG. 24 ) of the booster compressor. In a non-limiting exemplary embodiment, themonitoring device 1030 is aMurphy Powerview 100, which is commercially available. However, other engine monitoring devices can also be used. - In the illustrated embodiment, the
booster compressor panel 984 includes a plurality of analog gauges configured to continuously display certain operating parameters of theengine 700. For example, thebooster compressor panel 984 includes atachometer 1032, anexhaust temperature gauge 1034, acoolant gauge 1036 configured to display a temperature of the coolant of theengine 700, and anoil pressure gauge 1038 configured to display an oil pressure of theengine 700. Additionally, the boostercompressor control panel 984 can include a plurality ofcircuit breakers 1040. - The booster compressor panel can also include a three-way off/run/by-
pass switch 1042, astarter button 1044, anindicator light 1046, a loading switch 1048 and an engine rpm adjustment knob 1050. The three-way Off/Run/By-Pass switch 1042 can be configured to de-energize the control power and shut the engine 700 (FIG. 24 ) off by moving to the OFF position. When placed in the “By-Pass” position, the bypass valve 746 (FIG. 24 ) is energized to allow the engine 700 (FIG. 24 ) to start without loading the booster 702 (FIG. 24 ). After the engine 700 (FIG. 24 ) is started, the switch can be released and the switch will return to the Run condition. - The
starter button 1044, can be connected through theECU 841 to thestarter 916 of the feed air compressor engine 700 (FIG. 26 ). The loading switch 1048 can be connected to a valve for loading or unloading thebooster compressor 216A. The engine rpm control 1050 can be connected to athrottle sensor 914 which can be used by theengine 700 to adjust the engine speed of theengine 700. - The
booster compressor panel 984 can also include a filterheater toggle switch 1052, apumper fault relay 1054, a mainheater toggle switch 1056, and an airtemperature fault relay 1058, however, other controls can also be included. - The
display panel 986 can include any number of display devices configured to display the status of various components of thesystems - The
display devices FIG. 35 , are generic digital four-digit display panels configured to display numeric or alphanumeric representations of the output or status of various components of thesystems control panel 970 can includecontrol knobs devices knobs display devices output device 840. - The input/
output device 840 can be in the form of any known generic or graphical display, commonly used in the computer industry. In the illustrated but non-limiting embodiment, thedisplay 840 is a “touch screen” device. The following figures illustrate exemplary but non-limiting user screens that can be programmed into theECU 841 for the display and control of various parameters. These figures, which includeFIGS. 40 through 53 , include an exemplary set or sub-set of screens that can be provided with one of thesystems - Optionally, upon actuation of the main power switch 1020 (
FIG. 39 ), thedisplay 840 can include a log in screen (not shown), which requires a user to enter a user name or a password. - The
ECU 841 can be configured to display any screen as the initial screen after log in is completed. In some embodiments, the first screen viewable after log in is complete, is shown inFIG. 40 . In each of the user interface screens, illustrated inFIGS. 40-53 , the screen includes aheader area 1080 indicative of the values or fields displayed on the screen. For example, the screen illustrated inFIG. 40 is the “nitrogen generation unit” screen. This screen is intended to be a summary overview of a subset of the data received by theECU 841. The data fields illustrated inFIG. 40 as included in the nitrogen generation unit screen are merely exemplary, other data fields can also be used. In some embodiments, theECU 841 is configured to allow a user to change the fields displayed on each screen. - As shown in
FIG. 40 , the nitrogen generating unit screen includes a boosterdischarge pressure field 1082 that is configured to display data indicative of the pressure from thebooster compressor 216A. For example, thefield 1082 can be configured to display data indicative of the output of the sensor 934 (FIG. 24 ). The nitrogen generating unit screen can also include a boosterdischarge temperature field 1084 configured to display a value indicative of the temperature of the gas discharged from thebooster compressor 216A. For example, thefield 1084 can be configured to display data indicative of the output of thetemperature sensor 936. - This screen can also include a
field 1086 configured to display a value indicative of the opening degree of the valve 742 (FIG. 24 ). In some embodiments, those values can be expressed as a percentage, 100% being fully opened. - The nitrogen generating unit screen can also include a
field 1088 configured to display a flow rate of nitrogen being discharged from the associatedsystem field 1088 can be configured to display data indicative of the output from the sensor 654 (FIG. 19 ). - This screen can also include a
field 1090 configured to display total amount of gas discharged from the associated system, 200, 200A, 200B. Thus, theECU 841 can be configured to provide a running total of the amount of gas discharged from the associated system. Additionally, as noted above, thecontrol panel 970 can include a totalizer reset 1016 (FIG. 39 ). As such, thereset 1016 can be configured to clear the running total displayed in thefield 1090. - With continued reference to
FIG. 40 , the nitrogen generating unit screen can also include afield 1092 configured to display the purity of nitrogen discharged from the associated system. For example, thefield 1092 can be configured to display data indicative of the output from the sensor 906 (FIG. 19 ). - The nitrogen generating unit screen can also include a
field 1094 configured to display a temperature of the gases entering themembrane separation unit 266A. For example, thefield 1094 can be configured to display data indicative of the output of the sensor 922 (FIG. 11 ). Finally, this screen can also include afield 1096 configured to display the pressure at the outlet of thefeed air compressor 216A. For example, thefield 1096 can be configured to display data indicative of the output of the pressure sensor 902 (FIG. 10 ). However, other fields can also be included. - Additionally, the nitrogen generating unit screen can also include a plurality of fields that are “active” in the sense that a user can touch the screen in these areas to select or trigger a function associated with that field. These fields, as used herein, are referred to as “buttons” for ease of description.
- For example, as illustrated in
FIG. 40 , the nitrogen generating unit screen can include a next button 1100, a silence button 1102, asystem configuration button 1104, acalibration button 1106, and a log outbutton 1108. - The next button 1100 is configured to trigger the
ECU 841 to display the next screen; a plurality of such screens are described with reference toFIGS. 41-53 . The silence button 1102 can be configured to silence all audible alarms associated with thedisplay 840. - The
system configuration button 1104 can be configured to cause theECU 841 to display a system configuration screen on thedisplay 840. Similarly, thecalibration button 1106 can be configured to cause theECU 841 to display a calibration screen on thedisplay 840. Finally, the log outbutton 1108 can be configured to cause theECU 841 to exit the operation mode of the system and require a password to be input before any further use of thedisplay 840 is allowed. - Optionally, the nitrogen generating unit screen can include a graphical representation of the entire system associated with the
control panel 970. In the illustrated embodiment, the system associated with thecontrol panel 970 is thesystem 200A and thegraphical representation 1110 is a graphical representation of a side elevational view of thesystem 200A. - Optionally, the
graphical representation 1110 can include labels indicating the location at which the data from the various fields 1082-1096 are detected. For example, thegraphical representation 1110 can include a position identifier 1112 schematically representing a general position on thesystem 200A at which the data in the boosterdischarge pressure field 1082 is detected. Optionally, indicators or labels similar to the label 1112 can be provided for each of the fields 1084-1096. - Further, the
graphical representation 1110 can be configured to only generate such indicators when a user presses a portion of the screen in the vicinity of the fields 1082-1096. For example, thegraphical representation 1110 can normally be displayed without any labels including the label 1112. Then, only if a user or operator presses thefield 1082, does theECU 841 generate the label 1112. This technique can be used for any or all of the fields 1082-1096 as well as any of the fields described below with reference toFIGS. 41-53 . - Further, the
ECU 841 can be further configured to only generate labels, such as the label 1112, if the data from the corresponding sensor or other component breaches a threshold value indicating an alarm or a time period for maintenance of that particular sensor or component. Optionally, theECU 841 can be configured to cause such a label to blink and/or also trigger an audible alarm. As such, a user or operator is quickly and conveniently reminded of the location at which the corresponding sensor or component is located. - It is to be noted that the screens described below with reference to
FIGS. 41-53 include some of the same data fields identified above with reference toFIG. 40 . Thus, a description of those fields will not be repeated. - With reference to
FIG. 41 , theECU 841 can also be configured to display a “compressor” screen which can be organized to illustrate data relevant to the operation of thebooster compressor 246A. For example, in addition to thefields FIG. 40 , the compressor screen can also include a compressoroutlet temperature field 1120 configured to display a temperature of the gases discharged from the compressor. For example, thefield 1120 can be configured to display data indicative of the output of the temperature sensor 936 (FIG. 24 ). - The compressor screen can also include a booster
inlet pressure field 1122 configured to display a pressure at the inlet of thebooster compressor 216A. For example, thefield 1122 can be configured to display data indicative of the output of the sensor 908 (FIG. 19 ). Although thesensor 908 is disposed downstream from themembrane separation unit 266A, and thus, is not spatially close to thecompressor 246A, the booster inlet pressure is affected by the operation of thefeed air compressor 246A. For example, if the booster inlet pressure is too low, the compressor discharge pressure, which can be displayed infield 1096, can be raised until the booster inlet pressure is at an acceptable level. Thus, the compressor screen provides an advantage in that an operator has relevant information conveniently arranged for the operation of thesystem - In addition to the “buttons” 1100, 1102, 1104, 1106, 1108 described above with reference to
FIG. 40 , the compressor screen can also include aprevious button 1124 configured to allow a user to return to a previously viewed screen. - Additionally, the compressor screen includes a
graphical representation 1126 including a schematic representation of a booster compressor. Thegraphical representation 1126 can include all the features and options described above with reference to thegraphical representation 1110 illustrated inFIG. 40 . Thus, the description of those features will not be repeated. - With reference to
FIG. 42 , theECU 841 can also be configured to display a membrane section screen. In addition to the fields described above with reference toFIGS. 40 and 41 , the membrane section screen can also include a heaterinlet temperature field 1130 configured to display a temperature of the gases entering theheater device 540. For example, thefield 1130 can be configured to display data indicative of the output of the temperature sensor 554 (FIG. 11 ). Additionally, the membrane section screen can also include a heateroutlet temperature field 1132 configured to display a temperature of the gases discharged from theheater 540. For example, thefield 1132 can be configured to display data indicative of the output of the temperature sensor 556 (FIG. 11 ). - Further, the membrane section screen can include a membrane
inlet temperature field 1134 configured to display a temperature of the gases entering themembrane separation unit 266A. For example, thefield 1134 can be configured to display data indicative of a temperature detected by thetemperature sensor 922. - Finally, the membrane section screen can include a
graphical representation 1136. In the illustrated embodiment, thegraphical representation 1136 includes a schematic illustration of themembrane separation unit 266A as well as thefilter assembly 251A. As such, as noted above with reference to thegraphical representation 1110 ofFIG. 40 , thegraphical representation 1136 can be modified to include indicators or labels corresponding to the status or state of the sensors and/or components displayed in the above noted fields. - With reference to
FIG. 43 , theECU 841 can also be configured to display a booster screen configured to display data relevant to the operation of thebooster compressor 216A. In addition to the fields described above, the booster screen can also include a booster firststage pressure field 1138 configured to display a pressure at the discharge at the first stage of thebooster compressor 216A. For example, thefield 1138 can be configured to display data indicative of the pressure detected by the pressure sensor 938 (FIG. 24 ). Additionally, the booster screen can include a booster secondstage pressure field 1140 configured to display a pressure at the discharge of the second stage of thebooster compressor 216A. For example, thefield 1140 can be configured to display data indicative of the output of the pressure sensor 942 (FIG. 24 ). - The booster screen can also include a booster
inlet temperature field 1142, a booster first stage temperature field 1144, and a booster secondstage temperature field 1146. Thesefields field 1142 can be configured to display data indicative of the output of thesensor 926, the field 1144 can be configured to display data indicative of the output of thesensor 940, and thefield 1146 can be configured to display data indicative of the output of the sensor 944. - The booster screen can also include a booster
oil pressure field 1150 configured to display a pressure of the oil of thebooster compressor 216A. For example, thefield 1150 can be configured to display data indicative of the output of the sensor 948 (FIG. 24 ). - With continued reference to
FIG. 43 , the booster screen can also include a booster thirdstage temperature field 1152 configured to display a temperature of the third stage of thebooster compressor 216A. For example, thefield 1152 can be configured to display data indicative of the output of the temperature sensor 946 (FIG. 24 ). - Additionally, the booster screen can also include a
graphical representation 1160 of thebooster compressor 216A. As noted above with reference to thegraphical representations graphical representation 1160 can also be modified to include labels or indicators, the description of which will not be repeated. - Optionally, the
ECU 841 can be configured to display an “all devices” screen configured to display the data from all sensors described above. Additionally, although not illustrated, the “all devices” screen can also include a graphical representation (not shown) of theentire system graphical representation 1110. - With reference to
FIG. 45 , theECU 841 can also be configured to display a system configuration screen, for example, when a user activates thesystem configuration buttons 1104, to allow an operator to adjust various operating parameters of theECU 841 and/orcorresponding system - With reference to 46, the
ECU 841 can also be configured to display other screens configured for adjusting parameters of feedback control loops. For example, as illustrated inFIG. 46 , theECU 841 can be configured to display a membrane temperature and touch screen temperature control screens. With respect to the membranetemperature control field 1170, this screen includes a plurality ofbuttons ECU 841 is to use as a target temperature for maintaining the temperature of the gases output from themembrane separation unit 266A. - In the illustrated embodiment, the
buttons 174, 176, 178 each provide the user the option of using a predetermined temperature setting of 130°, 100°, 115°, respectively. Additionally, thebutton 1172 allows a user to maintain a currently detected temperature, as displayed in thetemperature field 1180. Another field, 1182 is configured to display the set temperature under which the system is operating. - The screen illustrated in
FIG. 46 also includes a touch screentemperature tuning field 1184 that is configured to allow a user to adjust the sensitivity of thetouch screen 840. - The screen of
FIG. 46 also includes a membrane temperature control tuning button 1186. By depressing this button, the user advances to the screen illustrated inFIG. 47 . - As shown in
FIG. 47 , a tuning screen allows a user to access a number of parameters for adjusting the operation of the feedback control routine used by theECU 841 for maintaining a temperature discharged from themembrane separation unit 266A. In some embodiments, theECU 841 uses the output of thesensor 926 to control the operation of thevalves 544 to adjust the temperature of the gases discharged from thefiltration unit 251A, which thereby controls the temperature of the gases discharged from themembrane separation unit 266A. - The remaining screens illustrated in
FIGS. 48-54 provide means for a user or operator to adjust various settings with respect to different sensors and components of thecorresponding system - Additionally, with respect to the screens illustrated in
FIGS. 40-44 , any one of these screens can include an additional field (not shown) for displaying the output of the sensors included in the external sensors group 964 (FIG. 38 ). TheECU 841 can be configured to allow a user to edit any one of the screens illustrated inFIGS. 40-44 to include an additional field for displaying the output of such a sensor. - It is contemplated that inert gas, such as nitrogen rich gas (N2), can be used for various applications. For example, the inert gas can be used in manufacturing facilities. In one embodiment, inert gas can be used in semiconductor manufacturing processes. Many kinds of inert gas (e.g., nitrogen gas) can be used to purge and provide an inert environment for semiconductor wafer processing. The inert environment prevents air from contacting materials that are prone to oxidation. Nitrogen can be used to purge equipment, such as equipment used in refineries or petrochemical plants. For example, inert gas can be employed to purge fluid lines containing explosive or flammable fluids. Many kinds of fluid lines can be purged of dangerous fluids before components in the fluid system are replaced or repaired. Inert gases can also be used in other settings, such as for packaging to prevent oxidation of packed items. Set forth below are additional examples of application for which the
systems - For example, the
systems - However, extinguishing coal fires is difficult given the large surface areas that would have to be treated with inert gas to stop the leak of oxygen into the mine. Such a large source of inert gas must have a sufficiently low content of oxygen to not only extinguish the fire, but to keep the fire out while the combustible materials cool down so that they do not reignite when oxygen eventually is reintroduced. The latest technologies include special foaming agents utilizing nitrogen or other inert gases as a carrier gas for the foam. The foam treats the surface of the coal ash on the unburnt coal fuel so as to provide a barrier that prevents oxygen from reaching the unburned coal. The foam also helps seal off crevices and leakage points to isolate the fire from incoming oxygen and contain the fire in desired locations within the mine. As such, fires are extinguished more quickly than with using nitrogen gas alone because the foam can better isolate and stop the spreading of fires within the mine.
- The
systems - Thus, because the carbon
dioxide removal device 380 can generate a significant back pressure, the flow rate and discharge pressure of gases from thesystem 210 can be higher if the gases are not passed through the carbondioxide removal device 380. - In the application of coal mine fire suppression or extinguishing, the discharge pressures from the
system 210 can be in the range of about 100-125 psig, as this is a common pressure range to use for foam generation or direct injection of nitrogen gas into a coal mine fire. Thus, in some applications, it is not necessary to run thebooster compressor 330. - Additionally, often times, mines are equipped with high capacity air compressors. Thus, with reference to
FIG. 7 , thesource 390 can be in the form of an air compressor at the site of a coal mine. Such compressed air can be delivered directly to theintake conduit 386 and thus passed through theseparation device 266 to generate the desired nitrogen gas. Further, this technique can also be used if theengine 220 and/or thecompressor 246 are inoperable. - In some embodiments, the purity of the inert gas, such as nitrogen gas, can be adjusted by adjusting the capacity of the
separation device FIG. 7H , theseparation unit 266′ can be adjusted so as to activate or deactivate the desired number ofseparation devices valves separation devices device 266. - In some embodiments, the back pressure regulator valve 233 (
FIG. 7 ) can be adjusted to adjust the flow rate of exhaust gas through thesystem 210. Optionally, further purity control can be achieved by adjusting the speed of theengine 220. For example, the speed of theengine 220 can be reduced, thereby lowering the volumetric flow rate of exhaust gases out of theengine 220 and the amount of ambient air mixed into the mixingplenum 229 can be reduced such that more exhaust gas is delivered to thecompressor 246. As such, the oxygen content of the exhaust gas will be lower and thus a higher level of “purity” can be obtained. Additionally, other adjustments can be made to thesystem 210 to achieve the desired flow rate, output pressure, and purity. For example, as noted above, thevalve 322 can also be adjusted to change the output pressure and purity of the gas discharged from the system. - The
systems - When the drill string has cut the well to the desired or “critical” depth, a casing pipe is typically cemented into place to protect the well bore. During this process, nitrogen can be used to assist the cementing process. For example, nitrogen can be added to the cement as the cement is pumped into the casing and returned back up the annulus, creating a bond between the well bore and the casing outside protecting the well bore. This process can be used when the cement hydrostatic pressure is higher than the well bore pressure, which in turn could cause lost or reduced circulation and loss of cement height required to protect the well bore in segregated zones. During such construction processes, nitrogen can be supplied up to about 5,000 standard cubic feet per minute (scfm) at pressures up to about 5,000 psi. Such cementing procedures are described above with reference to
FIGS. 1-4 . - With the
systems systems booster compressor 330 or an additional booster compressor may be used to inject the gas discharged from theseparation unit - As noted above, during these procedures, the purity of the gas discharged from the
separation unit FIG. 7H . Additionally, the purity of the gas discharged from thesystems separation units 266 by adjusting the backpressure regulator valve 233. Further purity control can be achieved by adjusting the speed of theengine 220 and/or thecompressor 246. Additionally, as noted above, thevalve 322 can also be adjusted to change the output pressure and purity of the gas discharged from the system. - Dry inert gas, such as nitrogen gas, is commonly used to assist drilling for hydrocarbons in vertical and in horizontal wells where the well bore pressure is lower than the hydrostatic pressure of the drilling mud used during drilling. For example, nitrogen gas can be added to the drilling mud at a rate required to reduce the hydrostatic pressure of the well bore to reduce losses of hydrocarbon to the bearing zone around the bore or to allow the hydrocarbon bearing zone to produce hydrocarbons during drilling. Further, using a gas such as nitrogen gas to reduce the hydrostatic pressure of the mud can help drilling through lost or lowered circulation zones or to increase the rate of penetration (ROP) of the drilling process.
- The drilling mud flow rate can produce enough velocity and volumetric flow to return drill cuttings back to the surface. In some applications, the drilling mud or fluid may be nitrogen gas alone pumped at a rate sufficient to carry drill cuttings upwardly to the surface. This flow rate could be as high as about 5,000 standard cubic feet per minute at pressures up to about 5,000 psi.
- Drilling of such wells can be performed using a drill string and bit rotated by surfaced equipment and/or the use of a down hole positive displacement motor (PDM). Such drill strings can be conventional jointed pipes deployed with a conventional drilling rig, a hydraulic work over rig, or a coil tubing strings deployed with an injector system.
- Using the
systems booster compressor 330 can be shut down or otherwise not used for these types of applications. Additionally, for underbalanced drilling, nitrogen purities at about 95% or higher can be used. However, there are other applications where higher purities are recommended. For example, but without limitation, where the well contains certain sensitive chemicals such as H2S, also known as “sour gas,” higher purity nitrogen should be used, for example, up to about 99.5% nitrogen, due to the corrosive effects of the sour gas on the drill string. - As in other applications, the nitrogen purity can be adjusted in several different ways. For example, with reference to
FIG. 7H , the number ofseparation units separation device 266 can be adjusted by adjusting the backpressure regulator valve 233. Additionally, the speed of theengine 220 and/or the speed of thecompressor 246 can be adjusted to adjust the volume of exhaust gas directed to theseparation unit 266. As noted above, thevalve 322 can also be adjusted to change the output pressure and purity of the gas discharged from the system. - In under balanced drilling operations where higher pressures are desired, such as pressures above 350 psig, the
booster compressor 330 can be operated to raise the pressure. For example, thebooster compressor 330 can be set to raise the pressure of the gas discharged from theseparation unit 266 up to about 5,000 psig. - Well bore maintenance procedures often incorporate an inert dry gas. For example, after a well has been constructed and completed, the well will start to produce hydrocarbons. From time to time, the well may require maintenance if production starts to decrease.
- For example, the well bore may benefit from being cleaned out, stimulated, or gas lifted. In these procedures, nitrogen gas is often injected alone or with other fluids through the completion string, a jointed tubing, or coil tubing, back to the surface so as to lift out debris such as sand, water, sludge, organic matter, or scale. This procedure restores the flow rate of hydrocarbons into and up through the well bore.
- Occasionally, well bores may also need stimulation to start or restart the flow of hydrocarbons or to maintain hydrocarbon production. Such stimulation techniques can include acidizing, chemical treatments, fracturing, or gas lifting. In these procedures, nitrogen gas can be used to flush out the stimulation fluids noted above and return them back to the surface. For example, the nitrogen can be used to reduce the hydrostatic pressure of the stimulation fluids used and to creating energy in the well bore to push these fluids back to the surface. Flow rates of the nitrogen gas can be as high as about 5,000 standard cubic feet per minute at pressures up to about 5,000 psi.
- The
systems - As noted above, the purity of the nitrogen gas discharged by the
systems membrane units 266, adjusting the flow rate of exhaust gas through theseparation devices 266, or by adjusting a backpressure regulator valve 233. Optionally, the purity can also be affected by adjusting the speed of theengine 220 and/or thecompressor 246. As noted above, thevalve 322 can also be adjusted to change the output pressure and purity of the gas discharged from the system. - Enhanced Oil (and/or Gas) Recovery (EOR)
- After a well has produced for a significant amount of time, large voids can be left behind within the producing formation and additionally, the pressure within the formation can be reduced over time. Thus, nitrogen gases can be used to fill the voids left behind and to increase the pressure of the formation.
- As such, the production from the formation and the life of the field itself can be improved. For example, nitrogen gas or other inert gases can be injected directly into the void spaces, an injection well can be drilled into the same formation through which the gas can be injected, or additional formation pressure can be generated through other artificial means to enhance the production from the well.
- Additionally, nitrogen gas or other inert gases can be used to enhance oil and gas recovery by injection into an injection string or gas lift mandrel in the production string. For example, nitrogen gas can be continuously added to the production to reduce the hydrostatic pressure and thereby increase the velocity of the hydrocarbon, even though the formation pressure has decreased below a critical flow pressure point.
- In using the
systems booster compressor 330 can also be used. As noted above, the purity of the nitrogen can be adjusted by adding or deleting separation units (FIG. 7H ), by adjusting the flow of exhaust gas through theseparation units 266, and/or adjusting a backpressure regulator valve 233. Additionally, the purity of the discharged gas can be controlled by changing the speed of theengine 220 and/or the speed of thecompressor 246. As noted above, thevalve 322 can also be adjusted to change the output pressure and purity of the gas discharged from the system. In these applications, the flow rates for nitrogen gas can be as high as about 5,000 standard cubic feet per minute and up to pressures of about 5,000 psi. - In applications such as pipeline purging, drawing, and pressure testing, an inert dry gas is often used to displace chemicals, volatile materials, or moisture within plant processing systems or operating pipelines. For example, an inert dry gas, such as nitrogen, can be used to directly displace such fluids out of the pipes or to push a “pig” or other internal plug to displace the materials remaining in the piping or pipeline. Dry nitrogen is a preferred gas for its flame retardant properties and its inert nature.
- The pigs noted above can also be used to scrape the pipeline in preparation for inspection, corrosion treatment, or pressure testing. It is often desirable that moisture is removed from such pipelines as well. Thus, in these applications, it is desirable to use an inert gas with a low dew point (e.g. −40° F. or lower) to achieve a sufficiently fast drawing of the pipeline. Further, hot dry gases also accelerate the drying process.
- In using the
system systems booster compressor 330 is not required. - Typically, for these types of applications, the gas generated by the
systems - In applications where very low dew points are desired, higher purity is advantageous because the higher the nitrogen purity, the lower the dew point of the gas. Thus, higher purity nitrogen gas is desirable for low dew point applications. Further, in applications where other sensitive chemicals are present, a higher nitrogen purity, such as about 99.5% nitrogen or higher, may be desirable.
- As noted above, the purity of the nitrogen discharged from the
systems membranes 266, or adjusting the flow of exhaust gas through theseparation devices 266 by adjusting a backpressure regulator valve 233. The purity of the nitrogen gas can also be adjusted by changing the speed of theengine 220 and/or the speed of thecompressor 246 so as to change the volume of exhaust gas directed to theseparation units 266. As noted above, thevalve 322 can also be adjusted to change the output pressure and purity of the gas discharged from the system. Optionally, a dew point analyzer device (not shown) can be included in either of thesystems systems - As described above with reference to
FIG. 7 , thesystems bypass 392 for directing the gases discharged from theseparation unit 266 to aheating device 397. Thisbypass 392 allows the discharge gas to be reheated through heat from the exhaust gas from theengine 220. However, other heaters can also be used. - For such applications, preferably, the
systems systems - For applications requiring higher pressures, such as pneumatic testing, relief valve testing, or other applications requiring pressures above 350 psig (for example, up to about 5,000 psig), the
booster compressor 330 can be used to raise the fluid discharged from theseparation unit 266 up to such pressures. In applications where it is desired to raise the temperature of high pressure fluid, i.e., fluid discharged from thebooster compressor 330, the fluid can be directed through thebypass line 395 to flow through thebypass 392 to theheater 397. - As is known in the art, maritime regulations require certain chemical tankers, crude oil tankers, and liquid natural gas (LNG) tankers to have a “pad” of inert gas within the cargo tanks. The “pad” is used to reduce the concentration of oxygen such that there is insufficient oxygen to support combustion. For example, typically, it is required that there is less than 8% and as low as 0.5% oxygen in such storage tanks depending on the safety factors applied in the particular commercial practice.
- The inert gas can also be used to pressurize chemical tanks as they are unloaded, for example, to replace the void created within the tank as the desired fluid is removed from the tank. As such, the inert gas provides a constant positive pressure of inert gas within the filled tank which prevents venting and contamination by the ingress of air that might have been drawn into the void.
- As noted above, flue gas systems can use combustion of hydrocarbon fuels and air to generate low oxygen gases. However, these systems also generate high percentages of carbon dioxide (typically over 10%) which is a normal product of combustion. Thus, such high carbon dioxide content exhaust gases may not be appropriate for tanks containing chemicals that react with carbon dioxide. Additionally, carbon dioxide can be acidic in the pressure of moisture.
- Thus, flue gas from combustion sources are not always acceptable as a “padding gas” even though it may be considered to be generally inert. In applications where flue gas can be used, some known flue gas systems have supplemental “gas topping” inert gas generators and compressors that operate at positive pressures because flue gas pressure is usually too low to properly pressurize cargo tanks.
- In using either of the
systems systems systems - For example, as noted above, the source 390 (
FIG. 7 ) can be an exhaust system of a shipboard engine. As described in detail above, thefiltration unit 251 is configured to deal with the typical types of contaminants found in exhaust gases from air/fuel combustion engines. Additionally, thesystems engine 220 or a mix of atmospheric air and the exhaust gas from theengine 220. Optionally, thesystems engine 220, and/or other flue or exhaust gases from thesource 390. - As noted above, the
filtration unit 251 can be configured to remove carbon dioxide, sulfur, oxides of nitrogen, and other contaminants. Thus, thesystems filtration unit 251, in applications for which flue gas has previously been unacceptable. - As noted above, the purity of the nitrogen gas discharged from the
systems separation unit 266, adjusting the flow rate of the exhaust gas from theengine 220 by adjusting the backpressure regulator valve 233. Optionally, the flow of exhaust gas can also be changed by adjusting the speed of theengine 220 and/or the speed of thecompressor 246. As noted above, thevalve 322 can also be adjusted to change the output pressure and purity of the gas discharged from the system. - The
systems systems systems - The various methods and techniques described above provide a number of ways to carry out the disclosed embodiments. Of course, it is to be understood that not necessarily all objectives or advantages described may be achieved in accordance with any particular embodiment described herein. Thus, for example, those skilled in the art will recognize that the methods may be performed in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objectives or advantages as may be taught or suggested herein.
- Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments disclosed herein. Similarly, the various features and steps discussed above, as well as other known equivalents for each such feature or step, can be mixed and matched by one of ordinary skill in this art to perform methods in accordance with principles described herein. Additionally, the methods described and illustrated herein are not limited to the exact sequence of acts described, nor are they necessarily limited to the practice of all of the acts set forth. Other sequences of events or acts, or less than all of the events, or simultaneous occurrence of the events, may be utilized in practicing the embodiments of the inventions.
- Although the inventions have been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the inventions extend beyond the specifically disclosed embodiments to other alternative embodiments and/or uses and obvious modifications and equivalents thereof. Accordingly, the inventions are not intended to be limited by the specific disclosures of preferred embodiments herein.
Claims (24)
1-30. (canceled)
31. A system configured to separate an inert gas from atmospheric air comprising:
a feed air compressor configured to compress and thereby raise a pressure of atmospheric air;
a separation device configured to separate the inert gas from the pressurized atmospheric air from the feed air compressor;
a booster compressor configured to raise a pressure of the inert gas from the separation device;
at least a first sensor configured to detect an operational parameter of the feed air compressor;
a least a second sensor configured to detect an operational parameter related to the operation of the separation device;
at least a third sensor configured to contact an operational parameter of the booster compressor; and
an electronic control system being connected to the first, second, and third sensors, the electronic control system comprising a display device configured to display a graphical user interface having at least first, second, and third screens;
wherein the first screen includes a plurality of data related to the operation of the feed air compressor including data indicative of the output of the first sensor, the second screen including a plurality of data related to the operation of the separation device including data indicative of the output of the second sensor, and the third screen including a plurality of data related to the operation of the booster compressor including data indicative of the output of the third sensor.
32. The system according to claim 31 additionally comprising a fourth sensor configured contact a condition external to the system, electronic control system being connected to the fourth sensor and configured to display data indicative of the output of the fourth sensor.
33. The system according to claim 31 additionally comprising a wheeled vehicle supporting the feed air compressor, the separation device, the booster compressor, the first sensor, the second sensor, the third sensor, and the electronic control system.
34-40. (canceled)
41. The system of claim 31 , wherein the graphical user interface includes a touch screen device and displays the first, second, and third screens on the touch screen device.
42. The system of claim 31 , wherein the first screen includes a display of an output of at least one of a compressor discharge pressure sensor, a nitrogen flow sensor, a compressor outlet temperature sensor, a nitrogen purity sensor, and a booster inlet temperature sensor.
43. The system of claim 42 , wherein the first screen includes a compressor discharge pressure field, a nitrogen flow field, a compressor outlet temperature field, a nitrogen purity field, and a booster inlet temperature field for displaying outputs of the respective one of the compressor discharge pressure sensor, the nitrogen flow sensor, the compressor outlet temperature sensor, the nitrogen purity sensor, and the booster inlet temperature sensor.
44. The system of claim 31 , further comprising a feed air compressor actuator group being connected to the feed air compressor and being configured to control at least one operational parameter of the feed air compressor, the feed air compressor actuator group including at least one of a combustion air valve for controlling the flow of air into the engine, an engine speed control actuator, a starter switch, and an unloading valve.
45. The system of claim 44 , wherein the electronic control system is operative to provide an output to the feed air compressor actuator group for controlling an operational parameter of the feed air compressor.
46. The system of claim 45 , wherein the graphical user interface includes a touch screen device and displays the first screen on the touch screen device, the touch screen device being in electrical communication with the electronic control system and being operative to receive an input from a user for selectively controlling at least one operational parameter of the feed air compressor displayed in the first screen, the touch screen further being operative to communicate the input to the electronic control system, the electronic control system providing an output to the feed air compressor actuator group being representative of the input of the user.
47. The system of claim 31 , wherein the second screen includes a display of an output of at least one of a compressor outlet temperature sensor, a nitrogen purity sensor, a nitrogen flow sensor, a heater outlet temperature sensor, a heater inlet temperature sensor, and a membrane inlet temperature sensor.
48. The system of claim 47 , wherein the second screen includes a compressor outlet temperature field, a nitrogen purity field, a nitrogen flow field, a heater outlet temperature field, a heater inlet temperature field, and a membrane inlet temperature field for displaying outputs of the respective one of the compressor outlet temperature sensor, the nitrogen purity sensor, the nitrogen flow sensor, the heater outlet temperature sensor, the heater inlet temperature sensor, and the membrane inlet temperature sensor.
49. The system of claim 31 , further comprising a membrane actuator group being connected to the membrane separation unit and being configured to control at least one operational parameter of the membrane separation unit, the membrane actuator group including at least one of a flow control valve and a dump valve.
50. The system of claim 49 , wherein the electronic control system is operative to provide an output to the membrane actuator group for controlling an operational parameter of the membrane separation unit.
51. The system of claim 50 , wherein the graphical user interface includes a touch screen device and displays the second screen on the touch screen device, the touch screen device being in electrical communication with the electronic control system and being operative to receive an input from a user for selectively controlling at least one operational parameter of the membrane separation unit displayed in the second screen, the touch screen further being operative to communicate the input to the electronic control system, the electronic control system providing an output to the membrane actuator group being representative of the input of the user.
52. The system of claim 31 , wherein the third screen includes a display of an output of at least one of a booster inlet pressure sensor, a booster discharge pressure sensor, a booster inlet temperature sensor, a booster discharge temperature sensor, a booster first stage pressure sensor, a booster oil pressure sensor, a booster first stage temperature sensor, a booster second stage temperature sensor, a booster third stage temperature sensor, and a booster second stage pressure sensor.
53. The system of claim 52 , wherein the second screen includes a booster inlet pressure field, a booster discharge pressure field, a booster inlet temperature field, a booster discharge temperature field, a booster first stage pressure field, a booster oil pressure field, a booster first stage temperature field, a booster second stage temperature field, a booster third stage temperature field, and a booster second stage pressure field for displaying outputs of the respective one of the booster inlet pressure sensor, the booster discharge pressure sensor, the booster inlet temperature sensor, the booster discharge temperature sensor, the booster first stage pressure sensor, the booster oil pressure sensor, the booster first stage temperature sensor, the booster second stage temperature sensor, the booster third stage temperature sensor, and the booster second stage pressure sensor.
54. The system of claim 31 , further comprising a booster actuator group being connected to the booster compressor and being configured to control at least one operational parameter of the booster compressor, the booster actuator group including actuators for starting, loading and controlling a pressure output from the booster compressor.
55. The system of claim 54 , wherein the electronic control system is operative to provide an output to the booster actuator group for controlling an operational parameter of the booster compressor.
56. The system of claim 55 , wherein the graphical user interface includes a touch screen device and displays the third screen on the touch screen device, the touch screen device being in electrical communication with the electronic control system and being operative to receive an input from a user for selectively controlling at least one operational parameter of the booster compressor displayed in the third screen, the touch screen further being operative to communicate the input to the electronic control system, the electronic control system providing an output to the booster actuator group being representative of the input of the user.
57. The system of claim 31 , wherein the graphical user interface is operative to display a fourth screen including a compressor discharge pressure field, a nitrogen flow field, a compressor outlet temperature field, a nitrogen purity field, a booster inlet temperature field, a heater outlet temperature field, a heater inlet temperature field, a membrane inlet temperature field, a booster inlet pressure field, a booster discharge pressure field, a booster inlet temperature field, a booster discharge temperature field, a booster first stage pressure field, a booster oil pressure field, a booster first stage temperature field, a booster second stage temperature field, a booster third stage temperature field, and a booster second stage pressure field.
58. The system of claim 31 , wherein the graphical user interface includes a touch screen device being operative to display a device selection screen, the touch screen device being in electrical communication with the electronic control system and being operative to receive an input from a user for selectively controlling at least one operational parameter of the feed air compressor, the membrane separation unit, and the booster compressor displayed in the device selection screen, the touch screen further being operative to communicate the input to the electronic control system, the electronic control system providing an output to the respective ones of the feed air compressor actuator group, the membrane actuator group, and the booster actuator group being representative of the input of the user.
59. The system of claim 31 , wherein the graphical user interface includes a touch screen device being operative to display a device calibration screen, the touch screen device being in electrical communication with the electronic control system and being operative to receive an input from a user for selectively setting at least one calibration parameter of at least one of an oxygen sensor, a temperature sensor, a pressure sensor, and a flow rate sensor displayed in the device calibration screen, the touch screen further being operative to communicate the input to the electronic control system, the electronic control system calculating a calibrated measurement for the respective ones of the oxygen sensor, the temperature sensor, the pressure sensor, and the flow rate sensor displayed in the device calibration screen.
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Also Published As
Publication number | Publication date |
---|---|
WO2007011979A3 (en) | 2007-09-20 |
CA2616262A1 (en) | 2007-01-25 |
CA2616262C (en) | 2013-07-02 |
WO2007011979A2 (en) | 2007-01-25 |
US20070151454A1 (en) | 2007-07-05 |
US7588612B2 (en) | 2009-09-15 |
WO2007011979A9 (en) | 2007-03-15 |
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