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Scott Can
THERMCAT Catalytic Gas Infrared Explosion Proof Heaters
PTAC Green ToolboxSeptember 29-30, 2003
Peter HowieScott-Can Industries Ltd
Scott Can
About Scott-Can Industries Ltd. Based in Edmonton Supplier and manufacturer of Catalytic Units
A reputation for innovation Provide Catalytic Heaters for:
Oil and Gas heating in Hazardous AreasPowder paint curing ovensDomestic radiant heaters
Allied with Infragas of Turin, ItalyA world leader in catalytic equipment
Scott CanInfrared Catalytic Heater
Basics Developed to allow safe and efficient heating
in the presence of hydrocarbon vapoursCatalyst reduces the temperature of
methane oxidation below the ignition temperature
Heaters produce flameless infrared radiant energy to safely heat hazardous areas
98% fuel efficientNo NOx or CO generated
Scott CanCatalytic Heaters - Oil & Gas
Industry Over 200,000 heaters in service in western
Canada’s oil and gas industry todaySpace heating for well site buildings, meter stations, dehydrators, compressor sites and oil batteries.
Pipeline installation of shrink coating Familiar to most field operators
Scott Can
The Need
An economic solution to maximize the use and mitigation of methane emissions
Ideal Solutions should: Generate an economic benefit Be low capital cost and easy
maintenance Not cause other problems – high
reliability Reduce GHG equivalent emissions
Scott Can
The Catalytic Solutions
Based on off the shelf catalytic heater components Heaters already in use for building heat Well suited for remote/isolated locations Low cost and safe compared to other options Provide other economic and intangible benefits GHG emissions reduction of 21tCO2eq/tCH4
reduction for fuel replacement
Scott CanGreen Roles for Catalytic
Heaters Small Vent Streams in Isolated Facilities
Standard Catalytic Building HeatersUse vent gas to back out fuel
Small Variable Vent StreamsCatalytic Converter Prototype AvailableConverts methane to CO2 for Supplemental Process Heat or GHG Reductions
Dilute Fugitive StreamsReduce Methane in Building Exhaust Air
Scott Can
Case 1 - Winterization Heaters
Catalytic Heater Winterization Systems installed on three well sites in Husky’s Saskatchewan heavy oil operations (Fall 2000)
All with underground fuel lines to tank burners
Winterization achieved by heating gas to keep ground and piping system from freezing
Combined with insulating above ground lines
Scott CanWinterization Heater Results
-40
-30
-20
-10
0
10
20
Feb 16 - Apr 6, 2000
Tem
p (d
eg C
)
Ambient T
Gas Riser Temp
Ground Warm Up Maintain Gas TemperatureWith THERMCAT
Scott CanWinterization Heaters – Lessons
Learned Based on field trials
Units have operated reliably through –25 degrees and blizzards
Systems can be started up in winter; fall start-up is better to build up heat in the ground
Use vent gas for both catalytic heaters and tank heaters
Best application – Sites with buried fuel lines to tanks
Scott CanKey Benefits of Catalytic
Winterization Reduce operating costs by 30-70 % Rapid economic payout
<3-4 months if propane backed out<1 yr if purchased natural gas backed out
Low Cost Alternative for Freeze Protection Easily Retrofitted High Operability and Low Maintenance GHG equivalent emissions reductions
achieved
Scott Can
Case 2 – Line Heater
Designed to prove ability of catalytic heaters to run on low pressure gas (under ½ psig) where backpressure is undesirable
Also tested benefits of heating the production upstream of the tank vs. in the storage tanks
Skid mounted, portable unit designed to be retrofitted into existing production lines
Scott CanProduction Line Heater Results
(Tout = Pipewall Temperature at Heater Outlet)(Tin = Pipewall Temperature at Heater Inlet)
0
10
20
30
40
50
60
70
80
May 17 - June 1, 2000
Te
mp
(d
eg
C)
ToutTin
Well Down
Scott CanTout (pipewall) vs Production
0
10
20
30
40
50
60
70
80
0 10 20 30 40 50
Production Rate (m3/d)
To
ut
(de
g C
)
Tout vs Production
Linear (Tout vs Production)
Scott CanNext Steps for Line Heater
Systems They work and are ready for wider use
Improved foam breakdown and oil/water/sand separation in the tanks
Consume Vent Gas rather than venting it Additional work required to quantify:
Overall efficiency vs. fire tubes in tanksQuantify impacts on tank treating effectiveness
Equipment Price Range $13,300-$15,000 For 120,000 BTU/hr line heaters
Scott CanExpanding Catalytic Heater
Uses Use Instrument or Power Gas to provide
building heatUse existing building heatersREUSE instrument or power gasBest where heating load profile generally matches the vent gas supply profile
Scott Can
Reuse Gas in Building Heaters
Actuator Vents or Chemical Pumps
Volume BottleCapacity - 1-2 ft3
Catalytic Building Heater
2-6 scfph/ft2 of heater
Safety Shutoff Valve& Restriction Orifice
SOV
Set at 3”w.c.
Make-up gas regulatorSet at 5”w.c.
Scott Can
New Concepts in Development Concentrated Stream Converter
Small & variable vents mainly methane (<50 m3/d)
To handle small variable flows where flaring and other solutions are not practical
Waste Heat Supported ReactorCollect and convert fugitives in building ventsUse hot exhaust streams to maintain reactionEliminate traces of methane at low cost
Scott Can
Years to Payout (100% Utilization) vs. Cost of Unit(Example unit converts 50-55 m3/d of methane)
$-
$10.00
$20.00
$30.00
$40.00
$50.00
$60.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Years to Payout
Va
lue
of
GH
G O
ffs
et
(CD
N$
/tC
O2e
q)
$10,000/unit
$5,000/unit
Target Payout Range
Credit Value Cap?
Scott Can
Summary There already are catalytic options available
for small concentrated vent streamsTHERMCAT is ready to go
We are also developing new catalytic options
Targeting economic or low cost systems Catalytic solutions can meet the need
Competitively vs. other options
Scott Can
Acknowledgements
Husky Oil for their funding support for initial and on-going work
BP and Nexen for their interest in field testing new concepts
New Paradigm Engineering for suggesting new concepts and supporting field testing
Dr. Bob Hayes for COURSE and NSERC funded work on new concepts
PTAC for Project launches and workshops
Scott Can
Contact Information
ScottCan Industries Ltd.
8220 Davies Road
Edmonton, Alberta T6E 4N2
Tel: (780) 463-5505
Fax: (780) 463-2273
Toll Free: 1-877-213-7832
Email: [email protected]