Using Advanced Small Modular Reactors in Oilfield Operations

TECHNICAL FIELD

The present disclosure relates generally to systems and methods utilizing advanced small modular reactors (SMRs) in oilfield applications. More specifically, this disclosure relates to utilizing SMRs in electric hydraulic fracturing operations.

BACKGROUND

Natural resources (e.g., oil or gas) residing in a subterranean formation can be recovered by driving resources from the formation into a wellbore using, for example, a pressure gradient that exists between the formation and the wellbore, the force of gravity, displacement of the resources from the formation using a pump or the force of another fluid injected into the well or an adjacent well. A number of wellbore servicing fluids can be utilized during the formation and production from such wellbores. For example, in embodiments, the production of fluid in the formation can be increased by hydraulically fracturing the formation. That is, a treatment fluid (e.g., a fracturing fluid) can be pumped down the wellbore to the formation at a rate and a pressure sufficient to form fractures that extend into the formation, providing additional pathways through which the oil or gas can flow to the well. Subsequently, oil or gas residing in the subterranean formation can be recovered or “produced” from the well by driving the fluid into the well. During production of the oil or gas, substantial quantities of produced water, which can contain high levels of total dissolved solids (TDS) can also be produced from the well, and a variety of exhaust gases and flare gases conventionally sent to flare can be formed. For example, oil and gas wells produce oil, gas, and/or byproducts from subterranean formation hydrocarbon reservoirs. A variety of subterranean formation operations are utilized to obtain such hydrocarbons, such as drilling operations, completion operations, stimulation operations, production operations, enhanced recovery operations, and the like. Such subterranean formation operations typically use a large number of vehicles, heavy equipment, and other apparatus (collectively referred to as “machinery” herein) in order to achieve certain job requirements, such as treatment fluid pump rates. Such equipment may include, for example, pump trucks, sand trucks, cranes, conveyance equipment, mixing machinery, and the like. Many of these operations and machinery utilize combustion engines that produce exhaust gases (e.g., including carbon dioxide (CO₂)/greenhouse gas emissions) that can be emitted into the atmosphere.

BRIEF SUMMARY OF THE DRAWINGS

For a more complete understanding of this disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

FIG. 1 is a schematic flow diagram of a system, according to embodiments of this disclosure;

FIG. 2 is a schematic flow diagram of a system, according to embodiments of this disclosure;

FIG. 3 is a schematic flow diagram of a system, according to embodiments of this disclosure;

FIG. 4A is a schematic flow diagram of a system, according to embodiments of this disclosure;

FIG. 4B is a schematic flow diagram of a system, according to embodiments of this disclosure; and

FIG. 5 is a schematic flow diagram of a system, according to embodiments of this disclosure.

While embodiments of this disclosure are depicted and described and are defined by reference to example embodiments of the disclosure, such references do not imply a limitation on the disclosure, and no such limitation is to be inferred. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those skilled in the pertinent art and having the benefit of this disclosure. The depicted and described embodiments of this disclosure are examples only, and not exhaustive of the scope of the disclosure.

DETAILED DESCRIPTION

Illustrative embodiments of the present invention are described in detail herein. In the interest of clarity, not all features of an actual implementation may be described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions may be made to achieve the specific implementation goals, which may vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure.

Throughout this disclosure, a reference numeral followed by an alphabetical character refers to a specific instance of an element and the reference numeral alone refers to the element generically or collectively. Thus, as an example (not shown in the drawings), widget “1a” refers to an instance of a widget class, which may be referred to collectively as widgets “1” and any one of which may be referred to generically as a widget “1”. For example, reference to hydrogen usage apparatus 70 can, in instances, include hydrogen combustion apparatus 70A, hydrogen fuel cell(s) 70B, hydrogen storage apparatus 70C, or a combination thereof.

To facilitate a better understanding of the present disclosure, the following examples of certain embodiments are given. In no way should the following examples be read to limit, or define, the scope of the disclosure. Embodiments described below with respect to one implementation are not intended to be limiting.

Carbon dioxide (CO₂) capture technologies can be expensive to implement and operate. The energy-intensive processes involved in capturing, separating, and compressing CO₂from exhaust (e.g., flue) gases can conventionally result in additional costs for power plants and industries. CO₂capture processes often require a considerable amount of energy, which can increase the cost of electricity generation and make it less economically attractive to capture CO₂. The regeneration of CO₂-sorbent is another challenge. The sorbent conventionally utilized in CO₂capture technologies must be regenerated after it has captured CO₂. This process typically requires heat, which can add to the energy consumption of CO₂capture. The scaling up of conventional CO₂capture technologies to commercial scale can also be challenging and expensive. Herein disclosed are systems and methods for reducing an amount of carbon dioxide produced at a wellsite, thus reducing the need for capturing CO₂from exhaust gases.

Herein disclosed are equipment, systems and methods for combining nuclear energy from Small Modular Reactor (SMR) technology in oilfield operations. In disclosed embodiments, SMR technology can be utilized in combination with electric hydraulic fracturing technology.

Advanced Small Modular Reactor (SMR) technology has advanced significantly in the latest iterations of nearly commercial designs. As described further hereinbelow, SMRs are a proposed class of nuclear fission reactors, smaller than conventional nuclear reactors, which can be built in one location (such as a factory), then shipped, commissioned, and operated at a separate site (e.g., proximate a wellsite for use in oilfield operations). This technology enables the use of these SMRs for many applications that have not heretofore been realistic. Concomitantly, the attempt to decarbonize numerous industries has intensified, and the oil field has also begun planning for decarbonization of oilfield operations, such as drilling and completions. This disclosure couples these efforts into a novel method of decarbonizing drilling, completions, stimulation, well rework, and enhanced oil production operations.

As described herein, an SMR can be utilized to provide energy to oilfield operations that may include, but are not limited to, drilling, completions, fracturing, stimulation, well rework, production operations and treatments, and/or enhanced oil recovery for the purpose of reducing carbon emissions, lowering costs, and/or meeting regulatory requirements. In embodiments, electricity can be generated directly, by the use of hydrogen generated from methane, H₂S, or water by reformation, electrolysis, or any advanced technique as may be developed to do so. In embodiments, existing steam generation technologies or any method of heat to electric capture technology can be utilized to make electricity. In embodiments, hydrogen generated by any of the aforementioned methods can be utilized to enrich and/or replace natural gas, such that the combined or substantially pure hydrogen gas may be used in oilfield operations to produce lower carbon emissions.

No SMR has heretofore ever been used to power oilfield drilling, completion, stimulation, well rework, or production operations. Furthermore, no SMR has heretofore been directly used to generate hydrogen, electricity or steam for such operations. According to this disclosure, an SMR may also be used to generate power to produce and/or transport materials for the aforementioned operations.

Utilizing SMR technology in oilfield operations, as disclosed herein, in embodiments combined with electric hydraulic fracturing technology can allow a very high percentage reduction, up to 100%, of the carbon dioxide currently emitted to drill for, complete, stimulate, and/or operate oil, natural gas, oil mining, and/or synthetic oil operations.

Herein disclosed is a method comprising: utilizing an advanced small modular reactor (SMR) to produce (e.g., mechanical and/or electrical) energy for (i.e., to “power”) or otherwise facilitate one or more oilfield operations. The one or more oilfield operations can comprise any oilfield operations, such as, and without limitation, drilling, completions, fracturing, stimulation, rework, production and/or enhanced oil recovery operations and treatments.

Utilizing the SMR to produce energy for oilfield operations can comprise utilizing an SMR to provide steam and utilizing the steam to produce electricity, and utilizing the electricity in the one or more oilfield operations. For example, with reference to FIG. 1, which is a process flow diagram of a method I, according to embodiments of this disclosure, an SMR 10 can be utilized to produce steam 15. As detailed further hereinbelow, the SMR 10 can comprise one or more nuclear reactor(s) or cores 11 configured to produce heat 12 via fission of a nuclear material. SMR 10 can further comprise steam generation apparatus 13 configured to produce steam 15 from the heat 12 and water 14. Utilizing the steam 12 to produce electricity 35 can further comprise producing rotational energy 25 by introducing the steam 15 into one or more steam turbines 20 and converting the rotational energy 25 to electricity 35 in electrical generation equipment 30. A depicted in the embodiment of FIG. 1, the method of this disclosure can further include introducing the electricity 35 produced in the electrical generation equipment 30 to a power distribution/power management/local grid (referred to hereinafter simply as a “local grid” or “power management”) configured to condition the electricity 35 to provide conditioned electricity 45 and distribute the electricity 45 to the location of the one or more oilfield operations, for example, at one or more wellsites, such as a first wellsite 50A, a second wellsite 50B, a third wellsite 50C . . . an n^thwellsite 50n depicted in FIG. 1.

The local grid 40 can be proximal one or more wellsites 50a to 50n at which the one or more oilfield operations are performed. For example, the local grid 40 can be centrally located, with wellsites 50a . . . 50n arranged therearound, in embodiments.

In embodiments, an SMR 10 can be utilized to power steam 15 generation to produce electricity 35 that can be stored in advanced batteries near the oilfield drilling, completion, stimulation, well rework, or production site (e.g., near one or more of wellsites 50a to 50n) to power operations at these sites. In embodiments, an SMR 10 can be utilized to power steam 15 generation to produce electricity 35 from steam engines and turbines 20 by transporting the steam 15 to distributed sites in proximity to the steam production/steam turbine(s) 20, and generating the electricity 35 on site.

Utilizing the electricity 35/conditioned electricity 45 in the one or more oilfield operations can further comprise utilizing the electricity 35/45 for electrolysis of water to produce product hydrogen, and utilizing the hydrogen in the one or more oilfield operations. For example, as depicted in FIG. 2, which is a process flow diagram of another system II according to this disclosure, a method of this disclosure can further include utilizing the electricity 35/conditioned electricity 45 for electrolysis of water 46 in electrolysis apparatus 60 to produce product hydrogen 65 and oxygen 66. The product hydrogen 65 can be utilized in the one or more oilfield operations (e.g., the product hydrogen 65 can be utilized in hydrogen usage apparatus 70 to provide electrical and/or mechanical power for the one or more oilfield operations. For example, as depicted in FIG. 2, utilizing the hydrogen 65 in the one or more oilfield operations can comprise combusting the hydrogen 65 in hydrogen combustion apparatus 70A, utilizing the hydrogen 65 in one or more fuel cells 70B, storing the hydrogen 65 for later use in hydrogen storage 70C (e.g., one or more batteries), or a combination thereof. The hydrogen combustion apparatus 70A can be configured for the combustion of the hydrogen 65 alone or in combination with natural gas, thus reducing an amount of carbon dioxide produced via the combusting. The hydrogen fuel cell(s) 70B can be configured to produce electricity for the one or more oilfield operations. The hydrogen storage 70C can be configured to store the hydrogen 65 prior to the use thereof to power (e.g., oilfield equipment 51 of) the one or more oilfield operations.

In embodiments, SMR 10 can thus be utilized to power electrolysis 60 of water 46 to hydrogen 65 and oxygen 66, and the hydrogen 65 subsequently used to reduce carbon dioxide from internal combustion engines (e.g., of hydrogen combustion 70A). In embodiments, SMR 10 can be utilized to power electrolysis 60 of water 46 to hydrogen 65 and oxygen 66, and the hydrogen 65 can be utilized in one or more hydrogen fuel cells 70B to power operations. In embodiments, SMR 10 can be utilized to power electrolysis 60 of water 46 to hydrogen 65 and oxygen 66, and the hydrogen 65 used to generate electricity that is stored in batteries (e.g., hydrogen storage, such as batteries, 70C) to power oilfield operations. Batteries of hydrogen storage 70C can be stationary or portable. That is, the stored hydrogen 65 can be utilized at the wellsite 50a to 50n at which the hydrogen 65 was produced/stored, or can be utilized at another wellsite 50a to 50n.

With reference to FIG. 3, which is a schematic process flow diagram of a system III according to this disclosure, in embodiments, utilizing the advanced small modular reactor (SMR) 10 to produce energy for one or more oilfield operations can comprise utilizing SMR 10 to provide steam 15, and utilizing the steam 15 in steam methane reforming apparatus 61 to produce hydrogen 65 and utilizing the hydrogen 65 in the (e.g., oilfield equipment 51 of) one or more oilfield operations. To power the oilfield equipment 51, the hydrogen 65 can be utilized in hydrogen usage apparatus 70, as described hereinabove with reference to FIG. 2. For example, utilizing the hydrogen 65 in the one or more oilfield operations can comprise combusting the hydrogen 65 in hydrogen combustion equipment 70A, utilizing the hydrogen 65 in one or more fuel cells 70B, storing the hydrogen 65 for later use in hydrogen storage apparatus 70C, or a combination thereof.

The steam methane reforming 61 can comprise steam methane reforming and optionally water gas shift (steam methane reforming/WGS), which utilizes steam 15 and methane (e.g., natural gas) 16 to produce product hydrogen 65 and carbon dioxide (CO₂) 66. As shown in FIG. 3, the CO₂66 can, in embodiments, be introduced into a wellbore 90 for carbon capture (e.g., a carbon capture well).

As noted above, the hydrogen 65 can be combusted in a combustion apparatus 70A alone or in combination with natural gas, thus reducing an amount of carbon produced via the combusting. The one or more oilfield operations can comprise electric fracturing, in which case the oilfield equipment 51 powered by the electricity 35/conditioned electricity 45 and/or hydrogen usage equipment 70 can include an electric fracturing pump and/or related fracturing equipment.

In embodiments, an SMR 10 can thus be utilized to power methane reformation to hydrogen 65 by use of advanced catalytic methods, thus resulting in the production of hydrogen 65 and carbon. In embodiments, the hydrogen 65 can subsequently be utilized to decrease the carbon dioxide emissions of internal combustion engines (e.g., in hydrogen combustion 70A)—that currently use up to 100% natural gas—by introduction of the hydrogen 65 to the methane stream or directly into the engine, whereby the electricity generated from this hydrogen 65 enhanced methane is created with less (e.g., 30 to 40% less) CO₂emissions.

In embodiments, as noted above, an SMR 10 can be utilized to power methane reformation 61 to hydrogen 65 by use of advanced catalytic methods resulting in hydrogen 65 and carbon dioxide 66 production. The produced hydrogen 65 can subsequently be utilized to decrease the carbon dioxide 66 emissions directly by using the hydrogen 65 to power engines and turbines (e.g., hydrogen combustion 70A, which can combust from greater than 0 to 100% hydrogen) directly to make electricity at the wellsite 50 or production facility. In embodiments, an SMR 10 can be utilized to power methane reformation 61 to hydrogen 65 by use of advanced catalytic methods resulting in hydrogen 65 and carbon dioxide 66 production, and this hydrogen 65 can then be utilized to decrease the carbon dioxide emissions during the oilfield operation directly by using the hydrogen 65 in hydrogen fuel cell(s) 70B, which fuel cell(s) 70B can then be transported to one or more wellsites 50a-50n and production facilities to provide electrical power.

In embodiments, as noted above, an SMR 10 can be utilized to power methane reformation 61 to hydrogen 65 by use of currently commercial steam reformation methods resulting in hydrogen 65 and carbon dioxide 66 production, with the carbon dioxide 66 production being routed to carbon capture well 90 situated, for example, at the hydrogen 66 production facility. This facility could be located centrally to the oilfield operations (e.g., wellsites 50A-50n) or could be located at existing hydrogen 66 production plants (e.g., location of steam methane reforming/WGS 61). The carbon dioxide 66 injection into an isolated geologic formation can provide for carbon-free hydrogen 65; this hydrogen 65 can be used to decrease the carbon dioxide emissions during an oilfield operation directly, for example, by using the hydrogen 65 in hydrogen fuel cell(s) 70B. The hydrogen fuel cell(s) 70B can be transported to wellsites (e.g., one or more of wellsites 50a-50n) and/or production facilities to provide electrical power, or by injecting the hydrogen 65 into commercial natural gas lines feeding current power plants, and thus offsetting the carbon emissions at fracturing sites using conventional power methods, or electrically generated operations in any oilfield operation.

With reference to the embodiment of FIG. 4A, which is a schematic process flow diagram of a system IVA according to this disclosure, and FIG. 4B, which is a schematic process flow diagram of a system IVB according to this disclosure, utilizing the advanced small modular reactor (SMR) 10 to produce energy for one or more oilfield operations can comprise utilizing an SMR 10 to provide steam 15, heat 12, or a combination thereof, and utilizing the steam 15, the heat 12, or the combination thereof in a thermoelectric generator 31 to produce electricity 35, and utilizing the electricity 35 (and/or a conditioned electricity 45 produced therefrom in power management 40 as described hereinabove with reference to FIG. 1 and FIG. 2) to power the one or more oilfield operations. The method can include conditioning the electricity 35 in a power management and distribution apparatus or local grid 40 to provide conditioned electricity 45 for the one or more oilfield operations. Accordingly, in embodiments, an SMR 10 is coupled with a thermoelectric generator 31 to produce electricity 35 for powering oil field equipment 51.

With reference to FIG. 5, which is a schematic process flow diagram of a system V according to this disclosure, utilizing the advanced small modular reactor (SMR) 10 to produce energy for one or more oilfield operations can comprise utilizing an SMR 10 to provide steam 15, as described herein, and utilizing the steam 15 in one or more oilfield operations 62 comprising production enhancement, enhanced oil recovery, or a combination thereof. Accordingly, in embodiments, an SMR 10 can be utilized to power steam generation 15 near an oilfield facility (e.g., one or more wellsites 50a to 50n) and the steam 15 utilized directly for production enhancement or enhanced oil recovery 62, such as steam flood, steam injection, or steam assisted gravity drainage.

In embodiments, an SMR 10 is coupled with ionic plasma device to produce electrons, thereby behaving as a voltaic cell or battery, for producing electricity to power oil field equipment 51.

The method of this disclosure can further comprise transporting the SMR 10 to a location proximate a location of the one or more oilfield operations (e.g., first wellsite 50A . . . n^thwellsite 50n comprising the oilfield equipment 51) and/or producing the SMR 10 onsite at the location/wellsite of the one or more oilfield operations.

In embodiments, a method according to this disclosure comprises utilizing an advanced small modular reactor (SMR) 10 to produce heat 12 and/or steam 15; and utilizing the heat 12 and/or the steam 15 to power oilfield equipment 51 during an oilfield operation. Utilizing the heat 12 and/or the steam 15 to power the oilfield equipment 61 during the oilfield operation can further comprise: converting the steam 15 to rotational energy 25 and using the rotational energy 25 to produce electricity 35 (as depicted in and described with reference to the embodiments of FIG. 1 and FIG. 2) and/or utilizing the steam 15 in a thermoelectric generator 31 to produce electricity 35 (as depicted in and described with reference to the embodiment of FIG. 4A), and utilizing the electricity 35 to power the oilfield equipment 51 during the oilfield operation; utilizing the steam 15 to produce hydrogen 35 via reforming (as depicted in and described with reference to the embodiment of FIG. 3), and utilizing the hydrogen 35 to power the oilfield equipment 51 during the oilfield operation; utilizing the heat 12 from the SMR 10 in a thermoelectric generator 31 to produce electricity 35 (as depicted in and described with reference to the embodiment of FIG. 4B) and utilizing the electricity 35 to power the oilfield equipment 51 during the oilfield operation; and/or converting the steam 15 to rotational energy 25 and using the rotational energy 25 to produce electricity 35 and utilizing the electricity 35 to produce hydrogen 65 via electrolysis 60 (as depicted in and described with reference to the embodiment of FIG. 2), and utilizing the produced hydrogen 65 to power the oilfield equipment 51 during the oilfield operation. The electricity 45 can be conditioned to provide conditioned electricity 45 prior to subsequent use in the above embodiments.

In embodiments, an SMR can be utilized for generating electricity for applying in methane pyrolysis, microwave methane pyrolysis, and/or microwave plasma methane pyrolysis to generate hydrogen.

In embodiments, a system of this disclosure comprises: an advanced small modular reactor (SMR) 10; apparatus for the production of electricity 35 and/or hydrogen 65 from steam 15 and/or heat 12 produced in the SMR 10; and one or more oilfield equipment 51 powered at least in part with the electricity 35 and/or powered via the hydrogen 65. In embodiments, the system comprises the apparatus for the production of electricity 35 from the steam 15 produced in the SMR 10, and the apparatus for the production of electricity 35 further comprises one or more steam turbines 20 configured to produce rotational energy 25 from the steam 15 produced in the SMR 10, and electrical generation equipment 30 configured to produce the electricity 35 from the rotational energy 25. As noted hereinabove, a system of this disclosure can further include a power management apparatus or local grid 40 configured to condition the electricity 35 to provide conditioned and/or distributed electricity 45 prior to use in the one or more oilfield equipment 51.

The one or more oilfield equipment 51 can comprise any equipment operated via the electricity 35/45 and/or the hydrogen 65, such as, for example, electric fracturing equipment. In embodiments, the one or more oilfield equipment 51 comprises drilling, completions, fracturing, stimulation, rework, production and/or enhanced oil recovery equipment.

As described hereinabove with reference to the embodiment of FIG. 2, a system II of this disclosure can further include electrolysis equipment 60 powered by the electricity 35 and/or conditioned electricity 45 and operable to produce hydrogen 65 via electrolysis of water 46. The system II can further include hydrogen usage equipment 70, as described hereinabove, configured for providing mechanical or electrical power to the one or more oilfield equipment 51. The hydrogen usage equipment 70 can include hydrogen combustion equipment 70A, hydrogen fuel cell(s) 70B, hydrogen storage equipment 70C, or a combination thereof.

As described hereinabove with reference to the embodiment of FIG. 3, a system III of this disclosure can comprise the apparatus for the production of hydrogen 65 from steam 15 produced in the SMR 10, wherein the apparatus comprises reforming apparatus 61 configured to produce hydrogen 65 from the steam 15 produced in the SMR 10, and wherein the system III further comprises hydrogen usage apparatus 70 configured to provide mechanical or electrical power to the one or more oilfield equipment 51.

As described hereinabove with reference to the embodiments of FIG. 4A and FIG. 4B, the apparatus for the production of electricity 35 and/or hydrogen 65 from steam 15 and/or heat 12 produced in the SMR of a system IVA/IVB of this disclosure can comprise a thermoelectric generator 31 configured to produce electricity 35 from the steam 15 and/or the heat 12 produced in the SMR 10.

An advanced Small Modular Reactor (SMR) that uses nuclear fission is a type of nuclear reactor with a smaller size and output compared to traditional nuclear reactors. These reactors are designed to be built in a modular fashion, meaning they can be manufactured at a plant and then transported to their destination for assembly. This approach can significantly reduce construction costs and time.

Microreactors (also referred to herein as microgrids) can be 100 to 1,000 times smaller than conventional nuclear reactors, while small modular reactors (SMRs) are larger than microreactors. For example, a microreactor can be in a range from 0 to 20 megawatts (MWe, or simply “MW”), while an SMR can be in a range from 20 to 300 megawatts. As utilized herein, an SMR 10 can cover a range (including the range of microreactors/microgrids) of from about 5, 10, 15, 20, or 25 megawatts to about 50, 20, 25, 30, 40, 50, 60, 70, 80, 90, 100, 150, 200, 300, 400, 500, 600, 700, 800, 900, or 1000 megawatts (for example, from about 5 to about 300 MW, from about 10 to about 200 MW, or from about 15 to about 100 MW). In embodiments, the SMR 10 is an SMR in a range of from about 5 to 1000 MWe, from about 15 to about 200 MWe, or from about 20 to about 100 MWe.

An SMR 10 of this disclosure can comprise one or more of the features described hereinbelow. Key features and benefits of advanced SMRs include: (1) Size and Scalability: SMRs are smaller in size than conventional nuclear reactors, making them more flexible and suitable for locations not feasible for larger reactors. This modular nature can allow for scalability; additional modules can be added as needed to increase power output. (2) Safety: Advanced SMRs often incorporate passive safety features. This means that they can shut down safely and remain cool without active intervention or electronic control, thus greatly reducing the risk of accidents. (3) Efficiency and Versatility: Many SMR designs offer higher fuel efficiency, and thus can be used for a variety of applications, including electricity generation, and heat production. (4) Reduced Environmental Impact: Like traditional nuclear power and as noted hereinabove, SMRs produce very low amounts of greenhouse gas emissions compared to fossil fuel-based energy sources. (5) Cost-effectiveness: The smaller size and modular construction of SMRs can lead to lower initial capital costs and shorter construction times, thus potentially making them a more viable option for many countries. (6) Advanced Technology: Some advanced SMRs use newer technologies, such as molten salt or high-temperature gas coolants, which can offer improved performance and safety. SMRs thus offer a more flexible, cost-effective, and safer alternative to larger nuclear reactors, while also supporting the global transition to a low-carbon energy future.

Small Modular Reactors (SMRs) share many components with traditional nuclear reactors, but are designed to be smaller, more efficient, and can incorporate advanced technologies. The key components of an SMR can include: (1) Reactor Core: The reactor core is where nuclear fission takes place. The core contains the nuclear fuel (e.g., enriched uranium or sometimes thorium), control rods, and the moderator. In an SMR, the core is smaller, but operates in a similar way to larger nuclear reactors, with the nuclear fuel undergoing fission to generate heat. (2) Control Rods: Control rods are inserted into or removed from the reactor core to control the rate of the nuclear reaction. By absorbing neutrons, control rods can slow down or stop the fission process, thus playing a critical role in regulating the power output of the reactor and ensuring safety. (3) Moderator: The moderator is a material that slows down the neutrons produced during fission, thus making them more likely to cause further fission reactions. Common moderators can include water, heavy water, or graphite. (4) Coolant: The coolant is a fluid that circulates through the reactor core to remove heat and transfer it to a steam generator or directly to turbines in some designs. Common coolants can include water, heavy water, molten salt, or gas (e.g., carbon dioxide or helium). (5) Pressure Vessels or Pressure Tubes: In water-cooled and water-moderated reactors, the reactor core is often contained within a pressure vessel or a series of pressure tubes. The pressure vessels or tubes can withstand high pressure and temperature and are thus utilized for maintaining the integrity of the reactor. (6) Steam Generator: In designs where the coolant does not directly drive the turbines, a steam generator can be used. The heat from the reactor is transferred to a secondary water circuit to produce steam, which can then drive the turbine-generator set to produce electricity. (7) Turbine and Generator: The steam produced in the steam generator or directly from the reactor can be utilized to drive a turbine, which in turn drives an electrical generator to produce electricity. (8) Containment Structure: The containment structure can be a robust and air-tight building that houses the reactor and primary coolant system. The containment structure is designed to contain any radioactive materials that might be released in the event of an accident. (9) Cooling System: depending on the design, SMRs may use various cooling systems, including traditional cooling towers, air cooling, or even advanced passive cooling systems that do not require active intervention. (10) Auxiliary Systems: Auxiliary systems include systems for emergency power, control and instrumentation, ventilation, and waste handling. SMRs can include advanced technologies and materials to enhance safety, efficiency, and flexibility compared to traditional reactors. The modular nature of SMRs can also allow for factory construction and easier site assembly.

Power Output. One of the most defining characteristics of SMRs is their power output, which, as noted hereinabove, is typically much lower than conventional nuclear reactors. SMRs usually generate between 10 to 300 megawatts-electric (MWe) per unit, as opposed to traditional reactors which often exceed 1000 MWe. SMRs can have a power output ranging from 10 to 1000, from 10 to 500, or from 10 to 300 megawatts-electric (MWe) per unit. This is significantly lower than that of traditional nuclear reactors. The smaller output of SMRs makes SMRs suitable for a variety of applications, including supplementing renewable energy sources, providing power in remote locations, or serving smaller electrical grids where a large nuclear reactor would be excessive. Conventional/traditional nuclear reactors often have a power output ranging from about 600 to over 1000 MWe. These larger reactors are designed to provide consistent base-load power for large-scale electricity grids; the high power output makes conventional nuclear reactors more suitable for areas with high electricity demand.

Physical Size. SMRs are physically smaller in size than conventional nuclear reactors, which impacts their site footprint. This smaller size can translate into a reduced controlled area, making them suitable for locations where space is limited or where large reactors are not feasible. The compactness of SMRs allows for a variety of innovations in reactor design and construction. For example, SMRs can be designed to be small enough to be transported by truck or rail, which opens up possibilities for remote or hard-to-reach locations. The smaller SMR size also means a smaller site footprint, which can reduce the environmental and logistical impact of the reactor. Conventional nuclear reactors are much larger in size than SMRs, requiring a significant amount of land for the reactor itself, as well as for auxiliary buildings and safety zones. The large size of conventional nuclear reactors is partly due to the design requirements for heat dissipation, safety systems, and the need to house large turbines and generators.

Core Size: The core of an SMR is significantly smaller than that of a traditional nuclear reactor. For example, an SMR core might have a diameter of less than 3 meters and a height of about the same, varying by design, while conventional reactor cores are larger, often exceeding 5 meters in diameter and height, depending on the design and power output. Plant Footprint: The total site area required for an SMR is less than that required by a conventional nuclear reactor. For example, the total site area required for an SMR can be less than 10 acres, for example, including all necessary safety and support structures, while a typical conventional nuclear reactor might utilize a site area of 100 to 500 acres or more, considering safety zones, auxiliary buildings, and other infrastructure. Weight and Transportability: Designed to be transportable, modular components of SMRs might weigh from a few hundred to a few thousand tons, while corresponding components of a traditional nuclear reactor are often too large and heavy for transportation, necessitating on-site construction.

Modularity. SMRs are designed to be modular, meaning they can be manufactured in a controlled factory setting and then transported to a desired site (e.g., a wellsite) for assembly. This modularity is a key differentiator from traditional nuclear reactors, which are typically built entirely on-site. The concept of modularity is central to the design and deployment of SMRs. SMRs can be constructed in modules at a manufacturing facility and then transported to the site for assembly. This approach can significantly reduce construction times and costs, and can allow for better quality control during manufacturing. The modular design can also provide scalability; additional units can be added as demand increases. This flexibility is a substantial shift from the traditional approach of custom-built, site-specific, conventional nuclear reactor designs. For example, traditional nuclear power plants are usually built on-site in a process that can take many years. Each conventional nuclear power plant is typically a unique project with bespoke design and construction requirements. This approach can lead to higher costs and longer construction times due to the complexities of on-site construction, along with the challenges of coordinating a large number of contractors and suppliers.

Factory Construction vs. On-Site Construction: SMRs can be designed to be built in factories and shipped to the site, allowing for standardization and quality control, while traditional nuclear reactors are built on-site, with each reactor often a custom project, leading to greater variability in construction practices and timelines. Assembly and Deployment Time: The modular design of SMRs enables rapid assembly and deployment, potentially within a few years from start to finish, while construction and commissioning of traditional nuclear reactors can take anywhere from 5 to 10 years or more. Scalability: Additional modules can be added to SMRs to increase capacity, allowing for a phased investment and scalability according to demand, while scaling up of a traditional nuclear reactor involves constructing additional large reactors, each a major project in itself. Component Standardization: SMRs emphasize standardized design for components, which can lead to cost reductions and easier maintenance, while, due to their bespoke nature, components of traditional nuclear reactors are often unique to each reactor, complicating maintenance and replacement.

Scalability. The modular design of SMRs allows for scalability. Power capacity can be increased by adding more modules, thus providing flexibility (e.g., in meeting electricity demand).

Construction Time. Due to their smaller size and modular construction, SMRs typically have shorter construction times compared to traditional nuclear plants, which can take many years to build.

Capital Cost. The initial capital cost for SMRs is generally lower than conventional nuclear reactors, making SMRs more accessible for smaller utilities or countries with limited infrastructure or investment capabilities.

Safety Features. Many SMRs incorporate advanced safety features, including, for example, passive safety systems that require no active controls or human intervention to ensure safety in case of an emergency.

Cooling Systems. SMRs often use advanced cooling systems, which can be different from those used in larger nuclear reactors. Some SMRs utilize natural circulation or air cooling to reduce the need for large water sources.

Fuel Type and Utilization. SMRs can use different types of nuclear fuel or have higher fuel utilization efficiency relative to traditional nuclear reactors. Some SMRs can be designed to use low-enriched uranium, thorium, or even spent fuel from other nuclear reactors.

Site Flexibility. Due to their smaller size and potentially lower cooling water requirements, SMRs can potentially be located in a wider variety of locations, including remote or off-grid areas.

Waste Production. SMRs can be designed to produce less nuclear waste, due to improved fuel efficiency and enhanced technologies.

Licensing and Regulatory Approaches. The licensing process for SMRs can be different than conventional nuclear reactors, due to the novel design features and safety systems of SMRs.

Quantifying the amount of nuclear fuel utilized and the amount of heat generated can provide additional parameters to contrast Small Modular Reactors (SMRs) with traditional nuclear reactors.

Nuclear Fuel Quantity. Amount of Fuel: Due to their smaller size, SMRs typically use less nuclear fuel compared to traditional nuclear reactors. For example, an SMR 10 of this disclosure might require between one to five tons of uranium fuel per year, depending on its design and power output, while a large conventional nuclear reactor may utilize 20 to 30 tons of uranium fuel annually. Fuel Enrichment Level: Some SMR designs may utilize fuel with a higher enrichment level than traditional nuclear reactors, potentially up to 20% uranium-235 (U-235), to achieve a longer operational cycle between re-fuelings, while traditional nuclear reactors can typically use fuel enriched to about 3-5% U-235. Fuel Utilization: Advanced SMR designs can have higher fuel utilization and longer fuel cycles, meaning they can operate longer before needing refueling, while traditional nuclear reactors usually have standard fuel cycles, with refueling periods depending on the reactor type and operational strategy.

Heat Generation. Thermal Power Output: The thermal power output (e.g., heat generated by the reactor before conversion to electricity) of SMRs is lower in SMRs (than conventional nuclear reactors) due to the smaller SMR size. The thermal power output of an SMR can range from 30 to 300 megawatts-thermal (MWth), while traditional nuclear reactors can typically have thermal outputs ranging from 1000 to 4000 MWth or more. Heat Density: Due to advanced design features and fuel types, some SMR designs may have higher heat densities within their cores than conventional nuclear reactors. Traditional nuclear reactors typically have established heat density parameters based on decades of operational experience and design optimizations. Efficiency of Heat Use: Advanced SMRs may employ novel heat utilization techniques, such as high-temperature reactors that can support industrial processes or district heating, aside from electricity generation, while traditional nuclear reactors are generally optimized for electricity generation, with a typical thermal-to-electric conversion efficiency of about 33%. These quantifiable differences in nuclear fuel use and heat generation further distinguish SMRs from traditional nuclear reactors. SMRs offer a more compact and potentially more efficient approach to nuclear power generation, with implications for fuel handling, waste management, and overall reactor design.

There can be notable differences in the materials of construction between Small Modular Reactors (SMRs) and traditional nuclear reactors. These differences are driven by the unique design features, operational requirements, and goals of SMRs, such as enhanced safety, reduced size, and modularity. Reactor Pressure Vessel (RPV) Materials: SMR designs can utilize advanced steel alloys or composite materials for the reactor pressure vessel to handle high temperatures and reduce the risk of corrosion. For example, SMRs of this disclosure can use advanced stainless steel or nickel-based alloys, in embodiments. Traditional nuclear reactors typically utilize conventional carbon steel with a stainless steel lining, which has been the standard for decades. These materials are well-understood in terms of their performance and longevity. Fuel Cladding: SMRs can utilize of advanced cladding materials, such as silicon carbide or advanced zirconium alloys, to enhance safety and performance. These materials can offer higher resistance to corrosion and better tolerance to high temperatures. Traditional nuclear reactors generally employ zirconium alloy cladding, which has good neutron transparency and strength, but can be vulnerable in extreme conditions, as evidenced in some nuclear accidents. Coolant System Materials: Depending on the type of coolant used (e.g., molten salt, liquid metal, or gas), SMRs may utilize specialized materials in order to withstand corrosive environments and high temperatures. For example, molten salt reactors can utilize materials highly resistant to corrosion. In traditional water-cooled nuclear reactors, the materials need to withstand the corrosive effects of high-temperature water and radiation, typically using a variety of stainless steels and nickel-based alloys. Structural and Shielding Materials: Due to their smaller size and different design considerations, SMRs may utilize novel structural materials for shielding and containment, which can include high-density concrete or new composite materials, while traditional nuclear reactors utilize heavy, reinforced concrete for containment structures, designed to withstand extreme conditions and potential impacts. Modular Construction Materials: For SMRs, the materials chosen are suitable for modular construction techniques, meaning they need to be transportable and adaptable to being assembled on-site, which can influence the choice of materials to ensure durability during transportation. Since traditional nuclear reactors are constructed on-site, there is less emphasis on the transportability and modular assembly of materials. Heat Exchanger Materials: Advanced heat exchangers in SMRs, especially in high-temperature designs, may use materials such as graphite or ceramics that can withstand extreme temperatures and corrosive environments, while traditional nuclear reactors typically employ standard materials, such as carbon steel or stainless steel, suitable for the operational temperatures and pressures of conventional water-cooled systems. The aforementioned material differences can be utilized in the SMR 10 design for improving safety, efficiency, and adaptability, as well as accommodating the unique challenges of modular construction and varied coolant types.

Integrating an SMR 10 with oilfield operations as described herein can enable a reduction in the production of carbon dioxide and other greenhouse gases and undesirable components during oilfield operations.

ADDITIONAL DISCLOSURE

The following are non-limiting, specific embodiments in accordance with the present disclosure:

In a first embodiment, a method comprises: utilizing an advanced small modular reactor (SMR) to produce energy for one or more oilfield operations.

A second embodiment can include the method of the first embodiment, wherein the one or more oilfield operations comprise drilling, completions, fracturing, stimulation, rework, production and/or enhanced oil recovery operations and treatments.

A third embodiment can include the method of the first or second embodiment, wherein utilizing the SMR to produce energy for oilfield operations further comprises utilizing an SMR to provide steam and utilizing the steam to produce electricity, and utilizing the electricity in the one or more oilfield operations.

A fourth embodiment can include the method of the third embodiment, wherein utilizing the steam to produce electricity further comprises producing rotational energy by introducing the steam into one or more steam turbines and converting the rotational energy to electricity in electrical generation equipment.

A fifth embodiment can include the method of the fourth embodiment further comprising introducing the electricity produced in the electrical generation equipment to a local grid.

A sixth embodiment can include the method of the fifth embodiment, wherein the local grid is proximal one or more wellsites at which the one or more oilfield operations are performed.

A seventh embodiment can include the method of any one of the third to sixth embodiments, wherein utilizing the electricity in the one or more oilfield operations further comprises utilizing the electricity for electrolysis of water to produce product hydrogen, and utilizing the hydrogen in the one or more oilfield operations.

An eighth embodiment can include the method of the seventh embodiment, wherein utilizing the hydrogen in the one or more oilfield operations further comprises combusting the hydrogen, utilizing the hydrogen in one or more fuel cells, storing the hydrogen for later use, or a combination thereof.

A ninth embodiment can include the method of the seventh or eighth embodiment comprising combusting the hydrogen, wherein the hydrogen is combusted in a combustion apparatus alone or in combination with natural gas.

A tenth embodiment can include the method of any one of the first to ninth embodiments, wherein utilizing the advanced small modular reactor (SMR) to produce energy for one or more oilfield operations further comprises utilizing an SMR to provide steam, and utilizing the steam in steam methane reforming to produce hydrogen and utilizing the hydrogen in the one or more oilfield operations.

An eleventh embodiment can include the method of the tenth embodiment, wherein utilizing the hydrogen in the one or more oilfield operations further comprises combusting the hydrogen, utilizing the hydrogen in one or more fuel cells, storing the hydrogen for later use, or a combination thereof.

A twelfth embodiment can include the method of the eleventh embodiment comprising combusting the hydrogen, wherein the hydrogen is combusted in a combustion apparatus alone or in combination with natural gas.

A thirteenth embodiment can include the method of any one of the first to twelfth embodiments, wherein the one or more oilfield operations comprises electric fracturing.

A fourteenth embodiment can include the method of any one of the first to thirteenth embodiments, wherein utilizing the advanced small modular reactor (SMR) to produce energy for one or more oilfield operations further comprises utilizing an SMR to provide steam, and utilizing the steam in one or more oilfield operations comprising production enhancement, enhanced oil recovery, or a combination thereof.

A fifteenth embodiment can include the method of any one of the first to fourteenth embodiments, wherein utilizing the advanced small modular reactor (SMR) to produce energy for one or more oilfield operations further comprises utilizing an SMR to provide steam, heat, or a combination thereof, and utilizing the steam, heat, or the combination thereof in a thermoelectric generator to produce electricity, and utilizing the electricity to power the one or more oilfield operations.

A sixteenth embodiment can include the method of the fifteenth embodiment further comprising conditioning the electricity in a power management and distribution apparatus to provide conditioned electricity for the one or more oilfield operations.

A seventeenth embodiment can include the method of any one of the first to sixteenth embodiments, wherein the SMR is an SMR in a range of from about 5 to 1000 MWe, from about 15 to about 200 MWe, or from about 20 to about 100 MWe.

An eighteenth embodiment can include the method of any one of the first to seventeenth embodiments further comprising transporting the SMR to a location proximate a location of the one or more oilfield operations and/or producing the SMR onsite at the location of the one or more oilfield operations.

In a nineteenth embodiment, a method comprises: utilizing an advanced small modular reactor (SMR) to produce heat and/or steam; and utilizing the heat and/or steam to power an oilfield operation.

A twentieth embodiment can include the method of the nineteenth embodiment, wherein utilizing the heat and/or steam to power an oilfield operation further comprises: converting the steam to rotational energy and using the rotational energy to produce electricity and/or utilizing the steam in a thermoelectric generator to produce electricity, and utilizing the electricity to power the oilfield operation; utilizing the steam to produce hydrogen via reforming, and utilizing the hydrogen to power the oilfield operation; utilizing the heat in a thermoelectric generator to produce electricity and utilizing the electricity to power the oilfield operation; and/or converting the steam to rotational energy and using the rotational energy to produce electricity and utilizing the electricity to produce hydrogen via electrolysis, and utilizing the hydrogen to power the oilfield operation.

In a twenty first embodiment, a system comprises: an advanced small modular reactor (SMR); apparatus for the production of electricity and/or hydrogen from steam and/or heat produced in the SMR; and one or more oilfield equipment powered at least in part with the electricity and/or powered via the hydrogen.

A twenty second embodiment can include the system of the twenty first embodiment comprising the apparatus for the production of electricity from steam produced in the SMR, wherein the apparatus for the production of electricity further comprises one or more steam turbines configured to produce rotational energy from the steam produced in the SMR, and electrical generation equipment configured to produce electricity from the rotational energy.

A twenty third embodiment can include the system of the twenty second embodiment further comprising a power management apparatus configured to condition the electricity prior to use in the one or more oilfield equipment.

A twenty fourth embodiment can include the system of the twenty second or twenty third embodiment further comprising electrolysis equipment powered by the electricity and operable to produce hydrogen from water electrolysis, and further comprising hydrogen usage equipment providing mechanical or electrical power to the one or more oilfield equipment.

A twenty fifth embodiment can include the system of the twenty fourth embodiment, wherein the hydrogen usage equipment comprises hydrogen combustion equipment, hydrogen fuel cell(s), hydrogen storage equipment, or a combination thereof.

A twenty sixth embodiment can include the system of any one of the twenty first to twenty fifth embodiments comprising the apparatus for the production of hydrogen from steam produced in the SMR, wherein the apparatus comprises reforming apparatus configured to produce hydrogen from the steam produced in the SMR, and wherein the system further comprises hydrogen usage apparatus configured to provide mechanical or electrical power to the one or more oilfield equipment.

A twenty seventh embodiment can include the system of any one of the twenty first to twenty sixth embodiments, wherein the apparatus for the production of electricity and/or hydrogen from steam and/or heat produced in the SMR comprises a thermoelectric generator configured to produce electricity from the steam and/or the heat produced in the SMR.

A twenty eighth embodiment can include the system of any one of the twenty first to twenty seventh embodiments, wherein the SMR is an SMR in a range of from about 5 to 1000 MWe, from about 15 to about 200 MWe, or from about 20 to about 100 MWe.

A twenty ninth embodiment can include the system of any one of the twenty first to twenty eighth embodiments, wherein the one or more oilfield equipment comprises drilling, completions, fracturing, stimulation, rework, production and/or enhanced oil recovery equipment.

A thirtieth embodiment can include the system of any one of the twenty first to twenty ninth embodiments, wherein the one or more oilfield equipment comprises electric fracturing equipment.

While embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of this disclosure. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the embodiments disclosed herein are possible and are within the scope of this disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, RI, and an upper limit, Ru, is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=Rl+k*(Ru−Rl), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, etc. When a feature is described as “optional,” both embodiments with this feature and embodiments without this feature are disclosed. Similarly, the present disclosure contemplates embodiments where this “optional” feature is required and embodiments where this feature is specifically excluded.

Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as embodiments of the present disclosure. Thus, the claims are a further description and are an addition to the embodiments of the present disclosure. The discussion of a reference herein is not an admission that it is prior art, especially any reference that can have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference, to the extent that they provide exemplary, procedural, or other details supplementary to those set forth herein.

Using Advanced Small Modular Reactors in Oilfield Operations

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