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Utilisation of High CO2- Content Flare Gas for Steam and Electricity GenerationSantiago PástorTechnical ManagerPETROBRAS EcuadorDecember 2008
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Index
1. Palo Azul Power Plant Project
2. B18 Field - CDM PROJECT: Incorporate Additional Gas Supply
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1.- Palo Azul Power Plant Project
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TopicsTopics
1. Location
2. Background
3. Technology and Operation
4. Environmental Issues
5. Location
6. Economic Issues
7. Video
8. Conclusions
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1. 1. LocationLocation
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LocationLocation……
Petrobras operates the Pata and Palo Azul fields in Block 18, located 300 Km. from Quito, the capital of Ecuador.
Concession area: approximately 110,000 hectares.
Location: Northeast section of the Ecuadorian Amazon Region, in the Province of Orellana.
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Panoramic Viewof the Palo Azul CPF
GUYANAS
URUGUAYCHILE
ARGENTINA
COLOMBIA
ECUADOR
VENEZUELA
PERU
BOLIVIAPARAGUAY
BRASIL
LocationLocation……
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2. Background2. Background
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Background Background ……
In 2006, the Central Processing Facilities (CPF) were built with a capacity to process 40,000 BOPD (28° API), 75,000 BWPD and 12 MMSCF with 77% CO2.
A power generation demand of 12 MW, with a 17.38 MW installed capacity, powered by provisional, portable diesel-fuelled reciprocal engines at a high fuel cost. Ecuador imports its diesel.
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GOR wells = 400; 12 MMSCFD/ (77% CO2)
Technological alternatives were analyzed for the use and disposal of the gas from flares for generating electricity and optimizing operating costs.
Background Background ……
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Analyzed alternatives :
Combustible gas in Internal Combustion Engines.
Gas in Gas Turbines.
Flare Gas and/or crude oil in electricity generation with steam cycle.
BackgroundBackground……
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Technical-economic analyses determined that the combined steam cycle system is the best option for achieving:
Reduction of environmental emissions and noise pollutionBetter use of flare gases Minimum gas treatmentSubstantial reduction of operating costs
BackgroundBackground……
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Limited operating window when gas quality decreasesWith full Load: 100% • Maximum gas
utilization: 30%• Requires other fuel
(diesel o crude oil): 70%
More environmental emissions, particularly CO2
Alternative of a dual combustion engine implied:
BackgroundBackground……
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0
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0 10 20 30 40 50 60 70 80 90 100
0
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Engine load%
Gasshare %
Dieselshare %
Transfer window
P = 68%Fuel share 40%CRO 60%, GAS 40%No estimate on heat rate.
P = 100%Fuel share 27%CRO 73%, GAS 27%No estimate on heat rate
P = 100%CRO modeCRO 100%, GAS 0%Guaranteed heat rate 8539 kJ/kWhrat 35°C
NOT APPICABLE OPERATING AREA
Fuel SharingAPPICABLE OPERATING AREA
Poor gas operational window: Dual combustion engine
BackgroundBackground……
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PHASE 3
DETAIL OF SELECTED ALTERNATIVE
BASIC PROJECT
PHASE 2
ALTERNATIVE SELECTION
CONCEPTUAL PROJECT
PHASE 1
IDENTIFICATION AND
EVALUATION
PHASE 4
EXECUTION
PROJECT APROVAL
PHASE 5
OPERATION
(1st year)
FRONT END LOADING (FEL)
Requirements for project definition
DSP – DECISION SUPPORT PACKAGE VP – VERIFICATION PACKAGE
DSP 1 DSP 2 DSP 3 VP 1 VP 2
Gate1
Gate2
Gate3
Gate4
Gate5
PLANNING CONTROL
The project was developed using SGPMP-PRODEP (PETROBRAS) methodology
BackgroundBackground……
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APPLIED LAWS AND REGULATIONS:
Ecuadorian Hydrocarbons Law, articles 11 and 24.
Substitute Regulation of the Hydrocarbons Operations Regulation, articles: 11 and 13.
Ecuadorian Water Act, article 82.
General Rules for Applying the Water Act, articles: 13, 14 y 15.
BackgroundBackground……
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Environmental Management Law, articles: 19 and 20.Environmental Regulation for the Electricity Industry, article 10.Electrical Sector Regime Law, articles : 2, 3, 30 and 40.Regulation of Concessions, Permits and Licenses for the Provision of Electrical Power Services, articles: 5, 11, 12 , 54, 55 and 95.
APPLIED LAWS AND REGULATIONS:
BackgroundBackground……
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GOVERNMENTAL APPROVALS:
Authorization to use gas: DNH (National Hydrocarbons Office) resolution #683 of Nov,17th 2006.
Authorization to use crude oil: DNH resolution #74 of8/Feb/2008
BackgroundBackground……
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GOVERNMENTAL APPROVALS:
Authorization to use water: CNRH (National Council of Water Resources) resolution dated 29/Nov/2005.
Environmental License: CONELEC (National Electricity Council) resolution #DE-06-055 of 6/Nov/2006.
Authorization Contract for construction, installation and operation: executed with CONELEC on 9/Nov/2007.
BackgroundBackground……
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3. 3. Technology and Operation
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System : 2 steam 6 MW turbogenerators and 1-5.38 MW motor generator.
12 MW net generation with gas, 17.38 MW installed capacity.
Back up motor generator fuelled by crude oil or diesel for start up and auxiliary system.
Hybrid System using all high CO2-content gas with no prior treatment,depending on required demand.
Technology andOperation
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Boilers with cutting-edge gas-crude oil dual burners.
All available gas calorific energy is used. (470 BTU/CF)
Additional contaminant of gas emissions (CO2, among others) are avoided by not burning fossil fuels, such as crude oil, diesel or bunker.
Technology andOperation
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Power Generation Plant Layout
GAS FWKO + SRU
CRUDE OIL
TO BOILERS
TO MOTORCRUDE OIL TREATMENT
MOTO-GENERATOR
BOILERSSTEAM TURBINES
5.38 MW
6 MW c/u
COOLING TOWER
Technology andOperation
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Water-Steam Cycle (Rankine Cycle)
Technology andOperation
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COOLING TOWER
BOILER
WATER TREATMENTFEEDWATER PUMPS
CONDENSER PUMPS
FLOW PUMPS
WATER REPLACEMENT PUMPS
TURBINE
DEAERATOR25 PSIG
CONDENSER
DRAIN PIT
CLARITY WATER
Generator
DEMINERALISED WATER TANK
PURGE WATER TANK
OSMOSIS FILTERS
STEAM 600 PSIG 750° FSTEAM
200 PSIG
Steam Circuit Layout
TO CPF
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3-D View of Plant
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Panoramic View of Boilers Area
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Boiler Unit
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Crude Oil Generator Unit
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4. 4. EnvironmentalEnvironmental IssuesIssues
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EnvironmentalEnvironmental IssuesIssues……
EMISSIONS OF THE BOILERS vs REQUIREMENTS DINAPAª
1
10
100
1,000
10,000
NOx CO PM SOx CO2
UN
ITS
[mg/
Nm
3] GAS @ 11% O2
OIL @ 11% O2
DINAPA LIMITGAS@11% O2DINAPA LIMIT OIL@11%O2
DINAPA: GOVERNMENT ENVIRONMENTAL OFFICE
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5. 5. EconomicEconomic IssuesIssues
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Project allows the use of 100% of flare gas for the steam cycle as thermal energy.
The achieved results consist of a 90% reduction in equivalent energy expenses, 37% savings (OPEX).
EconomicEconomic IssuesIssues
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Year 2007: Power Generation with Diesel # 2
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May June July
Augus
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Kw
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ay
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/ Kw
-hr
Energy Kw-hr
Diesel Gall/day
Unit Cost
EconomicEconomic IssuesIssues
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Year 2008: Power Generation with Flare Gas
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all /
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and
BOPD
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/ Kw
-hr
Energy Kw-hrDiesel and OilUnits Costs
EconomicEconomic IssuesIssues
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6. VIDEO6. VIDEO
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Existing Plant Existing Plant VideoVideo
Video
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7. Conclusions7. Conclusions
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ConclusionsConclusions
Flexible system, poor gas options, poor and rich gas or crude oil blends. Use of flare gas, no prior treatment required, only removal of liquids. Reduction of 60 MTCDE/year.Possibility to use 100% of available gas (12 MMSCFD). Current use is 50%.Flexibility for adapting to future field requirements, depending on oil and formation water production.
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Reduction of emissions compared to those of previous plant
Reduction of noise from 115 to 88dB in turbines area.Immediate effects consisting of a 90% of energy savings and 37% of OPEX, approximately
EQUIP.SO2
(mg/m3)NOx
(mg/m3)CO
(mg/m3)MP
(mg/m3)
Diesel Gen. 301 2,085 142 24
Gas Boiler < 5 17 < 5 < 5
ConclusionsConclusions
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2.2.-- B18 Field B18 Field -- CDM PROJECT: CDM PROJECT: Incorporate Incorporate AdditionalAdditional Gas Gas SupplySupply
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Gas projection indicates continuing decrease in quantity:
- Current 12 MMSCF vs.0.1MMSCF (2022)
• Power demand increasing, expected peak of 23 MW in 2011
• Future flare gas deficit in power demand peak: 3 MMSCFPD
Gas avalability vsPower Demand
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Project Generation Demand
2008
2010
2012
2014
2016
2018
2020
2022
0
5
10
15
20
25
MW
Years
POWER GENERATION DEMAND
POWER GENERATION WITH GAS POWER GENERATION WITH CRUDE OIL POWER DEMAND PROJECTION (MW)
Crude oil required= 1.6 MMBBLs
Crude oil equivalent= 0.3 MMBBLs
Total crude oil= 1.9 MMBBLs
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Gas consumption
2008
2010
2012
2014
2016
2018
2020
2022
0.000.501.00
1.50
2.00
2.50
3.00
3.50
4.00
MM
SCFP
D
Years
GAS CONSUMPTION
AVAILABLE NET GAS
REQUIRED GAS FROM OTHER FIELDS
TOTAL NET GASREQUIRED
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Gas purchase from nearby oil fields.
Near future: Replace crude oil burning with gas burning.
Expected savings aprox. 1.6 million barrels of crude oil in 14 years for the Block 18 oil field.
Project development, currently status at Identification & Evaluation phase.
Objectives…
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Expected total savings of aprox. of 1.3 MMTCDE (not burning crude oil) during 14 years.
Project meets CDM requirements
Bonuses CER´s are expected
Project could be part of the Programatic CDM activities of Petrobras-PESA
Objectives…
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Thank YouThank You