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184 IPCC Special Report on Carbon dioxide Capture and Storage 4.2.2.5 Weyburn Pipeline This 330 km, (305-356 mm diameter) system carries more than 5000 tonne day-1 (1.8 Mt yr-1) of CO2 from the Great Plains Synfuels Plant near Beulah, North Dakota to the Weyburn EOR project in Saskatchewan. The composition of the gas carried by the pipeline is typically CO2 96%, H2S 0.9%, CH4 0.7%, C2+ hydrocarbons 2.3%, CO 0.1%, N2 less than 300 ppm, O2 less than 50 ppm and H2O less than 20 ppm (UK Department of Trade and Industry, 2002). The delivery pressure at Weyburn is 15.2 MPa. There are no intermediate compressor stations. The amount allocated to build the pipeline was 110 US $ million (0.33 x 106 US$ km-1) in 1997. • Trenching and backfilling: onshore lines are usually buried to depth of 1 m. Offshore lines are almost always buried in shallow water. In deeper water pipelines narrower than 400 mm are trenched and sometimes buried to protect them against damage by fishing gear. 4.2.3 Design (i) The physical, environmental and social factors that determine (ii) the design of a pipeline are summarized in a design basis, which then forms the input for the conceptual design. This includes a system definition for the preliminary route and design aspects (iii) for cost-estimating and concept-definition purposes. It is also (iv) necessary to consider the process data defining the physical (v) characteristics of product mixture transported, the optimal sizing and pressures for the pipeline, and the mechanical design, such as operating, valves, pumps, compressors, seals, etc. The topography of the pipeline right-of-way must be examined. Topography may include mountains, deserts, river and stream crossings, and for offshore pipelines, the differing challenges of very deep or shallow water, and uneven seabed. It is also important to include geotechnical considerations. For example, is this pipeline to be constructed on thin soil overlaying granite? The local environmental data need to be included, as well as the annual variation in temperature during operation and during construction, potentially unstable slopes, frost heave and seismic activity. Also included are water depth, sea currents, permafrost, ice gouging in Arctic seas, biological growth, aquifers, and other environmental considerations such as protected habitats. The next set of challenges is how the pipeline will accommodate existing and future infrastructure – road, rail, pipeline crossings, military/governmental restrictions and the possible impact of other activities – as well as shipping lanes, rural or urban settings, fishing restrictions, and conflicting uses such as dredging. Finally, this integrated study will serve as the basis for a safety review. The conceptual design includes the following components: • Mechanical design: follows standard procedures, described a low-pressure CO2 gas pipeline operating at a maximum pressure of 4.8 MPa; a high-pressure CO2 gas pipeline operating at a minimum pressure of 9.6 MPa, so that the gas would remain in a dense phase state at all temperatures; Conceptual design There are six compressor stations, totalling 60 MW, including a station at the SACROC delivery point. The compressor stations are not equally spaced, and the longest distance between two stations is about 160 km. This is consistent with general practice, but some long pipelines have 400 km or more between compressor stations. in detail in (Palmer et al., 2004). • Stability design: standard methods and software are used to Significant nitrogen and oxygen components in CO2 would shift the boundary of the two-phase region towards higher pressures, and would require a higher operating pressure to avoid two-phase flow. perform stability calculations, offshore (Veritec, 1988) or onshore, though the offshore methods have been questioned. New guidelines for stability will be published in 2005 by Det Norske Veritas and will be designated DNV-RP-F109 On-Bottom Stability 4.2.4 Construction of land pipelines Construction planning can begin either before or after rights • Protection against corrosion: a well-understood subject of which the application to CO2 pipelines is described below. • CO2 pipelines may be more subject to longitudinal running fracture than hydrocarbon gas pipelines. Fracture arresters are installed at intervals of about 500 m. West (1974) describes the design of the SACROC CO2 pipeline (Section 4.2.2.1 above). The transportation options examined were: a refrigerated liquid CO2 pipeline; road tank trucks; rail tankers, possibly in combination with road tank trucks. The tank truck and rail options cost more than twice as much as a pipeline. The refrigerated pipeline was rejected because of cost and technical difficulties with liquefaction. The dense phase (Option ii) was 20% cheaper than a low-pressure CO2 gas pipeline (Option i). The intermediate 4.8 to 9.6 MPa pressure range was avoided so that two-phase flow would not occur. An added advantage of dense-phase transport was that high delivery pressures were required for CO2 injection. The final design conforms to the ANSI B31.8 code for gas pipelines and to the DOT regulations applicable at the time. The main 290 km section is 406.4 mm (16 inch) outside diameter and 9.53 mm wall thickness made from grade X65 pipe (specified minimum yield stress of 448 MPa). A shorter 60 km section is 323.85 mm (12.75 inch) outside diameter, 8.74 mm wall thickness, grade X65. Tests showed that dry CO2 would not corrode the pipeline steel; 304L corrosion-resistant alloy was used for short sections upstream of the glycol dehydrator. The line is buried to a minimum of 0.9 m, and any point on the line is within 16 km of a block valve.PDF Image | CARBON DIOXIDE CAPTURE AND STORAGE
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