EP-4739973-A1 - EXHAUST HEAT RECOVERY FOR A MOBILE POWER GENERATION SYSTEM

Abstract

An exhaust air connection receives exhaust air from a separate power generation system. A heat transfer assembly transfers thermal energy from the exhaust air to a source fluid to generate a heated source fluid. A valve regulates a flow of the exhaust air from the exhaust air connection to a heat recovery flow path disposed with the heat transfer assembly and to a bypass flow path bypassing the heat transfer assembly. A control system operates the valve to regulate the flow of the exhaust air. An exhaust releases to atmosphere the exhaust air from at least one of the heat recovery flow path and the bypass flow path.

Inventors

• VAHSHOLTZ, Matthew, James
• HIRVONEN, MIKA
• RODRIGUEZ, Steve
• VANN, Brett

Assignees

• Typhon Technology Solutions, LLC

Dates

Publication Date

20260513

Application Date

20230705

Claims (20)

1. 1. An exhaust heat recovery apparatus comprising: an exhaust air connection configured to receive exhaust air from a separate power generation system; a heat transfer assembly configured to transfer thermal energy from the exhaust air to a source fluid to generate a heated source fluid; a valve configured to regulate a flow of the exhaust air from the exhaust air connection to a heat recovery flow path disposed with the heat transfer assembly and to a bypass flow path bypassing the heat transfer assembly; a control system configured to operate the valve to regulate the flow of the exhaust air; and an exhaust configured to release to atmosphere the exhaust air from at least one of the heat recovery flow path and the bypass flow path.
2. 2. The exhaust heat recovery apparatus of claim 1, wherein the control system operates the valve to maintain a temperature of the heated source fluid within predetermined parameters.
3. 3. The exhaust heat recovery apparatus of claim 1, wherein the control system is further configured to regulate a flow of the source fluid through the heat transfer assembly to maintain a temperature of the heated source fluid within predetermined parameters.
4. 4. The exhaust heat recovery apparatus of claim 1, further comprising a second heat transfer assembly configured to transfer thermal energy from the heated source fluid to a second flow of air to generate a heated air flow, or a separate heated liquid flow.
5. 5. The exhaust heat recovery apparatus of claim 1, further comprising an actuator to actuate the valve, wherein the control system and the actuator are powered by the separate power generation system.
6. 6. The exhaust heat recovery apparatus of claim 1, wherein the control system is further configured to: determine at least one of a rate of the flow of the exhaust air and a temperature of the exhaust air; and based on the determination, operate the valve to regulate the flow of the exhaust air to the heat recovery flow path disposed with the heat transfer assembly and release excess exhaust air to atmosphere via the bypass flow path and the exhaust.
7. 7. The exhaust heat recovery apparatus of claim 1, wherein in the heat recovery flow path, the exhaust air from the exhaust air connection flows through the heat transfer assembly and exits the exhaust heat recovery apparatus via the exhaust, and in the bypass flow path, the exhaust air from the exhaust air connection bypasses the heat transfer assembly by flowing through a bypass duct and exits the exhaust heat recovery apparatus via the exhaust.
8. 8. The exhaust heat recovery apparatus of claim 1, wherein the exhaust air connection is detachably coupled to an exhaust stack of the separate power generation system in an operation mode, and wherein the exhaust heat recovery apparatus is separately and independently movable from the separate power generation system in a transportation mode.
9. 9. A system for heating source fluid, the system comprising: a first transport including a power generation system; and a second transport including: a base frame; an exhaust air connection mounted to the base frame and configured to receive exhaust air from the power generation system; a heat transfer assembly mounted to the base frame and configured to transfer thermal energy from the exhaust air to a source fluid to generate a heated source fluid; a control system configured to operate a valve to regulate a flow of the exhaust air from the exhaust air connection to a heat recovery flow path disposed with the heat transfer assembly and to a bypass flow path bypassing the heat transfer assembly; and an exhaust mounted to the base frame and configured to release to atmosphere the exhaust air from at least one of the heat recovery flow path and the bypass flow path.
10. 10. The system of claim 9, wherein the first transport includes a gas turbine, an exhaust collector coupled to an exhaust of the gas turbine, and an exhaust stack coupled to the exhaust collector to release exhaust air from the gas turbine to atmosphere.
11. 11. The system of claim 10, wherein the exhaust air connection is detachably coupled to the exhaust stack of the first transport in an operation mode, and wherein the first and second transports are separately and independently movable in a transportation mode.
12. 12. The system of claim 9, further comprising a second heat transfer assembly configured to transfer thermal energy from the heated source fluid to a second flow of air to generate a heated air flow.
13. 13. The system of claim 9, wherein the control system in the second transport is powered by the power generation system of the first transport.
14. 14. The system of claim 9, wherein the control system in the second transport is further configured to: determine at least one of a rate of the flow of the exhaust air and a temperature of the exhaust air; and based on the determination, operate the valve to regulate the flow of the exhaust air to the heat recovery flow path disposed with the heat transfer assembly and release excess exhaust air to atmosphere via the bypass flow path and the exhaust.
15. 15. The system of claim 9, wherein the control system operates the valve to maintain a temperature of the heated source fluid within predetermined parameters.
16. 16. The system of claim 9, wherein the control system is further configured to regulate a flow of the source fluid through the heat transfer assembly to maintain a temperature of the heated source fluid within predetermined parameters.
17. 17. A method comprising: receiving, at an exhaust air connection, a flow of exhaust air from a power generation system mounted on a separate power generation transport; transferring, in a heat transfer assembly, thermal energy from the received exhaust air to a source fluid to generate a heated source fluid; operating a valve to regulate the flow of the exhaust air from the exhaust air connection to a heat recovery flow path disposed with the heat transfer assembly and to a bypass flow path bypassing the heat transfer assembly; maintaining a temperature of the heated source fluid within predetermined parameters by operating the valve; releasing to atmosphere, via an exhaust, the exhaust air from at least one of the heat recovery flow path and the bypass flow path; and discharging the heated source fluid from the heat transfer assembly.
18. 18. The method of claim 17, wherein maintaining the temperature of the heated source fluid within the predetermined parameters further comprises maintaining the temperature of the heated source fluid at a predetermined target temperature.
19. 19. The method of claim 17, further comprising: receiving a flow of the heated source fluid from the heat transfer assembly; and transferring, in a second heat transfer assembly, thermal energy from the received heated source fluid to a second flow of air to generate a heated air flow.
20. 20. The method of claim 17, further comprising receiving power from the power generation system to operate the valve.

Description

EXHAUST HEAT RECOVERY FOR A MOBILE POWER GENERATION SYSTEM TECHNICAL FIELD [0001] Embodiments of the invention generally relate to exhaust heat recovery, and more particularly to an exhaust heat recovery transport attached to a power generation transport and using the exhaust of the power generation transport for heat transfer. BACKGROUND [0002] Hydraulic fracturing has been commonly used by the oil and gas industry to stimulate production of hydrocarbon wells, such as oil and/or gas wells. Hydraulic fracturing, sometimes called “fracing” or “fracking,” is the process of injecting fracturing fluid, which is typically a mixture of water, sand, and chemicals, into the subsurface to fracture the subsurface geological formations and release otherwise encapsulated hydrocarbon reserves. The fracturing fluid is typically pumped into a wellbore at a relatively high pressure sufficient to cause fissures within the underground geological formations. Specifically, once inside the wellbore, the pressurized fracturing fluid is pressure pumped down and then out into the subsurface geological formation to fracture the underground formation. A fluid mixture that may include water, various chemical additives, and proppants (e.g., sand, or ceramic materials) is pumped into the underground formation to fracture the underground formation and promote the extraction of the hydrocarbon reserves, such as oil and/or gas. [0003] Implementing large-scale fracturing operations at well sites typically require extensive investment in equipment, labor, and fuel. For instance, a typical fracturing operation uses a variety of fracturing equipment, numerous personnel to operate and maintain the fracturing equipment, large amounts of fuel to power the fracturing operations, and large volumes of fracturing fluid. Moreover, a single frac fleet may include 20+ semi-trailer loads of equipment including power generation trailers, fracturing trailers, hydration and blender trailers, sand silos, chemical storage containers, iron, hoses, cabling, data van, etc. It is desirable to improve operation and efficiency of the fracturing operations. SUMMARY [0004] The following presents a simplified summary of the disclosed subject matter in order to provide a basic understanding of some embodiments of the subject matter disclosed herein. This summary is not an exhaustive overview of the technology disclosed herein. It is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later. [0005] In some embodiments, an exhaust heat recovery apparatus is provided which comprises: an exhaust air connection configured to receive exhaust air from a separate power generation system; a heat transfer assembly configured to transfer thermal energy from the exhaust air to a source fluid to generate a heated source fluid; a valve configured to regulate a flow of the exhaust air from the exhaust air connection to a heat recovery flow path disposed with the heat transfer assembly and to a bypass flow path bypassing the heat transfer assembly; a control system configured to operate the valve to regulate the flow of the exhaust air; and an exhaust configured to release to atmosphere the exhaust air from at least one of the heat recovery flow path and the bypass flow path. [0006] In some embodiments, a system for heating source fluid is provided which comprises: a first transport including a power generation system; and a second transport. The second transport includes: a base frame; an exhaust air connection mounted to the base frame and configured to receive exhaust air from the power generation system; a heat transfer assembly mounted to the base frame and configured to transfer thermal energy from the exhaust air to a source fluid to generate a heated source fluid; a control system configured to operate a valve to regulate a flow of the exhaust air from the exhaust air connection to a heat recovery flow path disposed with the heat transfer assembly and to a bypass flow path bypassing the heat transfer assembly; and an exhaust mounted to the base frame and configured to release to atmosphere the exhaust air from at least one of the heat recovery flow path and the bypass flow path. [0007] In some embodiments, a method for heating source fluid is provided which comprises a plurality of steps. The steps include a step of receiving, at an exhaust air connection, a flow of exhaust air from a power generation system mounted on a separate power generation transport; and a step of transferring, in a heat transfer assembly, thermal energy from the received exhaust air to a source fluid to generate a heated source fluid. The steps further include a step of operating a valve to regulate the flow of the exhaust air from the exhaust air connection to a heat recovery flow path disposed with the heat tr