Advantages of Trailer-Mounted Gas Turbines Configuration for Electric Fracturing and Emissions Reduction with De-Flaring
Authors: Cruz M. J. Lozano , Mantini A. 
Published: January 2025

Electric fracturing or "Efrac" capacity in the USA has doubled since 2019, around 15% of the overall fracturing capacity, 18M hydraulic horsepower (hhp), today is electric; it's expected that by 2030 Efrac will double to 30%. This paper presents the typical configuration and primary components of a trailer-mounted gas turbine with a particular focus on the LM2500+G4, the most deployed single large trailer-mounted gas turbine in Efrac, which has been used in this space since 2013. The LM2500+G4 is a lightweight aeroderivative gas turbine with a power output of 33MW. This paper provides technical insights on the primary equipment components of a trailer-mounted gas turbine as well as the operational, economic, and environmental benefits. Additionally, it discusses the application of the trailer-mounted turbine as a solution to reduce emissions and flared gas at the well site.

An assessment of the overall benefits of using a single large gas turbine is performed considering typical operational conditions. Some of the benefits presented are fuel flexibility, noise, power density and footprint, fuel savings and emissions. Specific simulation of power density improvements and fuel savings is performed, and it is compared to the traditional approach of using diesel engines. This document presents the emissions evaluation when using the LM2500+G4 and introduces the impact of the NovaLT16, a dry-low-NOx industrial gas turbine when used to power a 30,000 hhp fracturing fleet at 70% pumping time. Further emissions reduction is presented considering the use of associated or flare gas as main fuel for the gas turbine.

There are significant, quantifiable benefits when using a trailer-mounted LM2500+G4 gas turbine to power an electric fracturing fleet. Fuel savings for a 44,000 hhp fracturing fleet powered by a single large gas turbine are estimated at $2.0M USD or 87% per pad in 17 days at 70% pumping time when compared to 22 diesel engines and respective fuel consumption. A trailer-mounted gas turbine also reduces noise by 20% and increases power density through footprint reduction of fracturing pumps at site by 56%.

The fuel flexibility ranging from 800-1300 BTU/scf allows the use of various gaseous fuels as the main fuel. Efrac when using natural gas turbines can reduce NOx emissions up to 90% while reducing CO2 emissions up to 25%.

A case study is presented assuming the use of associated gas as primary fuel (1,150 BTU/scf) achieving 65% CO2eq reduction. This study shows the primary components of a single larger trailer-mounted gas turbine for Efrac operations and the benefits of using this approach. The operational, economic, and environmental benefits associated with a trailer-mounted configuration are presented. It also shows the emissions reduction potential in CO2eq for aeroderivative and DLN gas turbines when using high hydrocarbons content fuels (C2+). The study is applicable for potential similar sites that could benefit by utilizing an electric and cleaner frac fleet technology approach.