Fouling Resistant Once Through Steam Generators (OTSG)

Transcription

1 Fouling Resistant Once Through Steam Generators (OTSG) SOLUTION DESRIPTION: New fouling resistant steam generator technologies for Steam Assisted Gravity Drainage (SAGD) produced water recycle. REATED: March 31, 2014 ALLENGE SPONSOR: OSIA s Water EPA is sponsoring this challenge. Our aspiration is to reduce water use and increase water recycling rates at oil sands mining and in situ (in place) operations without environmental burden shifting ( All projects are evaluated and actioned as they are received. OSIA has four Environmental Priority Areas (EPAs): Water, Land, Tailings, and Greenhouse Gases (GGs). For more information on this OSIA hallenge please visit anada s Oil Sands Innovation Alliance (OSIA) accelerates the pace of environmental performance improvement in anada s oil sands through collaborative action and innovation. OSIA Members represent more than 90 per cent of oil sands production. We bring together innovators and leading thinkers from industry, government, academia and the wider public to identify and advance new transformative technologies. hallenges are one way we articulate an actionable innovation need, bringing global innovation capacity to bear on global environmental challenges. 1

2 WAT TO SUBMIT TO OSIA OSIA requires sufficient non-confidential, nonproprietary information to properly evaluate the technology. Some items that will be especially important to present in your submission are: oncept and basic unit operations Technical justification for the approach (e.g. laboratory batch or continuous experiments; pilot or demo plants; process modeling; literature precedent) Describe quantities and qualities of utilities and consumables that are required Energy inputs quantity and type(s) apital and operating cost estimates if available based on described capacity targets 3rd party verification of your proposed technology. 3rd party verifiers should be reputable, independent engineering companies if possible Basis of cost estimation, including estimation scope, contingency, etc. IP status of your proposed technology What operating environment restrictions might your technology face: Explosive atmospheres Severe weather Power fluctuations FUNDING, FINANIALS, AND INTELLETUAL PROPERTY OSIA Members are committed to identifying emerging technologies and funding the development of the technologies to the point of commercialization, while protecting the Intellectual Property (IP) rights of the owner of the technology. Successful proposals can receive funding from OSIA members to develop and demonstrate the technology in an oil sands application. Multiple technologies may be funded, at the discretion of the Members. OW TO SUBMIT TO OSIA Submit a summary of your solution using OSIA s Environmental Technology Assessment Portal (E- TAP) Process, available at: Please note: ETAP is a staged submission process. The initial submission requires only a brief description and limited technical information. Upon review by OSIA, additional information may be requested. Instructions for submission are provided on the ETAP site. All information provided is non-confidential. OSIA will respond to all submissions. 2

3 #0001: Fouling Resistant Once Through Steam Generators (OTSG) DETAILED SOLUTION DESRIPTION The OSIA Water Environmental Priority Area Steering ommittee has identified fouling resistant OTSGs as a technology which could improve the environmental performance of the oil sands. The Water EPA S is interested in new steam generator technologies to replace existing steam generators in the existing process configuration for SAGD produced water recycle.. Proposals based on work that is a proven concept are desired. The successful technology will: Resist fouling and scaling, from contaminants in the boiler feed water or continually remove scale which is formed; Operate with pre-treated inlet water quality listed below. The ability to treat poorer quality water is desirable: SiO2 < 50 mg/l (minimum, < 25 mg/l desired), a/mg <0.5mg/L, 1,000-8,000 mg/l TDS,>25 mg/l TO Produce steam at 91% or better steam quality, 100% best, superheated steam is acceptable Lower quality steam is acceptable from lower quality inlet water 10-15MPa; Low NOx (<50 PPM); Natural gas is preferred fuel (others could be considered); and Large scale ( MW thermal, ~ t/hr of steam) and efficient (>85% on a higher heating value (V) basis) BAKGROUND The most common recovery process employed for producing oil from deep oil sands reservoirs (geological formations), is known as Steam Assisted Gravity Drainage (SAGD). In this process, steam is generated at a entral Processing Facility (PF), transported to well pads, and injected into a horizontal well bore within the formation. The heat supplied by the steam warms the heavy oil in the reservoir, allowing it to flow via gravity into a second well bore that captures the oil water mixture and produces it to the surface with the hydrocarbon at temperatures of over 180, and high levels of impurities, including salts, metals, silica and organic compounds Typical steam requirements in these types of processes range from 2 to 5 barrels or more of water per barrel of oil produced. Because of the large water requirements, recycling and reuse of the water used in the steam production is mandatory both to protect the environment and to minimize costs. urrent recycling rates are 90% or more, and make-up water is typically sourced from brackish water formations to further minimize environmental impacts. The produced oil water mix is separated, and the remaining water is then treated to be pure enough for steam generation. This produced water has high levels of impurities, including salts, metals, silica and organic compounds. It currently needs to be treated before being fed to the boilers. Preparing this boiler feed water continues to be challenging with present technologies as they require significant energy inputs and are very capital intensive. urrent treatment steps still leave current technology boilers vulnerable to fouling and scaling, which leads to loss of efficiency, tube failures and downtime for cleaning and repairing. One means of meeting this challenge that has not been thoroughly investigated are technologies that capture and remove impurities during the boiling operation, rather than treating the water beforehand. At a minimum, a boiler technology that can create high purity steam from treated water while eliminating fouling and increasing steam quality is sought. Far more valuable would be a technology that could produce 75% quality steam with entirely untreated produced water. 3

4 #0001: Fouling Resistant Once Through Steam Generators (OTSG) APPROAES NOT OF INTEREST The following approaches are not of interest: Approaches that have not demonstrated proof of concept Tube coatings, or tube configurations Low quality steam generation onfigurations that produce steam that is co-mingled with other products (such as the products of combustion from the boiler, or nitrogen) ADDITIONAL INFORMATION Supplemental Information Typical SAGD eat and Material balance. 4

5 OSIA SAGD TEMPLATE Base ase Mechanical Lift kpa Diluent Warm Lime Softening - OTSG 27,765 BPSD 10,210 BPSD 3, m 3 /d API Oil Treating Diluent lost to Fuel 42 BPSD 8,783 BPSD 7 m 3 /d Well Pad Facilities Water lost to Dilbit 13 BPSD Air ooler Vapour Recovery 2 m 3 /d Dilbit 51,941 BPSD Preflash Fluid Water Knock-Out Treaters PF Dilbit 8,258 m 3 /d PADS Emulsion Vessel 1 Vessel 2 x Mechanical 16.1 API 21.3 API 122,948 BPSD 19,547 m 3 /d Recycled Recovered Diluent Sour PF Produced Gas hemicals hemicals 0 BPSD 1.85 MMSFD 0 m 3 /d 52,283 Sm 3 /d Produced Gas 0.21 Sulfur (metric t/d) omposition Reservoir Mol% omposition (Dry Basis) O Mol% Mol% SOR: 3.00 (wet) N2 1.3 Mol% O Mol% GOR: S 0.13 Mol% N2 0.9 Mol% Mol% 2S 0.3 Mol% Bitumen Mol% De-Oiling Mol% 33,000 BPSD Mol% Mol% 5,247 m 3 /d Mol% Mol% 7.08 API Mol% IGF/ISF/ORF Units Skim Tank Mol% 5.05 % Sulfur (comp at test separator) De-oiled Water 1 Train Produced Water Mol% 589,560 kg/h 591,682 kg/h Produced Water 14,175 m 3 /d 14,234 m 3 /d 589,710 kg/h 1,492 mg/l TDS 1,492 mg/l TDS 14,182 m 3 /d 188 mg/l Silica 188 mg/l Silica 1,492 mg/l TDS 14 mg/l ardness 14 mg/l ardness 188 mg/l Silica 300 mg/l TO 300 mg/l TO mg/l ardness mg/l TO Produced Gas Water Treatment 0.93 MMSFD hemicals Blowdown to WLS Summary Table 26,233 Sm 3 /d Lime 363 kg/h 117,811 kg/h MU TDS (ppm) 7,172 MagOx 96 kg/h 2,829 m 3 /d PW TDS (ppm) 1,492 Electricity (ESP) Soda ash 37 kg/h 28,493 mg/l TDS PW TO (ppm) MW PW WLS Afterfilters 158 mg/l Silica LP Flash BD (%) 8% Tank 1 x WLS Treater WA Polishers BFW 0 mg/l ardness BD Recycle (%) 60% Steam WLS Feed WLS Overflow 3 x WA Units Tank 2,346 mg/l TO TDS to Boiler (ppm) 6, ,220 kg/h 856,388 kg/h 855,905 kg/h 2 x Polishers Boiler TO (ppm) ,757 m 3 /d WE 20,587 m 3 /d 20,576 m 3 /d MU Flowrate (kg/h) 149,027 6,160 mg/l TDS 6,062 mg/l TDS Backwash Service Water WLS Sludge (kg/d) 23, mg/l Silica 34 mg/l Silica 4,280 kg/h Disposal Type (L,S) L 10 mg/l ardness 3 mg/l ardness 103 m 3 /d Disposal Rate (kg/h) 63, mg/l TO 515 mg/l TO Disposal Solids (kg/d) 51,662 Water Losses to Reservoir: larifier Waste Regeneration 65,522 kg/h 980 kg/h (dry basis) Waste to Disposal Water Balance 1,576 m 3 /d 259 m 3 /d Stream Flow Flow TDS Silica ardness 10 % Losses 22,945 mg/l TO kg/h m 3 /d ppm ppm ppm Steam to reservoir 655,220 15, Losses to reservoir 65,522 1, Produced Water 591,682 14,234 1, Losses to production De-oiled Water 589,560 14,175 1, Steam Generation P Steam Make-up Water 149,027 3,584 7, % Quality Efficiency 91.5 % (LV) BFW Supernatant Flue Gas (includes Glycol eater) 655,220 kg/h Duty (abs) 1,437 GJ/h 851,624 kg/h WLS Feed 856,388 20,587 6, O2 2,191 metric t/d 15,757 m 3 /d WE 1,362 MMBTU/h 20,474 m 3 /d WLS Overflow 855,905 20,576 6, Make-up Water Ion SO metric t/d 10.0 MPag Duty (fired) 1,570 GJ/h (LV) 6,059 mg/l TDS larifier Waste to Land ,027 kg/h Exchange NOx 0.38 metric t/d 1,488 MMBTU/h (LV) 34 mg/l Silica Blowdown to Disposal 63,435 1,523 28, ,584 m 3 /d NOx emission: 9.66 g/gj Utility Steam 0 mg/l ardness LP Steam to WT ,172 mg/l TDS Energy 101 GJ/h (LV) 35.0 GJ/h Wet Steam OTSG mg/l TO LP Steam to eader 15, , mg/l Silica Flow Rate 462 MMSFD 15,133 kg/hr PS 77 % Quality 6 x OTSG Boilers Service Water 4, , mg/l ardness O2 in Fuel Gas 2.1% Wt% 851,624 kg/h Radiation Losses BFW Pump (LP&P) Power Treated Produced Gas BFW 851,624 20,474 6, mg/l TO 20,474 m 3 /d WE 32.1 GJ/hr 5.5 MW 1.85 MMSFD Method 1 Water Recycle: 86 % 92 kgmol/hr Emissions Summary LP Steam 679,396 kj/kgmol (LV) Source SO2 S O2 NOx Flash Air Blower 63 GJ/h metric t/d metric t/d metric t/d metric t/d 3.7 MW OTSG Flue Gas Recovered Sulfur Natural Gas to PF 32.8 GJ/hr Blowdown to Disposal MMSFD Glycol eater 63,435 kg/h 1,859 kgmol/hr 0.81 MMSFD 1,523 m 3 /d 810,745 kj/kgmol (LV) 40 Kgmol/hr Natural Gas (Total) 28,472 mg/l TDS 1,508 GJ/h MMSFD 2153 kg/h solids 1,900 kgmol/hr

6 ENERGY FLOW DIAGRAM Base ase: WLS - OTSG Glycol Air ooler 125 GJ/h Diluent Total Air ooler eat Released to Atmosphere Glycol Return GJ/hr Produced Gas ooler (relative to ambient air) 2.4 GJ/h 4.41 GJ/h 1.2 GJ/h Produced Gas Emulsion / BFW Exchanger Sales Oil oolers eat Exchangers Legend Preflash Emulsion 137 GJ/h Vapor 43.9 GJ/h Dilbit PADS Vessel Oil Treating Recovery Process to Process ot Glycol 144 Skim Tank Produced Water ooler old Glycol 13.4 GJ/h PW / BFW Exchanger GJ/h Direct ontact/quench Reservoir Make-up Water eater Exchangers Duty 22 GJ/h GJ/h Make-up Water Emulsion / BFW Produced Water Glycol ooler GJ/h PW / BFW Exchanger 84.5 De-Oiling / Water Treatment PW / MU water exchanger Produced Gas Air ooler (s) 3.5 Air Glycol eater 2 Diluent Glcyol eater 4.4 BFW GJ/h Sales Oil oolers Make-up Water Glycol eater 21.8 PW / MU water exchanger 18.1 Blowdown Glycol ooler 79.3 Stack Losses BFW Preheaters 86.7 Stack GJ/hr OTSG Air Glycol eaters (two services) 22.7 BD Water to Disposal 80 Air Glycol Preheater 195 (LV basis) OTSG Air Preheater (Flue Gas) N/A Water eat to Earth GJ/h Forced Draft Fan Utility oolers GJ/hr Blowdown ooler Air 20 Fan 33 Glycol Air ooler (based on 5 Ground Temp) 79.3 GJ/h 5 Electrical Loads Power Equivalent eat P Steam MW GJ/h 310 BFW P BFW Pump LP BFW Pump Downhole Pumps Radiation Losses Pad Auxiliaries PS GJ/hr Forced Draft Fan Utility Steam (relative to ambient) Misc Users ,133 kg/h OTSG VRU ompressors BFW Preheaters WLS/Evaporator GJ/h Glycol System LP Steam Total Flash 220 Direct O2 Generation 2,191 MT/day kg/m3 Bitumen 35.0 GJ/h Indirect O2 Generation 328 MT/day 62.5 kg/m3 Bitumen Total O2 Emissions 2,519 MT/day kg/m3 Bitumen 55 Assumes electricity grid O2 emissivity of 763 kg O2eq / MW-hr ombustion Air Direct Emissions from ombustion only 30 GJ/hr (LV) Glycol eater Natural Gas Glycol eater 1.16 GJ/h Inputs Energy P BFW Pump GJ/h 146 Natural Gas 1538 Electrical Power Produced Gas GJ/h (LV) Total GJ/h 11.4 GJ/h Natural Gas Tracing & Utility eat Input (LV) Building eat oolers 1538 GJ/h