A 50 MMBtu/hr Once Through Steam Generator (OTSG) pilot plant configured to fire on Neat Bitumen was designed and installed on behalf of JACOS at its Hangingstone facility in Fort McMurray, Alberta. The boiler design selected to prove the application was a down fired vertical twin pass/single furnace helical coil designed OTSG. Neat Bitumen obtained directly from the low pressure flash separator of the Hangingstone Central Plant was to substitute the use of natural gas. Due to the high sulfur content of the bitumen, the OTSG included the fugitive emission management system. In this application, the minimum required sulfur dioxide (SO2) removal rate from the combusted gases was 95 per cent or greater. To achieve this, a throwaway flue gas treatment system was installed. Both dual and single alkali processes were modeled for scrubbing SO2 from combusted gases, the agents, sodium hydroxide and calcium hydroxide. The final system recommended and installed was a single alkali process based on the agent calcium hydroxide. The objective of the pilot plant was to provide operational and maintenance experience in regards to the direct firing of Neat Bitumen as an alternative to natural gas.
Scheduled Design:
Phase 1: Feasibility Study, May 2006
Phase 2: Pilot Plant Design, Procurement and Installation, June 2007
Estimated Construction Cost:
Phase 1: $65,000
Phase 2: $7,350,000+/- 25 %
Final Cost:
Phase 1: $65,000
Phase 2: $8,500,000
Team Members Involved:
ME Engineering Ltd, UK
Key Personnel:
Phase 1: Roderick Facey, Ph.D., P. Eng.
Duties:
Undertake a feasibility study complete with conceptual design and capital estimate (+/- 25 %)
Phase 2: Jacques Soroka, P. Eng. MBA
Duties:
Provide detailed design, including process, mechanical, electrical and piping. We also included procurement, project, cost tracking and project management.
Relevant Skills:
Air emission modeling, throwaway fuel gas treatment system design, boiler specification
and evaluation and alternative fuel design
Quality Management Experience:
Responsible for concept to detailed design, including procurement and resident engineering.
We developed and prepared an operations manual detailing sequential operational steps required to fuel helicopters from the fuel cabinets of the new 408 SQN Fuel Storage Farm.
Design Delivery:
May 2006
Value of Service:
$30,000
Team Members Involved:
Gemini Corporation & Stantec (project management role only)
Key Personnel:
Don Taylor, Project Manager/Lead Technical Procedures Writer
Duties:
Operating procedures development; HMI development; operator training and technical mentoring.
Relevant Skills:
Project Management; HAZOP assessments; HMI development; standard operating procedure development; technical writing; and on-site operator and technical advisory training.
Quality Management Experience:
Responsibilities included the proofing for safe and reliable operations for conducting static and hot fueling of military helicopters.
We developed and prepared detailed commissioning procedures and assisted in the dry and wet commissioning of the new 408 SQN Fuel Storage Farm.
Design Delivery:
October 2005
Value of Service:
20,000
Team Members Involved:
Gemini Corporation (lead) & Stantec (project management role only)
Key Personnel:
Don Taylor, P.Eng.
Project Manager/Lead Technical Procedures Writer
Duties:
Commissioning procedures development; HMI development; operator training and technical mentoring.
Relevant Skills:
Project Management; HAZOP assessments; HMI development; standard operating procedure development; technical writing; and on-site operator and technical advisory training.
Quality Management Experience:
Responsibilities included the proofing for safe and reliable operations the commissioning and operational procedures of the fuel storage farm.