Systems and methods are disclosed that may include producing wellhead gas from a wellbore, removing hydrocarbons and/or other particulates from the wellhead gas produced from the wellbore to maximize and/or provide a consistent BTU level to the wellhead gas, and burning the wellhead gas in a wellhea
Systems and methods are disclosed that may include producing wellhead gas from a wellbore, removing hydrocarbons and/or other particulates from the wellhead gas produced from the wellbore to maximize and/or provide a consistent BTU level to the wellhead gas, and burning the wellhead gas in a wellhead gas burner to heat water and/or other chemicals used in hydrocarbon production and/or well completion processes, including, but not limited to hydraulic fracturing (fracking). The wellhead gas burner may also be configured as a primary heat source and integrated with a traditional gas burner system configured as a supplemental heat source. The wellhead gas burner and the traditional gas burner may also be operated simultaneously. The wellhead gas burner may also be mounted to a mobile superheater truck.
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1. A wellhead gas system, comprising: a separator connected in fluid communication with a wellhead gas source and configured to separate wellhead gas from liquid hydrocarbons produced from the wellhead gas source; anda wellhead gas burner connected in fluid communication with the separator and confi
1. A wellhead gas system, comprising: a separator connected in fluid communication with a wellhead gas source and configured to separate wellhead gas from liquid hydrocarbons produced from the wellhead gas source; anda wellhead gas burner connected in fluid communication with the separator and configured to burn the separated wellhead gas received from the separator to heat a wellbore treatment fluid,wherein the wellhead gas burner comprises an expansion chamber and a fuel rail in fluid communication with the expansion chamber,wherein the expansion chamber is configured to reduce at least one of a pressure or a velocity of the separated wellhead gas prior to delivering the separated wellhead gas to the fuel rail,wherein the wellhead gas burner comprises a plurality of fuel rail fingers connected in fluid communication with the fuel rail,wherein each fuel rail finger comprises a plurality of combustion chambers for burning the separated wellhead gas, andwherein each of the plurality of combustion chambers comprises at least one orifice configured to allow the separated wellhead gas to exit an associated fuel rail finger into an associated combustion chamber. 2. The wellhead gas system of claim 1, wherein the at least one orifice in each of the plurality of combustion chambers comprises size #40 orifices. 3. The wellhead gas system of claim 1, wherein each of the plurality of combustion chambers comprises a combustion tube holder that at least partially envelopes a combustion tube. 4. The wellhead gas system of claim 3, wherein each combustion tube extends further from its respective fuel rail finger than its respective combustion tube holder. 5. The wellhead gas system of claim 1, wherein the wellhead gas burner is configured to continuously burn the separated wellhead gas when the pressure of the wellhead gas produced from the wellhead gas source is between about 5 pounds per square inch (psi) and about 15,000 psi. 6. The wellhead gas system of claim 1, wherein the separator is configured to provide the separated wellhead gas with a British Thermal Unit (BTU) level that is about 500 BTUs per cubic foot. 7. The wellhead gas system of claim 1, wherein the separator is configured to provide the separated wellhead gas with a British Thermal Unit (BTU) level that is about 1000 BTUs per cubic foot. 8. The wellhead gas system of claim 1, wherein the separator is configured to provide the separated wellhead gas with a British Thermal Unit (BTU) level that is about 3500 BTUs per cubic foot. 9. The wellhead gas system of claim 1, wherein the wellhead gas burner is mounted to a superheater truck, a trailer, a frac heater unit, or a skid. 10. The wellhead gas system of claim 1, wherein the wellhead gas burner is integrated with a traditional gas burner. 11. The wellhead gas system of claim 10, wherein the plurality of fuel rail fingers of the wellhead gas burner are oriented substantially perpendicularly to a plurality of fuel rail fingers of the traditional gas burner. 12. The wellhead gas system of claim 10, wherein the plurality of fuel rail fingers of the wellhead gas burner are configured to be interstitially spaced with a plurality of fuel rail fingers of the traditional gas burner. 13. The wellhead gas system of claim 10, wherein the traditional gas burner is configured to burn at least one of propane, butane, gasoline, diesel, liquefied natural gas (LNG), and natural gas liquids (NGLs). 14. The wellhead gas system of claim 13, wherein the wellhead gas burner and the traditional gas burner are configured to operate simultaneously. 15. The wellhead gas system of claim 13, wherein the wellhead gas burner and the traditional gas burner are mounted to at least one of a superheater truck, a trailer, a frac heater unit, and a skid. 16. The wellhead gas system of claim 1 further comprising a pressure regulator upstream of the expansion chamber and configured to control the pressure of the wellhead gas entering the expansion chamber. 17. The wellhead gas system of claim 1, wherein the plurality of fuel rail fingers are perpendicularly connected with the fuel rail, and wherein the plurality of combustion chambers are mounted in series along a linear length of each fuel rail finger. 18. A wellhead gas system, comprising: a separator connected in fluid communication with a wellhead gas source and configured to separate wellhead gas from liquid hydrocarbons produced from the wellhead gas source;a wellhead gas burner connected in fluid communication with the separator and configured to burn the separated wellhead gas received from the separator to heat a wellbore treatment fluid, wherein the wellhead gas burner comprises an expansion chamber and a first fuel rail in fluid communication with the expansion chamber, wherein the expansion chamber is configured to reduce at least one of a pressure or a velocity of the separated wellhead gas prior to delivering the separated wellhead gas to the first fuel rail, wherein the wellhead gas burner comprises a plurality of fuel rail fingers connected in fluid communication with the first fuel rail, wherein each fuel rail finger comprises a plurality of combustion chambers for burning the separated wellhead gas, and wherein each of the plurality of combustion chambers comprises at least one orifice configured to allow the separated wellhead gas to exit an associated fuel rail finger into an associated combustion chamber; anda second fuel burner configured to burn a second fuel, wherein the second fuel burner comprises a plurality of fuel rail fingers connected in fluid communication with a second fuel rail, wherein each fuel rail finger of the second fuel burner comprises a plurality of combustion chambers for burning the second fuel, and wherein the plurality of fuel rail fingers of the wellhead gas burner are integrated with the plurality of fuel rail fingers of the second fuel burner. 19. The wellhead gas system of claim 18, wherein the plurality of fuel rail fingers of the wellhead gas burner are oriented substantially perpendicularly to a plurality of fuel rail fingers of the second fuel burner. 20. The wellhead gas system of claim 18, wherein the plurality of fuel rail fingers of the wellhead gas burner are configured to be interstitially spaced with the plurality of fuel rail fingers of the second fuel burner. 21. The wellhead gas system of claim 18, wherein each of the fuel rail fingers of the wellhead gas burner are movable relative to the first fuel rail. 22. The wellhead gas system of claim 18, wherein the second fuel is at least one of methane, ethane, propane, butane, gasoline, diesel, liquefied natural gas (LNG), and natural gas liquids (NGLs). 23. The wellhead gas system of claim 22, wherein the second fuel burner is configured to operate when the wellhead gas burner supplies less than about 3500 British Thermal Units (BTU) per cubic foot. 24. The wellhead gas system of claim 22, wherein the second fuel burner is configured to operate when the pressure of the separated wellhead gas drops below about 1000 pounds per square inch (psi). 25. The wellhead gas system of claim 22, wherein the wellhead gas burner and the second fuel burner are configured to operate simultaneously. 26. A method of operating a wellhead gas system, comprising: receiving wellhead gas from a wellbore;removing liquid hydrocarbons from the wellhead gas produced from the wellbore;passing the wellhead gas through an expansion chamber to reduce at least one of a pressure or a velocity of the wellhead gas;combusting the wellhead gas in a wellhead gas burner;heating a wellbore treatment fluid with heat produced by combusting the wellhead gas in the wellhead gas burner; andtreating a wellbore with the heated wellbore treatment fluid. 27. The method of claim 26, wherein the combusting the wellhead gas is accomplished when the pressure of the wellhead gas produced from the wellbore is between at least about 5 pounds per square inch (psi) and about 15,000 pounds per square inch (psi). 28. The method of claim 26, wherein the combustion of the wellhead gas occurs only when the pressure of the wellhead gas entering the wellhead gas burner is about 1000 pounds per square inch (psi). 29. The method of claim 26, wherein wellhead gas is combusted in the wellhead gas burner when the wellhead gas provides about 3500 British Thermal Units (BTU) per cubic foot. 30. The method of claim 26, further comprising: burning a second fuel in a second fuel burner to heat the wellbore treatment fluid. 31. The method of claim 30, wherein the second fuel is at least one of propane, butane, gasoline, diesel, liquefied natural gas (LNG), natural gas liquids (NGLs), and wellhead gas to heat the wellbore treatment fluid.
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