Gas transport and pressurization system

A gas transport and pressurization system, including a static valve, a compartment concentrically arranged around the static valve, a dynamic valve axially displaceable relative to the static valve, and a crankshaft connected to the dynamic valve, wherein gas from a ground gas well flows through the compartment, the dynamic valve, and the static valve to a gas outlet.

FIELD

The present disclosure relates to the field gas transport and pressurization, and more particularly, to a gas transport and pressurization system that self-regulates the temperature of pressurized gas.

BACKGROUND

Natural gas or fossil gas, or sometimes called just gas, is a naturally occurring hydrocarbon gas mixture consisting primarily of methane, but commonly including varying amounts of other higher alkanes, and sometimes a small percentage of carbon dioxide, nitrogen, hydrogen sulfide, or helium. It is formed when layers of decomposing plant and animal matter are exposed to intense heat and pressure under the surface of the Earth over millions of years. The energy that the plants originally obtained from the sun is stored in the form of chemical bonds in the gas. Natural gas is a fossil fuel. Natural gas is sometimes informally referred to simply as “gas,” especially when it is being compared to other energy sources, such as oil or coal. However, it is not to be confused with gasoline, which is often shortened in colloquial usage to “gas,” especially in North America.

Natural gas is a non-renewable hydrocarbon used as a source of energy for heating, cooking, and electricity generation. It is also used as a fuel for vehicles and as a chemical feedstock in the manufacture of plastics and other commercially important organic chemicals.

The mining and consumption of natural gas is a major and growing driver of climate change. It is a potent greenhouse gas itself when released into the atmosphere, and creates carbon dioxide during oxidation. Natural gas can be efficiently burned to generate heat and electricity; emitting less waste and toxins at the point of use relative to other fossil and biomass fuels. However, gas venting and flaring, along with unintended fugitive emissions throughout the supply chain, can result in a similar carbon footprint overall.

Natural gas is found in deep underground rock formations or associated with other hydrocarbon reservoirs in coal beds and as methane clathrates. Petroleum is another resource and fossil fuel found close to and with natural gas. Most natural gas was created over time by two mechanisms: biogenic and thermogenic. Biogenic gas is created by methanogenic organisms in marshes, bogs, landfills, and shallow sediments. Deeper in the earth, at greater temperature and pressure, thermogenic gas is created from buried organic material.

In petroleum production, gas is sometimes burned as flare gas. Before natural gas can be used as a fuel, most, but not all, must be processed to remove impurities, including water, to meet the specifications of marketable natural gas. The by-products of this processing include ethane, propane, butanes, pentanes, and higher molecular weight hydrocarbons, hydrogen sulfide (which may be converted into pure sulfur), carbon dioxide, water vapor, and sometimes helium and nitrogen.

Therefore, there is a long-felt need for a system that transports gas extracted from the ground without releasing it into the atmosphere. There is also a long-felt need for a system that pressurizes gas extracted from the ground such that it can be stored more efficiently or pumped to a down stream storage container or facility (e.g., loaded into a truck or tank). There is also a long-felt need for a system that can self-regulate the extremely high gas temperatures created by the pressurization process.

SUMMARY

According to aspects illustrated herein, there is provided a gas transport and pressurization system, comprising a static valve, a compartment concentrically arranged around the static valve, a dynamic valve axially displaceable relative to the static valve, and a crankshaft connected to the dynamic valve, wherein gas from a ground gas well flows through the compartment, the dynamic valve, and the static valve to a gas outlet.

In some embodiments, the gas transport and pressurization system further comprises a cylinder, the dynamic valve being sealingly and slidingly engaged in the cylinder. In some embodiments, the dynamic valve allows gas flow therethrough in a first direction, but not a second direction. In some embodiments, the static valve allows gas flow therethrough in the first direction, but not the second direction. In some embodiments, the gas transport and pressurization system further comprises a crankcase connected to the cylinder, the crankshaft being arranged in the crankcase, wherein the gas flows through the crankcase prior to entering the dynamic valve. In some embodiments, the gas transport and pressurization system further comprises a hydraulic motor connected to the crankshaft, the hydraulic motor operatively arranged to rotate the crankshaft and reciprocate the dynamic piston in a first direction and a second direction, opposite the first direction. In some embodiments, when the dynamic valve is displaced in the first direction gas in the cylinder is forced into the static valve and gas from the compartment is pulled into the crankcase, and when the dynamic valve is displaced in the second direction, gas from the crankcase is forced into the dynamic valve. In some embodiments, the gas transport and pressurization system further comprises a first control valve fluidly arranged between the compartment and the crankcase, the first control valve operatively arranged to regulate the flow of gas therethrough. In some embodiments, the gas transport and pressurization system further comprises a second control valve fluidly arranged between a second stage gas inlet and the crankcase, the second control valve operatively arranged to regulate flow of gas therethrough. In some embodiments, each of the static valve and the dynamic valve comprises at least one valvular conduit. In some embodiments, the gas transport and pressurization system further comprises a temperature sensor and transmitter arranged on at least one of an outlet of the compartment and an outlet of the static valve.

According to aspects illustrated herein, there is provided a gas transport and pressurization system, comprising a static valve, a compartment concentrically arranged around the static valve, a cylinder connected to the static valve, a dynamic valve sealingly and slidingly engaged in the cylinder, the dynamic valve axially displaceable relative to the static valve, a crankcase connected to the cylinder, and a crankshaft arranged in the crankcase and connected to the dynamic valve, wherein gas from a ground gas well flows through the compartment, the crankcase, the dynamic valve, and the static valve to a gas outlet. In some embodiments, the dynamic valve allows gas flow therethrough in a first direction, but not a second direction. In some embodiments, the static valve allows gas flow therethrough in the first direction, but not the second direction. In some embodiments, the gas transport and pressurization system further comprises a hydraulic motor connected to the crankshaft, the hydraulic motor operatively arranged to rotate the crankshaft and reciprocate the dynamic piston in a first direction and a second direction, opposite the first direction. In some embodiments, when the dynamic valve is displaced in the first direction, gas in the cylinder is forced into the static valve and gas from the compartment is pulled into the crankcase, and when the dynamic valve is displaced in the second direction, gas from the crankcase is forced into the dynamic valve. In some embodiments, the gas transport and pressurization system further comprises a first control valve fluidly arranged between the compartment and the crankcase, the first control valve operatively arranged to regulate the flow of gas therethrough. In some embodiments, the gas transport and pressurization system further comprises a second control valve fluidly arranged between a second stage gas inlet and the crankcase, the second control valve operatively arranged to regulate flow of gas therethrough. In some embodiments, each of the static valve and the dynamic valve comprises at least one valvular conduit.

According to aspects illustrated herein, there is provided a gas transport and pressurization system, comprising a static valve, a compartment concentrically arranged around the static valve, a cylinder connected to the static valve, a piston sealingly and slidingly engaged in the cylinder, a dynamic valve connected to the piston, wherein the piston and the dynamic valve are axially displaceable relative to the static valve, a crankcase connected to the cylinder, a crankshaft arranged in the crankcase and connected to the dynamic valve, and a hydraulic motor connected to the crankshaft and operatively arranged to rotate the crankshaft and reciprocate the dynamic piston in a first direction and a second direction, opposite the first direction, wherein gas from a ground gas well flows through the compartment, the crankcase, the dynamic valve, and the static valve to a gas outlet.

According to aspects illustrated herein, there is provided a gas transport and pressurization system that includes a ram. The assembly is a manifolded gas conduit with an integral ram type gas transport system. The transport system comprises of a reciprocating-type assembly including a crankshaft, connecting piston rod, and piston rotating gear. The piston is coupled with a cartridge incorporating an impingement loop check valve. The piston is fitted with seal rings and the cartridge rides in a linear bearing. The crankshaft is powdered by a hydraulic motor that is contained inside the gas conduit. The head or forward section comprises a double wall conduit that houses a second static impingement loop check valve in the center thereof and a gas flow conduit in the double wall conduit or jacket. The inlet gas is run first through the jacket and then fed through the pressure rated crankcase. This cools the gas within the static impingement loop check valve. The flow of inlet gas takes a path through the center of the pump or piston and is moved along by the reciprocating action of the rotating gear, or reciprocating dynamic impingement loop check valve. Lube oil is fed through the conduit wall at the linear bearing location and below the oil ring at the piston. The gas transport and pressurization system may further comprise a plurality of control valves. Gas transport and pressurization system may comprise a first control valve comprising a throttling valve that modulates the gas flow, head temperature, and outlet pressure, a second control valve comprising a bypass valve for unloading the check valve train, a third control valve comprising a gas inlet temperature control valve, and a fourth control valve that is the second stage inlet temperature control.

According to aspects illustrated herein, there is provided a gas transport and pressurization system comprising a ram assembly. The ram assembly is a ram-type compression pump. The internal valve train of the gas transport and pressurization system has no moving parts, and the internal checking action is capable of being modulated via external valve operations for the purposes of flow control, pressure control, temperature control, and dew point control. Gas from the ground is fed through a double wall head, arranged around a first static one-way valve and controls head temperatures. After passing through the double wall head, the gas flows through the center of the piston or pump and into a dynamic reciprocating one way-valve. The dynamic one-way valve “rams” the gas therein into the static one-way valve repetitively, thereby pressurizing the gas. This leads to increased gas temperature in the static one-way valve, which is reduced via the flow of cooler gas through the double wall head. This ram-type compressor/pump does not require blowdown operations at start up and instrumentation may vary depending on application.

These and other objects, features, and advantages of the present disclosure will become readily apparent upon a review of the following detailed description of the disclosure, in view of the drawings and appended claims.

DETAILED DESCRIPTION

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure pertains. It should be understood that any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the example embodiments. The assembly of the present disclosure could be driven by hydraulics, electronics, pneumatics, and/or springs.

It should be understood that use of “or” in the present application is with respect to a “non-exclusive” arrangement, unless stated otherwise. For example, when saying that “item x is A or B,” it is understood that this can mean one of the following: (1) item x is only one or the other of A and B; (2) item x is both A and B. Alternately stated, the word “or” is not used to define an “exclusive or” arrangement. For example, an “exclusive or” arrangement for the statement “item x is A or B” would require that x can be only one of A and B. Furthermore, as used herein, “and/or” is intended to mean a grammatical conjunction used to indicate that one or more of the elements or conditions recited may be included or occur. For example, a device comprising a first element, a second element and/or a third element, is intended to be construed as any one of the following structural arrangements: a device comprising a first element; a device comprising a second element; a device comprising a third element; a device comprising a first element and a second element; a device comprising a first element and a third element; a device comprising a first element, a second element and a third element; or, a device comprising a second element and a third element.

Moreover, as used herein, the phrases “comprises at least one of” and “comprising at least one of” in combination with a system or element is intended to mean that the system or element includes one or more of the elements listed after the phrase. For example, a device comprising at least one of: a first element; a second element; and, a third element, is intended to be construed as any one of the following structural arrangements: a device comprising a first element; a device comprising a second element; a device comprising a third element; a device comprising a first element and a second element; a device comprising a first element and a third element; a device comprising a first element, a second element and a third element; or, a device comprising a second element and a third element. A similar interpretation is intended when the phrase “used in at least one of:” is used herein. Furthermore, as used herein, “and/or” is intended to mean a grammatical conjunction used to indicate that one or more of the elements or conditions recited may be included or occur. For example, a device comprising a first element, a second element and/or a third element, is intended to be construed as any one of the following structural arrangements: a device comprising a first element; a device comprising a second element; a device comprising a third element; a device comprising a first element and a second element; a device comprising a first element and a third element; a device comprising a first element, a second element and a third element; or, a device comprising a second element and a third element.

Referring now to the figures,FIG.1Ais schematic view of gas transport and pressurization system10in a first state, namely, with dynamic one-way valve40in a fully compressed state.FIG.1Bis a schematic view of gas transport and pressurization system10, in a second state, namely, with dynamic one-way valve40in a fully charged state.FIG.2Ais a front elevational schematic view of gas and transport and pressurization system10.FIG.2Bis a side elevational schematic view of gas and transport and pressurization system10. Gas transport and pressurization system or system10generally comprises ram assembly, crank and/or crankcase30, and motor70. The following description should be read in view ofFIGS.1A-2B.

In some embodiments, gas is released from ground2via gas well4by any means known in the art. Gas is fed to ram assembly12from gas well4via conduit or piping6. Ram assembly12generally comprises crankcase30, dynamic valve40, and static valve50(seeFIG.2B). Specifically, gas first enters compartment20. Compartment20generally comprises two concentrically arranged cylinders sealingly connected at either end by a side wall to form a cylindrical sleeve compartment concentrically arranged around static valve50. Compartment20comprises inlet22connected to conduit6and outlet connected to conduit8. Gas flows from ground2, into compartment20via inlet22, and out of compartment20via outlet24. Since gas flowing from ground2is generally much cooler than the compressed gas within static valve50(e.g., 60° F. at 50 psi), gas flow through compartment20results in the cooling of the compressed gas within static valve50. Gas exits compartment20and flows to crankcase or inlet manifold30via conduit8. In some embodiments, system10comprises temperature sensor and transmitter TT operatively arranged at outlet24to detect the temperature of the gas at outlet24and to transmit that temperature to a remote location, for example, to a controller or one or more control valves (seeFIGS.2A-B). In some embodiments, and as shown inFIG.2A, system10comprises control valve XY3fluidly arranged between outlet24and crankcase30(i.e., in conduit8). Control valve XY3is operatively arranged to control the temperature of the gas entering crankcase30. Control valve XY3is operatively arranged to regulate the amount of gas entering crankcase30from outlet24. Since gas flowing from outlet24may have a high temperature, it is desired to regulate that temperature such that it is lower prior to entering crankcase30. As such, control valve XY3, and control valve XY4as will be described in greater detail below, regulates the flow of gas from outlet24to crankcase30thereby regulating the temperature of gas flow to crankcase30. In some embodiments, control valve XY3comprises a throttling valve.

Crankcase30is a pressure rated crankcase and sealingly connected to cylinder38. Crankcase30comprises crankshaft32and piston rod34. Piston36is slidingly engaged in cylinder38and is connected to piston rod34. Crankshaft32is rotated within crankcase30via motor70. In some embodiments, motor70is a hydraulic motor connected to a hydraulic fluid supply and a hydraulic fluid return (seeFIG.2A). Hydraulic fluid flows into hydraulic motor70from the hydraulic fluid supply, and out of hydraulic motor70back to the hydraulic fluid return. Hydraulic motor70converts the hydraulic pressure and flow into toque and angular displacement (rotation), thereby rotating crankshaft32. The speed of hydraulic motor70is adjustable (i.e., faster or slower). In some embodiments, hydraulic motor70is arranged outside of crankcase30(seeFIGS.1A-B). In some embodiments, hydraulic motor70is arranged inside of crankcase30(seeFIG.2A). In some embodiments, lube oil is supplied to crankcase30. In some embodiments, lube oil is supplied to cylinder38. In some embodiments, crankcase30and/or cylinder38is connected to a lube oil reclaim. In some embodiments, the lube oil reclaim comprises oil trap T.

As crankshaft32is rotated within crankcase30, piston rod34converts the angular displacement into linear activation of piston36. Piston36displaces linearly in direction D1and direction D2. Piston36is slidingly and sealingly engaged with cylinder38. In some embodiments, piston36comprises oil or piston rings radially arranged between piston36and cylinder38. Piston36comprises at least one one-way valve. Gas flows from conduit8and into crankcase30. The gas is directed through the one-way valve in piston36, or into the cylinder just aft of piston36(seeFIGS.1A-B). As dynamic vale40is displaced in direction D1, gas is pulled into cylinder38and crankcase30(seeFIG.1A). As dynamic valve40is displaced in direction D2, the gas flows through the one-way valve in piston36and into dynamic valve40. It should be appreciated that the one-way valve in piston36allows gas to flow through piston36in direction D1, but not in direction D2. It should also be appreciated that the one-way valve need not be located on piston36. Instead, and in some embodiments, a one-way valve is arranged in crankcase30. In such embodiments, and as shown inFIG.2A, displacement of piston36in direction D1pulls, by way of vacuum, gas into pressurized crankcase30, and displacement of piston36in direction D2transfers gas from crankcase30to dynamic valve40. This process continues repetitively.

Dynamic valve40is connected to piston36such that as piston36displaces in directions D1and D2, valve40displaces in directions D1and D2. As such, dynamic valve is referred to a s a reciprocating valve. Dynamic valve comprises end42connected to piston36and end44directed toward static valve50. Dynamic valve40is fluidly connected to the one-way valve of piston36. As gas flows through piston36from crankcase30, it enters dynamic valve40. In some embodiments, dynamic valve40comprises one or more valvular conduits, for example, the valvular conduit disclosed in U.S. Pat. No. 1,329,559 (Tesla), which patent is incorporated herein by reference in its entirety. As disclosed in Tesla, a valvular conduit comprises a plurality of impingement loops and center channels that allow fluid (i.e., gas) to flow in a first direction but not a second direction. Dynamic valve40comprises one or more valvular conduits (seeFIGS.2A-B) that allow gas to travel therein in direction D1but not in direction D2. It should be appreciated that dynamic valve40may comprise any suitable one-way valve. It should also be appreciated that the use of one or more valvular conduits in dynamic valve40provides the desired gas pressurization of the present disclosure. In some embodiments, a linear bearing is arranged between cylinder38and dynamic valve40.

As previously described, as piston36displaces in direction D2, gas flows through piston36and into the valvular conduits of dynamic valve40via end42. Gas already arranged in the valvular conduits of dynamic valve40flows out of end44of dynamic valve40(i.e., the gas remains in cylinder38between ends44of dynamic valve40and end52of static valve50). As piston36displaces in direction D1, dynamic valve40“rams” gas forward thereof into static valve50. This can be thought of as collecting or loading gas, as piston36and dynamic valve40displace in direction D2, and pushing or ramming gas, as piston36and dynamic valve40displace in direction D1.

In some embodiments, piston36is arranged concentrically around dynamic valve40, and end42of dynamic valve40is open to crankcase30. In such embodiments, dynamic valve40is sealingly and slidingly connected to piston36. Thus, there is no need for a one-way valve within piston36, as the one or more valvular conduits or one-way valves in dynamic valve40operate to allow gas flow through dynamic valve40in direction D1only.

Static valve50is fixed relative to cylinder38. In some embodiments, static valve50is sealingly connected to cylinder38. Static valve50comprises end52directed toward dynamic valve40and end52through which gas exits ram assembly12. Similar to dynamic valve40, static valve50comprises one or more valvular conduits. As dynamic valve40displaces in direction D1, it forces gas in cylinder38into the valvular conduits of static valve50via end52. Gas that was already in the valvular conduits of static valve50is forced out of static valve50at end54. This process continuously repeats as dynamic valve40reciprocates. It should be appreciated that static valve50may comprise any suitable one-way valve. It should also be appreciated that the use of one or more vascular conduits in static valve50provides the desired gas pressurization of the present disclosure. In some embodiments, system10comprises temperature sensor and transmitter TT operatively arranged at end54to detect the temperature of the gas flowing out of static valve50and to transmit that temperature to a remote location, for example, to a controller or one or more control valves (seeFIGS.2A-B). According to the Ideal Gas Law, pressure is directly related to temperature. Thus, as previously descried, at a fixed volume, as pressure increases temperature increases. As such, as gas pressurizes in cylinder38, dynamic valve40, and static valve50, the temperature thereof rises substantially. By running cooler gas from ground2through compartment20, which is concentrically arranged around static valve50, the gas within cylinder38, dynamic valve40, and static valve50can be cooled.

Gas flows from end54of static valve50and into header60. Gas then flows through check valve62to gas outlet64. Check valve62allows gas to flow in one direction only, from header60to gas outlet64. In some embodiments, header60is connected to control valve XY1. Control valve XY1is a throttling valve and modulates the gas flow, head temperature, and outlet pressure. By adjusting control valve XY1, the pressure and temperature within system10can be adjusted. Thus, when control valve XY1is fully closed, system10will output the highest gas pressure and thus the highest gas temperature. When control valve XY1is fully open, system10will output the lowest gas pressure and thus the lowest gas temperature. In some embodiments, control valve XY1comprises throttling or glove valve. In some embodiments, header60is further connected to control valve XY2. Control valve XY2is a bypass valve for unloading the check valve train. During startup of system10, in order to dissipate high pressure therein, control valve XY2is open (this unloads the forces on the reciprocating mechanisms). In some embodiments, control valve XY2comprises a block or full port ball valve.

In some embodiments, system10may comprise a plurality of ram assemblies, for example, ram assemblies12A-D as shown inFIG.2A. The use of multiple ram assemblies is beneficial because a larger volume of gas can be pressurized. In such embodiments, ram assemblies12A-D are connected to crankcase30and header60. Ram assembles12A-D operate exactly the same as described above. Ram assembly12A shows piston36and dynamic ram40in full compression, namely, end44is arranged substantially proximate to or abuts against end52. Ram assembly12B shows piston36and dynamic ram40in half charge, namely, piston36and dynamic ram40are displaced in direction D2from full compression and end44is spaced apart from end52. Ram assembly12C shows piston36and dynamic ram40in full charge, namely, end44is maximumly spaced apart from end52. Ram assembly12D shows piston36and dynamic ram40in half compression, namely, piston36and dynamic ram40are displaced in direction D1from full charge and end44is spaced apart from end52.

In some embodiments, gas from a second stage gas inlet flows into crankcase30(seeFIG.2A). The second stage gas inlet comprises low temperature gas, for example, from a cryogenic vapor receiver. In some embodiments, system10further comprises control valve XY4fluidly connected between the second stage gas inlet and crankcase30. Control valve XY4is the second stage inlet temperature control. Control valve XY4is operatively arranged to regulate the amount gas from the second stage gas inlet that is fed to crankcase30. The gas from the second stage gas inlet is mixed with gas from outlet24in order to regulate the temperature of the gas entering crankcase30. In some embodiments, control valve XY4comprises a throttling valve.

It should be appreciated that gas inlet4, the second stage gas inlet, the hydraulic fluid supply, the hydraulic fluid return, the oil lubrication supply, the oil lubrication return, are all components arranged in outside system OS (seeFIG.2A). All other components of system10are arranged inside system IS. Furthermore, the primary flow path as shown inFIG.2A, designates the flow path of gas from ground2, through ram assemblies12,12A-D, and to gas outlet64. The control flow path represents the gas temperature modulation elements such as control valves, as well as the oil lubrication system, and the hydraulic fluid supply system, namely, the systems used to act upon the gas flow in system10.

LIST OF REFERENCE NUMERALS