Method and apparatus for reducing costs and emissions from extracting and processing gas and oil from underground resources

Abstract

This invention relates to improvements in the current recovery of gases and oil liquids from an underground resource such as shale by means of hydraulic fracturing “Fracking.” The main improvements consist of increasing the yield of gases and oil liquids from drilled wells as well as eliminating the use of water which is a major problem. Mobile processing equipment, to upgrade the recovered resource and to convert it to a marketable product, is conducted where the resource is thermally extracted, resulting in the elimination of pipelines to conventional upgraders which produce an intermediate which is thence delivered by means of pipeline or rail to a far away conventional refinery. This new mobile approach which will be situated at or adjoining the drilled wells will lower capital and operating costs, reduce emissions, facilitate permitting, and help reduce public opposition to “Fracking.”

I therefore claim the following: 
     
         1 . In a method for recovering gases and liquids from underground energy resources which are converted by three steps to result in producing marketable product or products ready for use by the consumer, wherein said steps comprise an Upstream activity which relates to extraction, a Midstream activity which relates to upgrading the extracted material into an intermediate, and a Downstream activity which relates to refining the intermediate to a product in condition to be marketable to the consumer, while said three activities take place at three different locations which are remote from one another such that the Midstream is many miles away from where the extraction takes place, necessitating a pipeline to connect the well(s) to the Midstream location and another pipeline or transport means such as a train to deliver the intermediate from the Midstream to the Downstream refinery, the IMPROVEMENT consisting of situating the Upstream activity and the Midstream activity substantially at the same location to result in obviating the continuous cost in the transportation of the raw gas and oil liquids between the Upstream location and Midstream location, as well as the time and cost of securing the rights-of-way between the Upstream and the Midstream for a pipeline which also requires continuous maintenance and liability with respect to pipeline ruptures, spills, and leaks. 
     
     
         2 . The method as set forth in  claim 1  wherein the Midstream activity which relates to upgrading and Downstream activity which relates to refining are situated substantially in one location to result in obviating the cost in the transportation of the upgraded intermediate between the Midstream and Downstream, when the intermediate is transported by pipeline or by rail from the Midstream location to the Downstream location. 
     
     
         3 . The method as set forth in  claim 1  wherein said Upstream activity, said Midstream activity, and said Downstream activity are situated in substantially the same location in order to save the transportation costs from the Upstream to the Midstream and from the Midstream to the Downstream, as well as to avoid maintenance of pipelines, including ruptures, spills, and leaks. 
     
     
         4 . In a method for recovering gases and liquids from underground energy resources which are converted by three steps to result in producing marketable product or products being ready for delivery to the consumer, wherein said steps include an Upstream activity which relates to the extraction of such resource from drilled wells, which are spaced apart in close proximity to one another, the IMPROVEMENT wherein equipment to conduct the upgrading of said resource from said drilled wells is effected by miscellaneous activities practiced by various pieces of equipment that can be set up and be operated in close proximity of the drilled wells, be dismantled when the yield from the wells drops or ceases, and be moved to newly drilled wells to be re-set and operated again on relatively short notice, in order to economically process said extracted resource into an intermediate that results in the elimination of a major pipeline that connects the drilled wells to the Midstream upgrading facility which is immobile, and such facility is located at a distance of scores of miles or even a hundred or more miles away from said drilled wells while incurring large capital investment, long time to permit, and long time to construct. 
     
     
         5 . The method as set forth in  claim 4  wherein said underground resources are upgraded by means of upgrading equipment mounted on towed trailers to give such equipment mobility in order to make possible the parking of said trailers in close proximity to said drilled wells. 
     
     
         6 . The method as set forth in  claim 5  wherein said upgrading consists of cracking and desulfurization of said resource above ground, producing a clean intermediate. 
     
     
         7 . The method as set forth in  claim 6  wherein said intermediate is refined, by means of refining equipment mounted on towed trailers to give such equipment mobility in order to make possible the parking of said trailers in close proximity to upgrading equipment. 
     
     
         8 . The method as set forth in  claim 7  wherein said intermediate is refined into marketable product or products being in condition to be delivered as finished product or products directly to consumers, resulting in the elimination of pipelines and/or rail transport which extend hundreds or even thousands of miles from upgrading equipment. 
     
     
         9 . The method as set forth in  claim 5  wherein said towed trailers are assembled as a fleet of trailers to be pulled by a tractor in order to transport such fleet to and from the vicinity of drilled wells. 
     
     
         10 . The method as set forth in  claim 7  wherein said towed trailers are assembled as a fleet of trailers to be pulled by a tractor in order to transport such fleet to and from the vicinity of upgrading equipment. 
     
     
         11 . The method as set forth in  claim 4  wherein said miscellaneous activities include the injection of a pressurized, hot recycle gas into drilled wells to cause the release of gases and liquids by means of thermal energy which results in efficiently increasing the yield of gases and liquids from said underground resource, in reducing extraction cost, and reducing emissions, particularly by avoiding water contamination and its disposal in wells. 
     
     
         12 . The method as set forth in  claim 11  wherein said recycled gas is heated by induction. 
     
     
         13 . The method as set forth in  claim 4  wherein said Upstream activity includes the cracking and desulfurizing of the extracted resource to convert it to an intermediate. 
     
     
         14 . The method as set forth in  claim 1  wherein said Midstream activity which relates to upgrading the extracted material into an intermediate is further characterized by said intermediate being a clean synthesis gas. 
     
     
         15 . The method as set forth in  claim 14  wherein said synthesis gas is converted to methanol. 
     
     
         16 . The method as set forth in  claim 15  wherein said methanol is converted to gasoline suitable for delivery to retail gasoline stations to service consumers. 
     
     
         17 . The method as set forth in  claim 1  wherein said Midstream activity which relates to upgrading the extracted material into an intermediate is further characterized by said intermediate being clean natural gas. 
     
     
         18 . Apparatus for extracting and processing energy from drilled wells in the form of solid, semi-solid, liquid and gas, or a mixture thereof, comprising reaction vessels adapted to be transported on trailers for mobility to be situated in the proximity of said drilled wells in order to drastically reduce the need for pipelines, elimination of conventional immobile upgraders as well as conventional immobile refineries. 
     
     
         19 . The apparatus as set forth in  claim 18  wherein said vessels are adapted to articulate about a pivot in order to change positions from a reclined position to an upright position. 
     
     
         20 . The apparatus as set forth in  claim 19  wherein said vessels are adapted to upgrade gases and liquids into an intermediate when in the upright position and in a reclined position during,travel from one location to another location. 
     
     
         21 . The apparatus as set forth in  claim 20  wherein said intermediate is converted to a refined product by making use of portable vessels. 
     
     
         22 . The apparatus as set forth in  claim 18  wherein said vessels are interconnected when in operative mode under pressure. 
     
     
         23 . The apparatus as set forth in  claim 21  wherein said refined product is methanol by making use of portable vessels. 
     
     
         24 . The apparatus as set forth in  claim 23  wherein said methanol is converted to gasoline in portable vessels. 
     
     
         25 . The apparatus as set forth in  claims 20 ,  21 ,  23  and  24  wherein said vessels are connected to pressurizing equipment.