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Using Nuclear Heat for In-Situ Recovery of Unconventional Hydrocarbons: A Case for the High Temperature Gas Reactor (HTGR)
Joseph D. Smith, PhD Advanced Process & Decision Systems Idaho National Laboratory
October 18-22, 2010 30th Oil Shale Symposium Colorado School of Mines Golden, Colorado
Presentation Overview
• Background • Project Purpose • HTGR Integration of SAGD Process
– Process modeling – Economic modeling
• Conclusions • Future work
Hybrid Energy Systems for Unconventional Hydrocarbon Recovery
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U.S. Energy Statistics
General Statistics • 4.6% of the world’s population • 21.1% of the world’s energy
consumption – 15.1% domestically supplied
• Petroleum supplies 37% of U.S. energy consumption
– 71% is used in the transportation sector
• Transportation accounts for 28% of U.S. energy demand
U.S. Oil Statistics • Consumption of 7.1 billion barrels,
2008 – 4.7 billion barrels imported, 66.3%
• U.S. oil productivity – Peaking in 1972 at 18.6 barrels/day
per well – 10.9 barrels/day per well in 2000
• An alternative technology is required for liquid transportation fuels to increase U.S. energy security
The steam assisted gravity drainage (SAGD) and oil shale recovery processes produces heavy hydrocarbon products, which can be
refined into higher value petroleum products.
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Background/Intro Domestic Shale offers Security Western Oil Shale deposits account for 2 trillion barrel reserve
Most concentrated in world Mahogany Zone >100 ft thick
May produce 30 gal kerogen - derived SCO/ton shale rock But…requires lots of Energy and Water and generates GHGs
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Hybrid Energy Systems for Unconventional Hydrocarbon Recovery
Background/Intro Heat for Processing
Mining Retort Upgrading Oil Shale Refinery
Surface Processing
Drilling Heating Upgrading Oil Shale Refinery
In-situ Processing
Processing requires lots of energy (fossil fuels, HTGR) to extract crude and upgrade it to produce a liquid fuel
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Q
Hybrid Energy Systems for Unconventional Hydrocarbon Recovery
Drawbacks of Conventional In-Situ Hydrocarbon Recovery
• Returns are heavily dependent upon volatile crude market and natural gas price
• Heat produced through natural gas combustion
• Significant production of greenhouse gases
Solution: Implement a high temperature gas reactor (HTGR) with the conventional process to eliminate natural gas usage and minimize CO2 emissions.
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HTGR Layout
Circulator
Core* 500 to
600 Mwt
Core Inlet350 to 500 °C
Core Outlet900 to 950 °C
To / From the Process Heat Applications
Reactor Island
Core Support Structure /
Outlet Plenum
Control Rods, Access Ports &
Inlet Plenum
IHX
IHX Outlet850 to 925 °C
IHX Inlet325 to 450 °C
Reactor & IHX Pressure Vessels
(primary & secondary pressures 5 to 7 MPA)
Nuclear Heat Supply SystemHelium Flow
Hot Ducts
* Core includes fuel, graphite, core structural and other ceramic components and the metallic core barrel
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HTGR Project Details • Integrate high temperature gas reactor (HTGR) technology into the
unconventional hydrocarbon recovery processes – SAGD process has been evaluated for bitumen production – Oil shale evaluation is in progress
• HTGR can produce high temperature heat, electricity, and/or hydrogen • HTGR integration will:
– Reduce CO2 emissions – Extend the life of the natural resource used as feedstock – Provide predictable availability and stable energy costs
• Suitability of HTGR integration for the SAGD process was assessed as follows: – Technical merit, i.e. is the process suited for integration – Rough order of magnitude economic comparison of conventional
and HTGR- integrated bitumen selling prices
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SAGD Process Assumptions • 56,000 barrels of bitumen extracted • 80,000 barrels of dilbit produced
– Dilbit – blend of bitumen and naphtha to make the bitumen flowable for transport
• 70% bitumen • 30% naphtha
• Steam to oil ratio: 2.5 barrels of steam per barrel of oil – Steam flow determine natural gas or HTGR heat consumption
• Steam conditions: – 310°C – 10 Mpa
• Water recovery – 85%
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In-situ Oil Shale processing using HEAT from an HTGR • Closed HX system from HTGR to underground pipes for slow kerogen heating
to 350 - 400 °C using various heat transport media (HTMs) Issue for Modeling • How far can HTGR Heat via HTM be economically transferred?
– Ex-stu
Shell Process
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HTGR Outputs and Assumptions
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Process Block Flow Diagrams - SAGD
Conventional Process Nuclear Integrated Process
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Target area for HTGR integration
Process Modeling Results - SAGD
HTGR integration reduces natural gas consumption and the associated CO2 emissions.
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Economic Modeling Overview and Assumptions
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Economic Modeling Overview and Assumptions • Calculated economic inputs:
– Total capital investment (TCI) • SAGD process cost based on most recent literature and vendor data • HTGR cost estimate is in the process of being refined
– Alberta construction adders applied to HTGR – Annual revenues and operating costs
• Based on the economic inputs the following indicators were calculated: – Bitumen price for an internal rate of return (IRR) of 12% for a range of
carbon taxes: – IRR for low, average, and high bitumen selling prices (wholesale price,
without taxes and delivery) • Low (March 2009) - $37.82/bbl • Average - $80.18/bbl • High (July 2008) - $122.53/bbl
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Preliminary Economic Results - SAGD
These results are preliminary, they are for a
conservative case.
Additional refinement of the HTGR cost estimate is
currently underway.
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Results Summary HTGR in-situ unconventional hydrocarbon recovery modeling
– Highlights differences between HTGR assisted process w/ HTGR supplying heat + power and/or hydrogen compared to a conventional industrial application using fossil fuels
• Technical – Greater energy efficiencies for equal product output – Greater process product yields for equal energy input
• ENVIRONMENTAL – Significant reduction of GHG emissions – Potentially less water use
• Economic – Significantly lower process fuel costs – Avoidance of future carbon taxes
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Hybrid Energy Systems for Unconventional Hydrocarbon Recovery
Future Work
• Refine the HTGR capital cost estimate and include in the economic model – Consider independent owner/operator arrangements
and financing of SAGD and HTGR processes – Work with potential end users to, modeling their specific
processes • Perform a similar analysis for in-situ and ex-situ oil shale
extraction – Process model with material and energy balance for
technical assessment – Economic analysis
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Wrap up • Current energy status
– The U.S. imports over 65% of it’s petroleum products – Domestic oil production peaked in 1972 – In-situ SAGD and oil shale processes can be used to offset
imported oil (not including Canada) using feedstocks from Canada and the U.S.; however, both processes have large carbon footprints
• Alternative solution – Nuclear Heat (HTGR) can be integrated, via high temperature heat
• Technical merit – Nuclear integration is technically viable and reduces CO2
emissions • Economic viability
– Preliminary economic results indicate that in a carbon constrained environment, Nuclear integrated options can be competitive
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Questions
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Back-up Slides
Oil Shale Reserves equivalent to Saudi Oil Reserves Located in NW Colorado, SW Wyoming, NE Utah When heated to approximately 400°C, produces
Shale Oil Natural Gas
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Background /Introduction - Oil Shale
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-
Reactor Unit
Recuperators
Compressors
Turbine
Generator
Contaminated Oil Lube System
Un-contaminated Oil Lube System
Shut-off DiskCBCS & Buffer Circuit
CCS & Buffer Circuit
Inter-cooler
Pre-cooler
Reactor Unit
Recuperators
Compressors
Turbine
Generator
Contaminated Oil Lube System
Un-contaminated Oil Lube System
Shut-off DiskCBCS & Buffer Circuit
CCS & Buffer Circuit
Inter-cooler
Pre-cooler
PEBBLE BED MODULAR REACTOR
PBMR
ANTARES
AREVA
MODULAR HTGR CONCEPT
GENERAL ATOMICS
(FRG) THTR 1986 - 1989 (U.S.A.) FORT ST. VRAIN
1976 - 1989 PEACH BOTTOM 1 (U.S.A.)
1967 - 1974 (FRG) AVR 1967 - 1988 DRAGON
(U.K.) 1963 -1976
EXPERIMENTAL REACTORS DEMONSTRATION OF BASIC HTGR TECHNOLOGY
HTTR (Japan)
1998 - Present
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Hybrid Energy Systems for Unconventional Hydrocarbon Recovery
The HTGR Is Not A New Technology
Normal Operation Source Term
Fuel Safety Limits
Fuel Kernel!(UCO, UO2)!
Coated Particle!
Outer Pyrolytic Carbon!Silicon Carbide!Inner Pyrolytic Carbon!Porous Carbon Buffer!
Severe Accident Behavior
Containment And
Barriers And
Defense in Depth
Mechanistic Accident
Source Term
PARTICLES
COMPACTS
FUEL ELEMENTS
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Coated Particle Fuel Performance is at the Heart of Many of the Key Pieces of the Safety Case for the HTGR
TRISO coated particle fuel passes major milestone without a single particle failure achieving first major objective for US fuel qualification
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Fuel is the Key to the HTGR
Sample SAGD Process
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HTGR to Supply High-Temperature Helium or Steam to Retort Interval
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INL Analysis Based on Shell Process
Conclusions - SAGD • HTGR integration lowers the carbon footprint of the SAGD
process through the incorporation of steam generated without burning fossil fuels
• In a carbon constrained market reasonable carbon taxes can be applied which would cause the nuclear-integrated process to be competitive with the conventional process
• The economic results are preliminary, as the HTGR capital cost estimate is being refined, but provide a rough order of magnitude comparison of conventional and HTGR- integrated SAGD process
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