Patent Application
20240151251
Natural gas supplied controls often need to be vented. When natural gas supplied controls are actuated, they must also be vented. Often, they are supplied pressure to open and the internal contents are burped or expelled to reduce pressure and close. If the supply pressure is comprised of hydrocarbons, those hydrocarbons are expelled. This results in undesirably increased emissions. Consequently, there is a need for a new method of supplying and venting of natural gas pneumatic controls.
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:
Several embodiments of Applicant's invention will now be described with reference to the drawings. Unless otherwise noted, like elements will be identified by identical numbers throughout all figures. The invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.
As noted, the solar powered system in
Second, solar powered systems are often more environmentally friendly. This is a benefit as many of the benefits discussed herein are likewise environmentally beneficial.
As shown the system has an array 101. Virtually any type of arrays 101 can be utilized. The arrays 101 are coupled to the charge controller 103 which ensures the battery 102 is properly charged. Virtually any type of battery 102 or charge controller 103 can be used. While one battery 102 is shown, in other embodiments one or more batteries can be used. In one embodiment the battery 102 comprises an OGRE 12 Volt AGM battery. This is for illustrative purposes and should not be deemed limiting.
As noted, the controller 103 can comprise any controller 103 known in the art. In one embodiment the controller 103 comprises a Specialty Concepts ASC 12 Volt controller. This is for illustrative purposes and should not be deemed limiting.
As noted, the array 101 can comprise virtually any type of array. In one embodiment, the array comprises a Rich Solar RS-M150, 150 Watt 12 Volt monocrystalline panel and brackets. This is for illustrative purposes and should not be deemed limiting.
Also shown is the storage tank 104. Virtually any type of tank 104 can be utilized. The contents of the tank 104 will vary depending upon the specific application. The size, capacity, etc. of the storage tank 104 can be adapted depending upon application. The storage tank 104 stores air from the compressor 105. The storage tank 104 allows for a build-up of air such that the compressor 105 need not run continuously.
Coupled to, and downstream of the storage tank 104 is a pneumatic system 106. The pneumatic system 106 can be used for a variety of purposes including venting, opening and closing valves, turning on equipment, etc. The pneumatic system 106 can be coupled to various vessels 120 (not shown in
As can be seen, when needed, the pneumatic system's 106 and operate on and have the pressure relieved using pure air rather than process gasses (such as natural gas and entrained liquids). When necessary to refill the storage tank 104, the battery 102 instructs the air compressor 105 to engage. This causes the air compressor 105 to apply air to the storage tank 104.
The headspace from the vessel 120 often includes the contents from the vessel 120. If the vessel 120 housed methane, for example, methane gas, carbon dioxide, and other gasses can be found in the vessel 120 or the headspace of the vessel 120. These pressurized gasses are referred to herein as produced wet gas. If the pneumatic control system 106 is controlled by these wet gasses (pressurized gasses), for example, then when the pneumatic control system 106 releases pressure, it is releasing the wet gasses. These gases are emitted into the atmosphere causing an increase in emissions. This is undesirable for a variety of reasons. By venting using air, rather than headspace, the emissions are reduced or eliminated. The term pressurized gasses includes gasses as well as entrained fluids within the gasses.
As shown, the SPARC system 100 is coupled to a pneumatic system 106. In
The pneumatic system, in one embodiment, is used to control process operations on a vessel. These process operations can include any process which is typically monitored or controlled by a pneumatic system. One embodiment will be discussed wherein the pneumatic controls operate dump controls. This is for illustrative purposes only, however, and should not be deemed limiting.
As shown the pneumatic system 106 comprises dump controls 107 and dumps 108. In the embodiment depicted, the vessel 120 collects water and oil, each of which must be occasionally dumped to reduce a fluid level. In the embodiment depicted, the SPARC system operates to control the dump controls 107 and the dumps 108. These dumps 108 can comprise any subsequent location to house or remove liquid previously stored in the vessel 120. The dumps 108, for example, can comprise another storage vessel. The dumps 108, in one embodiment, assist by partially emptying the vessel 120 to a desired fluid level. When the desired fluid level is reached, the dump controls 107 are closed again and the vessel 120 can continue to collect fluid. In the embodiment depicted, the dumps controls 107 and the dumps 108 operate from air from the SPARC as opposed to wet gas.
The dump controls 107 can comprise a valve, such as a gate valve, which only opens upon exceeding a specified amount of pressure. In one embodiment the dump controls 107 comprises a pneumatic valve which can be controlled via pressure. Thus, when a specific condition is met, such as pressure of the pneumatic system 106, pressure of the vessel 120, fluid level of a vessel 120, etc., the dump controls 107 can open to relieve or burp the built-up pressure of the pneumatic system 106 as well as partially empty the vessel 120. In one embodiment, for example, the dump control 107 comprises a 25 pound spring which holds the dump gate valve closed. When greater than 25 pounds of pressure is supplied to the dump controls 107, then the dumps controls 107 can open. This simultaneously partially lowers the level of the vessel 120 as well as relieving the pressure by venting the gas. When the SPARC system is operational, the dump controls 107 are operating and releasing air which can be relieved to the atmosphere. In other embodiments, however, the dump controls 107 are in fluid connection with a flare, incinerator, or other equipment which destroys the vented gas from the dump controls 107.
In operation, when a vessel 120 needs to be controlled, such as a valve being opened, the pneumatic system 106 supplies pressure to open the valve. Once opened, however, the pressure within the pneumatic system 106 needs to be relieved. The gas used to open the valve on the vessel 120 is relieved via a switch or equivalent.
The pneumatic system 106, as shown, also comprises a supply regulator 109, and a tank regulator 115. The tank regulator 115 drops the pressure of the headspace to a desirable operating pressure. In one embodiment the tank regulator 115 drops the pressure to about 75 psi. In some embodiments the system further includes a supply regulator 109 which can further reduce the pressure to a reduced operating pressure. In one embodiment the supply regulator 109 has a pressure of about 25 psi. The specific operating pressure will be dependent upon the pressure of the vessel 120, the pressure and desired pressure of the pneumatic system 106, etc.
As depicted, the pneumatic system 106 also comprises a check valve 110. This ensures that natural gas will not undesirably enter the SPARC system 100. As will be shown below, in some embodiments, the SPARC system 100 can operate on either air or the headspace of the vessel 120. The check valve 110 ensures that wet gas from the vessel 120 cannot enter the SPARC system. Getting wet gas in the SPARC system can plug or damage the SPARC system.
As shown in
As noted, in one embodiment, and as depicted, the pneumatic system 106 can be powered by either the SPARC system 100, or the pressure associated with the vessel 120. This allows flexibility in the system. If, for example, the SPARC system 100 malfunctions or is down, the pneumatic system 106 would then switch and be powered by the pressure associated with the vessel 120. If the vessel 120 has natural gas, as an example, the pneumatic system 106 would then function and operate on natural gas.
As can be seen in
As noted, in one embodiment, because the system vents using air as opposed to the produced wet gas, or the headspace, emissions are eliminated. This results in decreased emissions, which is environmentally beneficial. However, it is also economically beneficial as this results in more gas downstream in the sales line which can be sold. Thus, rather than using some of the produced wet gas for venting, which results in waste and unwanted emissions, this product is conserved and subsequently sold.
Turning to
Similarly,
There are considerable environmental benefits and impacts when using air for pneumatic controls as opposed to wet gas. Less wet gas is released. Further, less emissions result. Aside from environmental benefits, there are also economic benefits. This wet gas which was previously released, is now captured and sold. A waste stream is eliminated.
When scaled, these measures result in a significant reduction of emissions. Assuming 200 devices, this results in 20,000 mTCO2epy. This is the amount of carbon dioxide which is no longer emitted. As noted, aside from reduced emissions, the ability to capture more methane results in significant increases in revenue.
Turning now to
As noted above, venting pneumatic systems can result in gas, wet gas, and other components being released to the atmosphere. As shown above, a high bleed system results in more gas being released than a low bleed system. While low bleed systems, such as low bleed mizers are available, they are often prohibitively expensive. Thus, there is a need to replace a high bleed system with a cost-effective low bleed system. The valve discussed herein can comprise virtually any valve in the art. It can include low bleed or constant bleed mizers, control valves, etc. In one embodiment, however, the valve comprises a three-way valve which allows venting to the atmosphere, but also venting to a burner, flare, etc. Thus, rather than releasing gas directly to the atmosphere, this vented gas can be routed to a burner or an incinerator. In many embodiments it is preferable to incinerate or burn a gas rather than vent it straight to the atmosphere. There are many benefits from this including positive environmental impact, reduced odor, etc. Further, often the burner or flare is used for other purposes such as to heat a stream. Therefore, the energy in the vent gas is captured as opposed to simply being released to the atmosphere.
The system discussed herein can be added where traditional mizers have been previously utilized. However, rather than requiring a $500 mizer valve, the system allows for the utilization of a traditional pneumatic valve or switch which can cost about $100. Thus, this system results in considerable cost savings.
Placing the valving or switch system, in some embodiments, is difficult as there is not a ready location to store and house the valve. Consequently, in one embodiment a mount 112 is disclosed. As shown in
As shown, the mount 112 has a plurality of mounting holes 114. The mounting holes 114 can be used to couple the mount 112 to equipment or structure to house and support the mount 112. While two mounting holes 114 are shown, this is for illustrative purposes only and should not be deemed limiting. There can be a single mounting hole 114, or there can be a plurality of mounting holes 114. Further, while the mounting holes 114 are shown as being located in the outer periphery of the void 111, this is for illustrative purposes and should not be deemed limiting. Virtually any device can be used to couple the mount 112 to equipment or a structure, including but not limited to, bolts, screws, wiring, etc.
As shown the mount has a vertical component 116 and a horizontal component 113. In one embodiment the horizontal component 113 is approximately perpendicular to the vertical component 116. In one embodiment the vertical component 126 and the horizontal component 113 are integrally made as a single unit, whereas in other embodiments they comprise separate and distinct components which are coupled together.
As shown the horizontal component 113 has slots 117 which allow the coupler 112 to couple to a switch 119 (shown in
As shown the vertical component 126 has a circular void 111. It has a curved top. This is for illustrative purposes and should not be deemed limiting. As an example, while the void 111 is depicted as circular, in other embodiments the void 111 can comprise a square, triangular, or other polygonal shape.
The horizontal portion 113, as depicted, extends out and approximately perpendicular to the vertical portion 126, as shown. In the embodiment depicted, there are two fins which extend out from the vertical portion 126. The fins create an internal cavity in which the switch 119 can be inserted and coupled. The fins also have coupling slots 117 which provide a location for the switch 119 to couple to the fins of the horizontal portion 113. In other embodiments, however, the mount 112 will not have external fins. Regardless of the configuration, the mount 112 provides a location for which to couple to equipment and to a switch/valve 119.
The size and shape of the mount 112 can vary depending upon the location to be mounted as well as the size, shape, and type of the switch 119. In
The mount 112 can comprise virtually any material. It can comprise plastic, rubber, metal, and combinations thereof. The mount 112 can be manufactured via any method known in the art including 3D printing, molding, casting, etc.
As noted, the mount 112 provides a novel opportunity to house and secure a switch 119. In one embodiment, the switch 119 is a three-way switch which allows selection of the location of the vented gas.
The mount 112 allows for conversion of an off-the-shelf pneumatic valve to be converted and utilized as a low bleed system. A high bleed system can be converted to a low bleed system by utilization of the mount 112.
In one embodiment the mount 112 utilizes a switch 119 which is in fluid communication with a SPARC system as described above. In such embodiments, the emissions are reduced to zero as the system utilizes air as opposed to wet gas.
Turning to
In one embodiment, the vessel 120 comprises a float which compares the desired fluid level to the actual floating level. If the actual floating level is greater than the desired float level, then the vessel 120 needs to be partially dumped to lower the fluid level. This can be accomplished via various methods known in the art. One such method involves a ball float which is coupled to a vessel float lever. The vessel float lever 126 extends outward from the vessel 120. If the fluid level is too high, the end of the vessel float lever 126 applies a downward force. This downward force is felt by the switch lever 127. In one embodiment the switch lever 127 comprises a contact 130. The contact 130 is the point of the switch lever 127 which receives contact from the vessel float lever 126. The contact 130 can comprise virtually any material, including but not limited to, plastic, rubber, metal, and combinations thereof.
When a downward force is applied at one end of the switch lever 127, the switch lever 127 pivots via the lever pivot 129. Thus, a downward force upon the switch lever 127 forces the switch lever 127 downward.
As shown, and in one embodiment, the pneumatic switch 119 has a switch peg 128. The switch peg 128 extends beyond the body of the pneumatic switch 119. In one embodiment, the position of the switch peg 128 determines which output is aligned with the input. In one embodiment the switch peg 128 comprises a biasing mechanism which forces the switch peg 128 into an extended position. The biasing mechanism can comprise a spring, for example. When the switch peg 128 is pressed downward, this overcomes the biasing of the biasing mechanism, and changes the configuration of the switch. As noted, in one embodiment, the switch 119 is in a closed position when the switch peg 128 is in the extended position. However, when pressed downward, the pneumatic supply line 121 is coupled to the pneumatic supply out line 123. The pneumatic supply out line 123, which was previously not pressurized, becomes pressurized as the switch 119 is opened.
As can be seen, the switch peg 128, and its interaction with the switch lever 127 can change the configuration of the switch 119. As shown, the vessel float lever 126 extends through the void 111 in the mount 112. It can then engage with the switch lever 127.
When the switch peg 128 is pressed downward, and the switch 119 allows flow through the switch 119 and into the pneumatic supply out 123, pressure is then applied to the dump control 107. As noted above, in some embodiments the dump control 107 has a biasing mechanism such as a spring, for example, which forces the dump control 107 to remain in the closed position until pressure overcomes the biasing mechanism. When the pneumatic supply out 123 overcomes the biasing mechanism, the dump valve 125 moves from closed to open. When this occurs, fluid from the vessel 120 is allowed to flow through the valve 125 and in the shown line. As demonstrated, the line is in fluid communication with the dumps 108. The dumps 108 can comprise another holding tank, for example.
In one embodiment, the switch 119 keeps the dump control 107 in an open position to partially dump the vessel 120 until the desired level within the vessel 120 has been obtained. When this occurs, the vessel float lever 126 will no longer apply a downward force upon the switch lever 127, and accordingly the switch peg 128. The biasing mechanism will then force the switch peg 128 into the extended position. This cuts off flow from the pneumatic supply 121 and the pneumatic supply out 123. The dump control 107 is no longer under pressure, and the dump valve 125 which controls fluid flow out of the vessel 120 in this location shuts off, stopping fluid flow to the dumps 108.
In one embodiment, with the switch peg 128 in the extended position, the pneumatic supply out 123 is coupled to the pneumatic discharge 124. In one embodiment the pneumatic discharge 124 is open to the atmosphere. Thus, when the switch peg 128 returns to the extended position, due to the biasing mechanism, pressure is relieved from the pneumatic supply out 123.
In one embodiment the pneumatic discharge 124 further comprises a three-way valve which can direct the discharged gas either to the atmosphere, or to a flare, incinerator, etc.
As can be seen, the mount 112 and the switch 119 can convert a constant bleed system to a low, intermittent bleed, system. As shown previously, this can reduce emissions and waste by 90%. This turns a waste stream into a stream which can be used or sold.
Without the mount 112 and switch 119 described herein, a previously continuous, high-bleed system, allowed a constant bleeding of the pneumatic line. However, with the low bleed approach the emissions and loss are substantially decreased, as shown above. Further, this can be accomplished at a much lower capital cost than traditional mizers. Thus, the system and method discussed herein has significant and profitability benefits.
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
The present invention claims priority to U.S. Provisional Application No. 63/546,068 filed Oct. 27, 2023, U.S. Provisional Application No. 63/541,787 filed Sep. 30, 2023, U.S. Provisional Application No. 63/464,080 filed May 4, 2023, and U.S. Provisional Application No. 63/382,788 filed Nov. 8, 2022, the entirety of all of which are hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63546068 | Oct 2023 | US | |
| 63541787 | Sep 2023 | US | |
| 63464080 | May 2023 | US | |
| 63382788 | Nov 2022 | US |
