Waste to Wealth. Case Study Glycol Dehy Waste Gas to Engine Air Intake (SlipStream)
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1 Waste to Wealth Case Study Glycol Dehy Waste Gas to Engine Air Intake (SlipStream) Sean Hiebert, CET, P.Eng. Operations Engineer WCBU Operations Energy Efficiency ConocoPhillips Canada Phone: (403) Cell: (403)
2 Introduction Typical Compressor Station Typical Glycol Dehydration Unit Operation Conventional Waste Gas Handling Options 1-3 Pilot Site Proposed Design Objectives Location/Technology Description Before/After Photos Installation Discussion Challenges Project Results 2
3 Typical Compressor Station Large Natural Gas Reciprocating Engine (driving a compressor) H2O $$ BTEX Methane Still Column Vent Glycol Dehydration Skid (Contactor/Regenerator) A glycol dehydration unit operation is often adjacent to an engine-driven compressor, but not always! TEG Reboiler 3
4 Typical Glycol Dehydration Unit Operation Option 1 Option 1: Vent Waste Gas off Still Column H2O $$ Dehy Still Column Overheads (Waste Gas) BTEX Methane Dry Gas Lean Glycol Wet Gas Rich Glycol High Pressure Glycol/Gas Contactor Low Pressure Glycol Regeneration System 4
5 Typical Glycol Dehydration Unit Operation Option 2 H2O $$ BTEX Methane Option 2: Pipe to Tank/Condensing Tank and Vent Waste Gas Dry Gas Lean Glycol Tank Dehy Still Column Overheads (Waste Gas) Wet Gas Rich Glycol High Pressure Glycol/Gas Contactor Low Pressure Glycol Regeneration System 5
6 Typical Glycol Dehydration Unit Operation Option 3 CO2 H2O Heat Option 3: Pipe to Tank/Condensing Tank and Incinerate/Flare Waste Gas Fuel Gas to Incinerator Dry Gas $$ Dehy Still Column Overheads (Waste Gas) Lean Glycol Tank Wet Gas Rich Glycol High Pressure Glycol/Gas Contactor Low Pressure Glycol Regeneration System 6
7 7 Opportunity
8 Pilot Site - Proposed Design (Dehy waste gas to engine) CO2 H2O Heat Fuel Gas Air Dehy Waste Gas Dry Gas Compressor Engine Lean Glycol Tank Dehy Still Column Overheads (Waste Gas) Wet Gas Rich Glycol High Pressure Glycol/Gas Contactor Low Pressure Glycol Regeneration System 8
9 Pilot Site - Objectives Objectives Site GHG emission reductions (CO2 credits) Engine FG consumption reduction additional sales (engine RemVue AFRC upgrade with dehy waste gas SlipStream) Dehy condensing tank vent reduction/elimination (VOC s) Site Benzene emission reductions (currently venting) Internal combustion engine BTEX destruction (vs. flaring or incinerating) Regulatory compliance (now & future) Worker exposure reduction Site odor improvements Remote Field Dehydration Unit Operation/Optimization As all dehy waste gas is being conserved/utilized, dehy optimization not as significant CCEMC project ~50% subsidization (RemVue AFRC & SlipStream) Project aligns with CPC s SPIRIT Values & corporate sustainability/ghg emission reduction initiatives 9
10 Pilot Site - Location and Technology Description Pilot Location Description Sweet Location (0% H2S) Compressor Package (remote field gas gathering/compression) Engine: Cat G3516LE (809kW, 1085HP) Engine is currently loaded to ~95-100% Control System: RemVue 500AS AFRC w/ SS50 SlipStream Add-on TEG Glycol Dehydration Skid Dehydrates ~200 E3m3/d of raw natural gas Operates with a Kimray glycol energy exchange pump Operates without a flash tank Operates in conjunction with a BTEX condensing tank Currently regulated to 3 tonnes/yr of Benzene emitted Stricter Benzene regulations coming (Jan : 2 tonnes/yr, Jan : 1 tonne/yr) Technology Description RemVue AFRC & SlipStream REM Technology Inc. SlipStream is an add-on of the RemVue AFRC technology Allows for the safe utilization of site low-pressure gas vs. venting/combusting Compressor Packing/Crankcase Vents, Dehy Still Column Overheads (waste gas), Dehy Flash Tank, Atmospheric Tanks, Instrument Vents Can safely displace up to ~50% of the engine s normal FG consumption Engine can safely/efficiently destroy & disperse site Benzene emissions 10
11 Pilot Site - Before Dehy waste gas venting from Condensing Tank 11
12 Pilot Site - Before Conventional reciprocating engine set-up Air Fuel Gas 12
13 Pilot Site - After Dehy Waste Gas Collected/Piped to Engine Air Intake Dehy Waste Gas (off condensing tank) 13
14 Pilot Site - After Dehy Waste Gas (from Dehy) SlipStream Valve Train (Monitors/Controls/Isolates/Measures/Filters) Liquid Knock-out w/ High Level Switch 14
15 Pilot Site - After Dehy Waste Gas Air 15
16 Pilot Site After (In Operation) SlipStream: kg/hr, ~0.42 E3m3/d (waste gas from dehy) Engine FG: kg/hr, ~4.0 E3m3/d (site FG sales pipeline) **Approx. 10% of engine FG is currently dehy waste gas! 16
17 Pilot Site After (In Operation) From Cat G3516LE Spec Sheets: (at 100% load) - Engine rating: 1085 bhp - Exhaust THC: 3.2 g/bhp-hr (677ppm) **>98% Benzene Destruction - Exhaust Stack Temp: 1150 degf (621 degc) **AER D60 incinerator minimum exit temperature requirement >600 degc Improved emission plume dispersion expected - Exhaust stack flow rate: 5977 ft 3 /min - Stack temperature: 621 degc - Stack height: > 1.2 x building peak height 17
18 Installation Discussion Challenges Obtaining field buy-in (many initial concerns) Unconventional thinking to introduce waste gas into an engine Solids/liquids carrying through into the engine Engine internal corrosion concerns (water-saturated BTEX stream) High heating value (engine detonation concerns) Plugging of engine flame arrestor screens (intake system) LEL concerns in air intake Introducing gas pre-turbo Unit downtime/reliability No one wants to be the Guinea Pig! (1 st within COP) Stakeholder engagement Operations, M&R, Inspector, mechanical & I/E crews Scheduling (MOC, materials, labor) Awareness/Training 18
19 19 Project Results Success! We think... Staged Commissioning/Start-up Approach Sept 28 th, 2013 Commissioned/Started-up the package with a RemVue 500AS w/ SS50 control system Oct 15 th, 2013 Commissioned/started-up the dehy waste gas SlipStream Ongoing site training/monitoring Detailed engine inspection to be conducted at the next scheduled service Currently displacing >10% of the engine s normal FG Engine currently running on ~15 kg/hr, 0.42 E3m3/d of dehy waste gas ~2675 tonnes CO2e/yr GHG reduction >98% Dehy BTEX destruction in the adjacent internal combustion engine Improved emission plume dispersion (engine exhaust stack vs. conventional) Site odor has significantly improved Worker BTEX exposure has been significantly reduced Operations has stated that the engine is starting/running great Appears to be another viable dehy waste gas handling option Stay tooned!
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