System and Method of Treating a Subterranean Formation with Captured Exhaust Gases from Pump Engines and Auxiliary Equipment

Abstract

A system and method for capturing and repurposing exhaust gases from pump engines during subterranean formation treatments, such as hydraulic fracturing. The system comprises a source of a clean carrier fluid, gas injectors, a source of a treatment fluid, and a high-pressure pump, with configurable kits (e.g., Dry Kits, Wet Kits, Blender Dry Kits, Blender Wet, Single Pump Kits). Captured exhaust gases, including CO2 and N2, are combined with a treatment fluid to produce energized or foamed treatment fluids, improving viscosity and proppant transport. The system achieves up to 99.99% emission capture, supports foam qualities from 1% to 70%, and reduces environmental impact, equipment requirements, and operational footprint. Adaptable for onshore and offshore use, the invention enhances hydraulic fracturing efficiency and minimizes pollution.

What is claimed is: 
     
         1 . A system for treating a subterranean formation with a treatment fluid mixed with exhaust gases from one or more internal combustion engines used to power pumps and auxiliary equipment, comprising:
 (a) a treatment fluid formulated for hydraulically fracturing an underground formation;   (b) at least one source of the treatment fluid in the form of a blender or container, wherein the source is configured to supply the treatment fluid;   (c) at least one internal combustion engine producing exhaust gases and configured to power a high-pressure pump;   (d) at least one high-pressure pump connected to the internal combustion engine and capable of pressurizing the treatment fluid; wherein the high-pressure pump is fluidly connected to a wellhead and to the source of the treatment fluid;   (e) at least one injector, fluidly connected to both the exhaust gas source and the conduit of the treatment fluid; wherein the injector is connected to a source of clean carrier fluid for mixing with the treatment fluid.   
     
     
         2 . The system of  claim 1 , wherein the treatment fluid comprises a mixture of a water-based liquid and an artificial proppant or natural sand, thereby forming a slurry for hydraulic fracturing. 
     
     
         3 . The system of  claim 1 , wherein the treatment fluid constitutes a liquid reactive medium capable of chemically modifying an underlying rock formation without the addition of an artificial proppant or natural sand. 
     
     
         4 . The system of  claim 1 , wherein the internal combustion engines utilize different types of fuel to power the pumps and auxiliary equipment, including diesel, gasoline, fuel oil (mazut) crude oil, gas, or mixed fuel options. 
     
     
         5 . The system of  claims 1 and 4 , wherein the internal combustion engines comprise piston, rotary, or turbine types, all configured to power pumps and auxiliary equipment. 
     
     
         6 . The system of  claim 5 , wherein the temperature of the exhaust gases is monitored and controlled to enhance their performance in the treatment fluid. 
     
     
         7 . The system of  claims 1, 4, and 5 , wherein various types of pumps provide sufficient pressure and flow rates for the treatment fluid. 
     
     
         8 . The system of  claim 7 , wherein the pumps are configured to operate under varying pressures and flow rates according to the formation requirements. 
     
     
         9 . The system of  claim 1 , wherein the captured exhaust gases are utilized to convert the treatment fluid into an energized or foamed form, thereby enhancing the fluid properties. 
     
     
         10 . The system of  claim 1 , wherein exhaust gases are captured to reduce the carbon footprint of the treatment operation, capturing carbon dioxide in a range of 3.00% to 99.99% of the total CO2 exhaust produced during the operation. 
     
     
         11 . The system of  claim 1 , wherein the exhaust gases are injected into the treatment fluid or clean carrier fluid without separating the gases into individual components. 
     
     
         12 . The system of  claim 1 , wherein the exhaust gases are partially separated or purified before being injected into the treatment fluid or the clean carrier fluid. 
     
     
         13 . The system of  claim 1 , wherein the exhaust gases are used directly as collected from the internal combustion engines without temporary storage in a pressurized vessel. 
     
     
         14 . The system of  claim 1 , wherein the exhaust gases are temporarily held in a pressurized vessel before injection. 
     
     
         15 . A method for treating a subterranean formation using the system of  claim 1 , comprising:
 (a) collecting exhaust gases in a common gas manifold;   (b) injecting the collected exhaust gases into a clean carrier fluid via a single injector;   (c) directing a resulting mixture from the single injector into a dedicated high-pressure pump for further pressurization; and   (d) combining the resulting mixture with a main stream of pressurized treatment fluid directed into a wellhead for formation treatment.   
     
     
         16 . The method of  claim 15 , wherein exhaust gases from each pump are collected and injected separately into the clean carrier fluid using multiple injectors and directed to a dedicated high-pressure pump for further pressurization, thereby combining the resulting mixture with the main stream of pressurized treatment fluid, which reduces the temperature of the hot exhaust gases and eliminates the need for a hot exhaust gas manifold. 
     
     
         17 . The method of  claim 15 , wherein exhaust gases are collected in a common gas manifold before injecting into the main stream of treatment fluid via a single injector, with the gas-fluid mixture directed into the main high-pressure pumps for further pressurization and eliminating the need for a dedicated pump. 
     
     
         18 . The method of  claim 16 , wherein exhaust gases from each pump are collected and injected separately into the clean carrier fluid using multiple injectors, and the gas-clean carrier fluid mixture is directed into the main stream of treatment fluid before going into the main high-pressure pumps for further pressurization, which eliminates the need for both a dedicated pump and a hot exhaust gas manifold. 
     
     
         19 . The method of  claim 16 , wherein exhaust gases generated by a single internal combustion engine are collected and injected into a stream of treatment fluid directed to the fluid end of the same engine's high-pressure pump assembly for further pressurization into a wellhead, thus isolating the processes of gas generation, injection, and mixture pressurization within a single pump assembly. 
     
     
         20 . The method of  claim 15 , further comprising monitoring the temperature of the exhaust gases during collection to optimize their use in the treatment fluid.