【Ten Years of Rapid Development in Chemical Engineering Equipment】Between 2015 and 2024, the world’s first 5MW-class offshore high-temperature flue gas waste heat power generation unit was tested successfully
Thread Content
Safety first. Prevention first – let’s give praise and support to the achievements made in China’s chemical engineering technology and equipment. **********************【Ten Years of Great Development in Chemical Engineering Equipment】A continuously updated summary post is available; feel free to join the discussions at https://bbs.hcbbs.com/thread-3576046-1-1.html (Source: Haichuan Chemical Engineering Forum) ***************** On August 13, 2024, the world’s first 5MW-class offshore high-temperature flue gas waste heat power generation unit was tested in Tianjin, and it is set to be used as a demonstration system in the development project of the 9-7 oil field in Wenchang. This breakthrough not only represents a significant advancement in the utilization of waste heat from flue gas in offshore oil and gas field power stations, but it also holds milestone significance for the green and low-carbon development of offshore oil and gas fields in pursuit of the \"dual carbon\" goals. The power plant is the “heart” of an offshore platform; it typically generates electricity by burning the oil and gas produced on site, but this process releases large amounts of hot exhaust gases, making it one of the main sources of carbon emissions in offshore oil and gas exploration. This waste heat power generation unit uses the waste heat from the high-temperature flue gas generated during the operation of the power plant as a heat source; an organic medium that circulates within the unit drives an expander to generate electricity, thereby converting waste thermal energy directly into clean electrical energy. Compared to the combustion emissions of conventional flue gas, the waste heat utilization potential of power plants equipped with high-temperature flue gas waste heat recovery systems can be increased to 60%-70%, resulting in a significant improvement in the quality of the energy. Upon implementation of this power generation device, comprehensive utilization of the waste heat from the flue gas in the main power stations of offshore oil and gas fields will be achieved, with the overall energy efficiency of these main power stations expected to increase by 7%, thereby reducing the consumption of crude oil and natural gas in offshore oil and gas fields. According to calculations, once put into use, this device will be able to generate 40 million kWh of electricity from waste heat each year, enough to meet the annual energy needs of 30,000 households. At the same time, it is estimated that cumulative savings in natural gas consumption will amount to about 300 million cubic meters, with carbon dioxide emissions reduced by around 800,000 tons – which is equivalent to planting 7.5 million trees. Previously, there were no precedents at home or abroad in the field of generating power from the waste heat of high-temperature flue gas at sea. The R&D and design team of CNOOC pursued innovation from the outset, developing its own technical solutions for the overall approach. They overcame various technical challenges, including those related to process and equipment design, compact skid-mounted design, and power cycle testing and verification. In collaboration with Chinese ship design and manufacturing teams, they established an independent technical service capability covering the entire chain of equipment development, skid-mounted production, and testing, thereby creating a system of self-developed and controllable equipment. In the future, this technology will be widely applied to the power plants on China National Offshore Oil Corporation’s existing platforms, helping offshore oil and gas fields to achieve energy savings, emission reduction, cost cuts, and improved efficiency during development. It will also establish a new paradigm for the integrated use of multiple energy sources on offshore platforms, thereby injecting new momentum into the green and low-carbon development of the offshore oil industry.
Oil and gas drilling platforms are like islands at sea; the operation and maintenance of all their systems, as well as their daily activities, rely on electricity generated by burning petroleum or natural gas. “As the ‘heart’ of offshore platforms, power plants not only supply electricity but also emit large amounts of hot exhaust gases during operation, making them a major source of carbon emissions in offshore oil and gas exploration. ”An Weizheng, chief engineer for mechanical, electrical, and instrumentation at the Engineering Research and Design Institute of CNOOC Research Institute, explained that these flue gas temperatures reach up to 500 degrees Celsius, representing a rich source of thermal energy; however, due to current equipment and technological limitations, only 35% of this waste heat is utilized. The direct emission of large amounts of hot flue gas not only wastes heat sources but also increases the burden on the atmosphere. Against the backdrop of the goals of reaching carbon peak and carbon neutrality, how to make full use of this massive \"wealth\" has become the dream pursued by those working in CNOOC. “Initially, the R&D team at CNOOC Research Institute proposed the idea of using waste heat from flue gas to generate steam power, drawing on the principles of steam power generation by utilizing the waste heat from flue gas as a ‘fuel’. ”Recalled Xu Haibo, head of the General Layout and Mechanical Engineering Department at the Engineering Research and Design Institute of CNOOC Research Institute. Steam power generation refers to the process of using water converted into steam to drive turbines or other types of generators, thereby producing electrical energy. However, during the planning phase, the R&D team realized the gap between reality and ideals: the installation of steam cycle power generation units and associated equipment requires a large amount of space, and processes such as supplying high-quality fresh water and disposing of waste water are complicated; moreover, offshore platforms have low operability and economic efficiency. Although the first exploration plan did not become a reality, it did not discourage the R&D team; instead, it served as a strong motivation to push them forward even more determinedly on the path of generating power from the waste heat of hot flue gases at sea. To tailor solutions for marine applications, it is first necessary to find the appropriate technical approach. After extensive collection, comparison, and research, the \"Organic Rankine Cycle\" came to the attention of the R&D team at CNOOC Research Institute – a technology that enables the conversion of waste heat into electrical energy. “In China, related technologies are primarily applied in areas such as industrial wastewater and low-temperature heat sources like geothermal energy. Abroad, high-temperature ORC power generation technology has been put into use on land, but its application at sea remains unexplored. ”Xu Haibo said, “There are no established cases or existing experience to follow; everything has to start from scratch.” ” Starting in 2014, the R&D team learned while working, overcame one technical challenge after another, gradually mastered the essence of the relevant technologies, and determined the final technical approach: using the waste heat from the high-temperature flue gas generated by the main power plant as a heat source, heating an organic working fluid through intermediate heat exchange with heat transfer oil to produce high-temperature steam, which then drives a turbine expander to generate electricity. At the same time, the used steam is turned back into a low-temperature liquid state through devices such as condensers and pumps, thus starting a new cycle. It is understood that, compared to the combustion emissions from traditional flue gases, the potential for utilizing waste heat in power plants equipped with waste heat recovery systems can increase to 60% to 70%. According to calculations, once the waste heat power generation system is installed on the drilling and production platforms at the Wenchang 9-7 oil field, it will be able to generate 40 million kWh of electricity per year – enough to meet the annual energy needs of 30,000 households. Over a period of 20 years, this system could save approximately 300 million cubic meters of natural gas, reduce carbon dioxide emissions by around 800,000 tons, which is equivalent to planting 7.5 million trees.
【Ten Years of Rapid Development in Chemical Engineering Equipment】2016 – Successful development of straight-seam submerged arc welded pipes for transporting supercritical carbon dioxide, with diameters and wall thicknesses at advanced levels https://bbs.hcbbs.com/thread-5673904-1-1.html (Source: Haichuan Chemical Industry Forum [Haichuan Network])
【Ten Years of Rapid Development in Chemical Engineering Equipment】The world’s largest carbon dioxide storage power plant in 2017: 3048 mm ultra-large diameter low-temperature gas transmission pipes https://bbs.hcbbs.com/thread-5673907-1-1.html (Source: Haichuan Chemical Industry Forum [Haichuan Network])