899623

THE GEOPRESSURED-GEOTHERMAL PROGRAM: ENERGY CONVERSION

STATUS AND FUTURE POSSIBILITIES

J. Negus-de Wys, T. W. Lawford, D. D. Faulder

Idaho National Engineering Laboratory

Idaho F a l l s , Idaho 83415

ABSTRACT Geopressured resources, w i t h simultaneous

production o f methane and h o t b r i n e , provide a
The Geopressured-Geothermal Program, n a t u r a l a p p l i c a t i o n f o r a h y b r i d power cycle.
sponsored by t h e Department o f Energy (DOE) I n such a system, methane separated from t h e
began i n 1976 w i t h t h e Wells o f Opportunity. b r i n e f u e l s a gas engine o r gas t u r b i n e t o
This e a r l y research concentrated on resource produce electricity. Heat from t h e engine
c h a r a c t e r i z a t i o n a t several l o c a t i o n s i n Texas exhaust i s t r a n s f e r r e d t o t h e b r i n e , which i s
and Louisiana. More r e c e n t l y , t h e program has then run through a conventional b i n a r y c y c l e
included we1 1 operations and supporting system. A d d i t i o n a l heat i s s u p p l i e d by t h e
university research in geoscience and thermal energy i n t h e b r i n e . A d d i t i o n a l power
engineering. Long term flow testing, i s a v a i l a b l e by u t i l i z i n g t h e h y d r a u l i c energy
r e i n j e c t i o n o f b r i n e , and scale prevention were i n t h e f l u i d a t t h e wellhead ( t y p i c a l f l o w i n g
accomplished a t t h e Gladys McCall Well. The wellhead pressures are i n t h e range o f 800 t o
Pleasant Bayou Well provided a d d i t i o n a l data f o r 3000 p s i ).
modeling and p r e d i c t i n g geopressured r e s e r v o i r
behavior. This year a h y b r i d power system (HPS) The Wells o f Opportunity e a r l i e r i n t h e
was constructed a t Pleasant Bayou i n cooperation Geopressured-Geothermal Program v e r i f i e d t h e
with the E l e c t r i c Power Research I n s t i t u t e availability of a l a r g e resource of gas,
(EPRI). This i s t h e f i r s t conversion o f t h e thermal, and h y d r a u l i c energy. The gas resource
geopressured-geothermal resource to i n t h e G u l f Coast area i s estimated t o be 5,700
electricity. An economic review of t r i l l i o n cubic f e e t ( 1 t r i l l i o n s c f = 1 quad);
geopressured-geothermal resource development t h e thermal energy i s estimated t o be about
concludes t h a t using o f f - t h e - s h e l f technology, 11,000 quad (Wallace et al., 1977).
e l e c t r i c i t y can be produced f o r $0.125/kWh from Additionally, i t was learned e a r l y i n t h e
a Gladys McCall type resource (40,000 bpd b r i n e program t h a t t h e h o t b r i n e c o u l d be disposed o f
production, 27 s c f methane/bbl , 288oF b r i n e , by r e i n j e c t i o n i n t o r e l a t i v e l y shallow a q u i f e r s
and 10-year resource l i f e ) . The Pleasant Bayou without induced seismicity or other
type resource can produce e l e c t r i c i t y f o r environmental e f f e c t s . Long term f l o w t e s t i n g
$0.32/kWh. Advanced technology c o u l d reduce t h e and c o n t r o l o f scale formation have demonstrated
c o s t t o $0.16/kWh. t h a t t h e b r i n e c o u l d be r e l i a b l y produced a t
r a t e s o f 15,000 t o 20,000 bpd w i t h o u t f r e q u e n t
A review and s t a t u s o f t h e HPS i s presented shutdowns because o f s c a l i n g . However, t h e
with future p o s s i b i l i t i e s f o r t h e program, p r e d i c t a b i l i t y o f r e s e r v o i r behavior remains a
i n c l u d i n g 1) recovery o f medium and heavy o i l c h a l l e n g i n g and ongoing research focus.
w i t h h o t geopressured b r i n e , 2) d i r e c t use,
e s p e c i a l l y aquaculture, and 3) development and I n March o f t h i s year EPRI j o i n e d t h e DOE i n
use o f advanced technology f o r conversion a t t h e t h e c o n s t r u c t i o n o f a h y b r i d power system a t
H u l i n Well, t h e deepest, h o t t e s t w e l l i n t h e Pleasant Bayou. The purpose o f t h e Pleasant
program. The estimated improvement in Bayou conversion p r o j e c t i s t o determine t h e
e f f i c i e n c i e s w i t h advanced conversion technology increase i n e f f i c i e n c y obtained by using t h e
range from 100 t o 160%. This would g r e a t l y waste heat from t h e h i g h temperature exhaust gas
reduce t h e c o s t t o produce e l e c t r i c i t y . i n t h e power c y c l e . This w i l l be t h e f i r s t time
that conversion of t h e thermal energy i n
geopressured brine t o e l e c t r i c i t y has been
Introduction undertaken.

The Geopressured-Geothermal Program, under

t h e sponsorship o f t h e Department o f Energy, has T e s t i n g o f t h e h y b r i d c y c l e f a c i l i t y , which
constructed a hybrid power system a t t h e began t h i s summer, i s scheduled t o l a s t f o r one
Pleasant Bayou Well i n Brazoria County, Texas year. The f i r s t t h r e e months w i l l be a p e r i o d
and has i n i t i a t e d t e s t i n g . of start-up, shakedown, and t e s t i n g . The

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CH2781-3/89/0000-2173$1.00 0 1989 IEEE

remaining n i n e months w i l l be f o r continuous Excessive sand production occurred a t f l o w
o p e r a t i o n a t t h e design process flow r a t e of r a t e s g r e a t e r than 22,000 bpd. By reducing t h e
10,000 bbllday. Much o f t h e equipment f o r t h e b r i n e f l o w r a t e , t h e sand production has been
HPS i s reused from previous p r o j e c t s and i n some controlled. The produced sand has been
instances t h i s f a c t places a c o n s t r a i n t on t h e i d e n t i f i e d as coming from t h e b r i n e r e s e r v o i r by
system, e.g., pressure r a t i n g s . t h e U n i v e r s i t y o f Texas. The f l o w r a t e has been
maintained a t about 20,000 bpd. When t h e HPS i s
i n operation, t h e f l o w w i l l be s p l i t t o take
Geological S e t t i n g 10,000 bpd t o t h e conversion system.
The Pleasant Bayou Well penetrates t h e The i n i t i a l d a i l y f l u i d a n a l y s i s showed a
Andrau sand i n the F r i o 'C' s t r a t i g r a p h i c gas/water r a t i o o f 29 s c f / b b l ; r e c e n t analyses
i n t e r v a l a t 14,684 t o 14,716 f e e t . The t o p o f show 22 s c f / b b l . The o r i g i n a l 85.5% methane
t h i s sand i s i n t e r p r e t e d t o be a d i s t r i b u t a r y content has d e c l i n e d t o about 82%; o r i g i n a l
channel; t h e lower and major p o r t i o n o f t h e 10.5% CO2 content has increased t o about 13%.
i n t e r v a l i s i n t e r p r e t e d t o be a d i s t r i b u t a r y L i t t l e o r no s u l f a t e i s shown i n t h e b r i n e
mouth bar (Tyler and Hamlin, 1986). An a n a l y s i s (Table 1).
i n t e r p r e t a t i o n o f the high constructive d e l t a i c
d e p o s i t i o n a l system i n which these types o f The b r i n e gas a n a l y s i s shows t h a t ethane a t
sands are found i s shown i n Fig. 1. A s t r u c t u r e 2.6%, is the dominant minor hydrocarbon
map on t h e t o p o f t h e IT-5' marker i n t h e F r i o component. Only 2% o f t h e gas i s made up o f
formation i s shown i n Fig. 2. Major down-to- nitrogen (0.44%) and hydrocarbon components
the-basin growth f a u l t s t r e n d NE-SW and bound o t h e r than methane and ethane (Table 1 ) .
t h e Chocolate Bayou East F i e l d . Pleasant Bayou
Well #2 i s l o c a t e d downdip a t -14,000 f e e t , The aromatic hydrocarbons dominate t h e
2,000 f e e t below t h e t o p o f t h e Chocolate Bayou a n a l y s i s o f hydrocarbons condensed from t h e gas
domal s t r u c t u r e . The r e s e r v o i r boundary t o t h e stream. The occurrence of benzene is
south i s unknown. A n e t sandstone thickness map i n t e r e s t i n g t o note because o f e a r l i e r work by
o f the C zone i n t h e Andrau sand i s shown i n G u l f Research Lab i n Harmorsville, PA ( Z a r r e l l a
Fig. 3. This i s t h e zone o f i n t e r e s t t o t h e e t a l . , 1967). The c o n c e n t r a t i o n o f benzene i n
Geopressured-Geothermal Program. The sand ppm was recorded w i t h t h e d i s t a n c e t o known o i l
thickness i s 125 f e e t i n t h e Pleasant Bayou and gas occurrence i n t h e same r e s e r v o i r . A
Well, showing a t h i c k e n i n g o f 65 f e e t from t h e p l o t o f these data shows an apparent c o r r e l a t i o n
area t o t h e n o r t h e a s t h i g h e r on s t r u c t u r e . The o f i n c r e a s i n g benzene c o n t e n t w i t h p r o x i m i t y t o
paleogeography c o n f i g u r a t i o n and l i t h o l o g y o f known r e s e r v o i r e d o i l and gas i n t h e same
the sand support the interpretation o f a formation. The content o f benzene a t Pleasant
d i s t r i b u t a r y channel mouth bar. A SW-NE cross Bayou, when added t o t h i s p l o t , suggests c l o s e
s e c t i o n shows t h e r e l a t i o n s h i p o f Pleasant Bayou p r o x i m i t y t o hydrocarbon accumulation (Fig. 5 ) .
Well #2 t o t h e major s t r u c t u r e (Fig. 4 ) . This c o r r e l a t i o n c o u l d p o s s i b l y be u t i l i z e d by
t h e o i l and gas i n d u s t r y i n c a l c u l a t i n g t h e
Porosity from core analysis is 19%; distance by which a b r i n e w e l l missed t h e
p e r m e a b i l i t y i s 200 md. The t o t a l r e s e r v o i r d e s i r e d hydrocarbon r e s e r v o i r .
pore volume modelled by t h e U n i v e r s i t y o f Texas
i s about 8.7 b i l l i o n b a r r e l s .
The Hybrid Power System

Well and B r i n e C h a r a c t e r i s t i c s The goal o f t h e i n i t i a l t e s t p e r i o d i s t o

operate t h e HPS over a wide range o f o p e r a t i n g
The Pleasant Bayou Well was reworked i n situations, including off-design conditions, t o
1986, b u t because o f inadequate funding, t h e o b t a i n data h e l p f u l f o r t h e design o f f u t u r e
w e l l was shut i n . Production equipment was commercial operations. A period o f operation
i n s t a l l e d i n l a t e 1987 and e a r l y 1988. I n May w i t h maximum power output w i l l f o l l o w . T h i s
1988 t h e w e l l was placed on production. Since longer p e r i o d o f o p e r a t i o n w i l l c o n s t i t u t e an
then, t h e w e l l has flowed continuously about e v a l u a t i o n o f t h e r e l i a b i l i t y o f t h e HPS and
20,000 barrels of brine per day from a w i l l p r o v i d e t h e o p p o r t u n i t y t o develop and
p e r f o r a t i o n i n t e r v a l o f -14,644 f t t o -14,704 document those f e a t u r e s o f design, operation,
ft. The b r i n e temperature i s about 278oF and maintenance t h a t are i m p o r t a n t t o achieving
(compared w i t h a formation temperature o f high r e l i a b i l i t y .
3010F). The brine contains 70,000 mg/L
chlorides and 127,000 mg/L t o t a l d i s s o l v e d The o b j e c t i v e s o f t h e p r o j e c t are t o demon-
s o l i d s (Table 1 ) . s t r a t e t h e h y b r i d c y c l e concept f o r e l e c t r i c i t y
generation and to obtain data regarding
Severe calcium carbonate s c a l i n g was t r e a t e d o p e r a t i o n over time o f a power p l a n t u s i n g a
with a phosphonate scale i n h i b i t o r squeeze. geopressured resource. E l e c t r i c i t y w i l l be
Subsequent coupon m o n i t o r i n g w i t h t h e a d d i t i o n produced from a gas engine burning methane and
o f scale i n h i b i t o r has a s s i s t e d i n c o n t r o l l i n g from a b i n a r y c y c l e o p e r a t i n g on heat from t h e
t h e scale formation. engine exhaust and from t h e geopressured b r i n e .

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7 1 I
 Demonstration o f t h e h y b r i d concept on a brine-to-isobutane heater. The b r i n e , which
geopressured w e l l has t h e b e n e f i t o f t e s t i n g leaves t h e separator a t 278oF i s cooled t o
current technology available to produce 21OOF i n t h e brine-to-isobutane b o i l e r . The
e l e c t r i c i t y from geopressured resources. During brine from the boiler then enters the
t h e year o f operation, much i s expected t o be brine-to-isobutane preheater. The
learned about potential problems such as pressure-enthalpy diagram f o r isobutane w i t h t h e
s c a l i n g , corrosion, f l o w i n s t a b i l i t i e s , and gas b i n a r y c y c l e p o r t i o n o f t h e HPS design process
engine l i f e w i t h t h e impure wellhead gas. path i s presented i n Fig. 6 (Gas Processors
Supp. ASSOC., 1987). A s i m p l i f i e d process f l o w
The s p e c i f i c o b j e c t i v e s of the HPS test diagram o f t h e h y b r i d c y c l e power p l a n t i s shown
program are as f o l l o w s : i n Fig. 7.

1. Evaluate the potential of a The h y b r i d power c y c l e gives an advantage i n

combustion/geothermal hybrid power conversion through the u t i l i z a t i o n o f the
c y c l e f o r use i n t h e development of exhaust heat from t h e combustion engine. This
geopressured and low- temperature increase i n e f f i c i e n c y obtained by u s i n g t h e
hydrothermal resources . waste heat from t h e h i g h temperature exhaust gas
i n t h e power c y c l e t o heat t h e evaporator w i l l
2. Demonstrate t h e t e c h n i c a l f e a s i b i l i t y be c a l c u l a t e d d u r i n g t e s t operations.
o f t h e HPS f o r use w i t h a geopressured
resource . Isobutane i s n o t t h e optimum working f l u i d
f o r a standard b i n a r y c y c l e on a resource w i t h a
3. Evaluate t h e r o l e o f combustion thermal temperature as low as a t Pleasant Bayou
energy in geopressured resource (278OF). Propane c o u l d be used i n s t e a d of
development economics. isobutane t o generate more power. However,
propane has a h i g h e r vapor pressure than
4. E s t a b l i s h a precedent and procedures isobutane, exceeding t h e pressure r a t i n g s o f
f o r t h e p e r m i t t i n g o f a HPS u t i l i z i n g a most o f t h e reused equipment.
geopressured resource.
A comparison was made by EPRI o f t h e
5. I d e n t i f y t h e need and d i r e c t i o n f o r d i f f e r e n c e i n power production between propane
f u t u r e research and development, w i t h and isobutane a t Pleasant Bayou. Propane would
the ultimate goal of commercial yield approximately 5% more n e t power than
a p p l i c a t i o n (HPS Test Plan, 1989). isobutane. This r e l a t i v e l y small advantage was
n o t enough t o j u s t i f y t h e purchase o f a l l new
Prior to construction o f t h e HPS t h e equipment and w i l l n o t compromise t h e primary
d i s s o l v e d methane i n t h e geopressured b r i n e was goals o f t h e HPS.
separated from t h e b r i n e and piped t o a sales
gas l i n e . With t h e HPS, approximately h a l f o f P a r a s i t i c Loads
t h e methane (200 mcf/day) w i l l be used t o feed a
gas f i r e d engine/generator. The e l e c t r i c i t y Power production and p a r a s i t i c loads a t t h e HPS
produced by t h i s generator w i l l feed d i r e c t l y design c o n d i t i o n are summarized i n Table 2.
i n t o t h e Houston Power and L i g h t g r i d . The
design e l e c t r i c i t y production i s 650 kW (gross), TABLE 2. SUMMARY OF POWER PRODUCTION AND
which represents about 55% o f t h e gross power PARASITIC LOADS
output o f t h e HPS: Two C a t e r p i l l a r 398 engines
were s e l e c t e d f o r use i n t h i s p r o j e c t . The
design c a l l e d f o r t h e engines t o be skid-mounted Power Production:
with all necessary c o n t r o l s and a u x i l i a r y
equipment for industry application. For Gas Engine 650 kW
industry a p p l i c a t i o n c o n s i d e r a t i o n should be Binary Cycle Turbine 541 kW
given f o r a d d i t i o n a l gas engines t o u t i l i z e t h e
entire gas production for conversion to Gross Power Production 1191 kW
e l e c t r i c i t y because o f f a v o r a b l e economics.
P a r a s i t i c Loads:
A p p r t i o n o f t h e h o t b r i n e (about 50%) a t
278oF w i 11 be passed through heat exchangers Condensers 75 kW
to heat the fluid i n t h e b i n a r y system C i r c u l a t i n g Pump 74 kW
(isobutane) to approximately 21OOF. The Miscellaneous 60 kW
cooled brine, a t approximately 164oF, w i l l be
mixed w i t h t h e unused b r i n e and pumped i n t o t h e T o t a l Load 209 kW
disposal w e l l . Net Power Production 982 kW

Exhaust gas from t h e gas engine a t 1130oF The parasitic load l a b e l e d "condensers"
i s used t o b o i l about 14% o f t h e isobutane i n includes four water pumps, one f o r each
the exhaust gas-to-isobutane boiler. The Baltimore A i r c o i l Condenser u n i t , and e i g h t f a n
remainder o f t h e isobutane i s b o i l e d i n t h e motors. Fans are approximately 85% o f t h e 75 kW

2175
condenser p a r a s i t i c load. The l o a d l a b e l e d The h o t t e s t s u r f a c e i n c o n t a c t w i t h isobutane i s
" c i r c u l a t i n g pump" i s t h e isobutane pump used t o t h e p o r t i o n o f t h e tube bundle where t h e exhaust
pump t h e condensed isobutane l i q u i d i n t o t h e gases first enter. Here t h e exhaust gas
high-pressure heat exchangers. The temperature i s near i t s design i n l e t value o f
miscellaneous loads t o t a l 60 kW and i n c l u d e t h e 1130OF, b u t an e x c e l l e n t b o i l i n g heat t r a n s f e r
utility cooler, lube oil pumps, air c o e f f i c i e n t on t h e isobutane side, combined w i t h
conditioning, pressurizing a i r f o r the t r a i l e r s , a low convective h e a t t r a n s f e r c o e f f i c i e n t on
instrument a i r , c o n t r o l power and l i g h t i n g . the gas s i d e combine t o keep t h e o u t s i d e
These p a r a s i t i c loads a r e a h i g h e r percentage of (isobutane s i d e ) o f t h e tube a t an estimated
generator o u t p u t than would be expected f o r a 246OF, w e l l below t h e c r i t i c a l temperature o f
commercial power p l a n t . 550oF. The heat f l u x a t t h e tube entrance i s
estimated t o be 15,500 B t u / h r - f t z , over 2-1/2
times t h e average f o r t h e whole heat exchanger.
Process Equipment The heat exchanger i s designed t o minimize vapor
blanketing in t h i s r e g i o n by l o c a t i n g t h e
Isobutane i s pumped t o a pressure o f 330 isobutane inlet here and u t i l i z i n g several
psia by t h e isobutane c i r c u l a t i n g pump, a b a f f l e s which c r e a t e d h i g h v e l o c i t i e s over t h e
m u l t i - s t a g e v e r t i c a l t u r b i n e pump. Isobutane i s tubes.
heated t o i t s bubble p o i n t by warm b r i n e i n t h e
b r i n e - t o - i s o b u t a n e preheater, a shell-and-tube Although a s a f e t y c o n t r o l i s provided t o
heat exchanger w i t h c o u n t e r - c u r r e n t f l o w . A f t e r divert the exhaust gas directly t o the
l e a v i n g t h e b r i n e - t o - i s o b u t a n e preheater, t h e atmosphere i f t h e l i q u i d l e v e l i n t h e b o i l e r
isobutane f l o w s p l i t s w i t h some o f t h e isobutane drops below a s p e c i f i e d value, we i n v e s t i g a t e d
being b o i l e d by exhaust gas from t h e engine and t h e case o f a tube exposed t o vapor over one
t h e remainder b o i l e d by t h e h o t b r i n e . h a l f o f i t s length. I t was assumed t h a t t h e
bottom h a l f o f t h e tube (where t h e h o t exhaust
Isobutane vapor from t h e b r i n e - t o - i s o b u t a n e gas e n t e r s ) was l i q u i d covered. The exhaust gas
b o i l e r and exhaust gas-to-isobutane b o i l e r i s temperature a t t h e tube m i d p o i n t was c a l c u l a t e d
combined, passed through an entrainment t o be a t 498oF, and t h e tube o u t s i d e s u r f a c e
separator, and expanded through a t u r b i n e t o temperature a t t h e p o i n t was c a l c u l a t e d t o be
generate e l e c t r i c i t y . Exhaust isobutane l e a v i n g 292oF. These calculations conservatively
the t u r b i n e i s condensed i n f o u r B a l t i m o r e neglect tube w e t t i n g from s p l a s h i n g by t h e
A i r c o i l condensers. Condensed isobutane e n t e r s b o i l i n g going on below t h e l i q u i d surface, which
the isobutane accumulator b e f o r e being pumped would further lower the tube surface
back through t h e loop, thus completing t h e temperature. I t can t h e r e f o r e be concluded t h a t
b i n a r y cycle. thermal degradation o f t h e isobutane due t o
c o n t a c t w i t h h o t surfaces i n t h e heat exchanger
Wellhead gas used i n t h e power p l a n t w i l l be w i l l n o t be a problem (Lawford, 1988).
burned i n a gas engine. The h y b r i d c y c l e design
i s based on t h e use o f two C a t e r p i l l a r 398
engines. These engines r e q u i r e j a c k e t c o o l i n g Mechanical I n t e g r i t y
which i s g e n e r a l l y done by c i r c u l a t i n g water.
Jacket c o o l i n g can a l s o be accomplished by The f a c t t h a t t h e tubes s t a y q u i t e cool has
p u t t i n g water i n t h e j a c k e t where i t b o i l s t o been discussed. A maximum tube sheet
make steam. This second method o f c o o l i n g i s temperature of 256OF was c a l c u l a t e d which
called ebullient cooling. Use of an should n o t induce excessive thermal s t r e s s e s
e b u l l i e n t - c o o l e d engine i s b e s t f o r t h e h y b r i d (Texas Metal F a b r i c a t i o n s , 1988). The exhaust
c y c l e s i n c e t h e j a c k e t heat i s a v a i l a b l e a t a gas i n l e t chamber (head) would be expected t o
h i g h e r temperature. However, e b u l l i e n t - c o o l e d see temperatures near t h e i n l e t gas temperature
engines were n o t a v a i l a b l e , so t h e c u r r e n t o f 1130OF. However, t h i s temperature w i l l be
design was based on engines w i t h water-cooled f a i r l y u n i f o r m over t h e e n t i r e chamber, and t h e
jackets. chamber i s b o l t e d , n o t welded, t o t h e much
c o o l e r tube sheet. Thus, stresses between t h e
chamber and tube sheet should n o t be excessive.
Thermal E f f e c t s
The e n t i r e gas s i d e o f t h i s heat exchanger
Several areas o f concern have been addressed has such a low design pressure ( 5 p s i g ) t h a t i t
i n design reviews, i n c l u d i n g 1) thermal e f f e c t s , i s n o t considered a pressure vessel. Also t h e r e
2) mechanical i n t e g r i t y , and 3) c o r r o s i o n . The a r e minimal complications from minor leakage
temperature associated with t h e combustion from t h e gas s i d e t o t h e atmosphere.
engine exhaust gases has given r i s e t o concerns
about t h e d y o m p o s i t i o n o f isobutane. Isobutane The s h e l l (isobutane) s i d e i s designed t o
tends to c r a c k " o r t h e r m a l l y decompose a t t h e ASME S e c t i o n VI11 D i v i s i o n I Pressure Wells
temperatures above 550oF. Analyses made by Code and t h e TEMA-R standard. The ASME code
INEL v e r i f y t h e adequacy o f t h e design t o r e q u i r e s t h a t s t r e s s c a l c u l a t i o n s be made t o
m a i n t a i n t h e temperature o f a l l surfaces i n back up t h e design, and t h a t thermal stresses
c o n t a c t w i t h the isobutane below t h i s value. must be considered i n those c a l c u l a t i o n s . The

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- - 1
s h e l l s i d e has a l s o been hydrotested a t 1-1/2 Corrosion
times t h e design pressure o f 350 psig, although
t h i s t e s t was probably made a t room temperature. Corrosion of t h e heat exchanger d u r i n g
o p e r a t i o n i s n o t expected t o present a problem
The j u n c t u r e o f t h e tubes and t h e tubesheet with r e s p e c t t o t h e i n t e g r i t y o f t h e heat
are b o t h r o l l e d and sealwelded. R o l l i n g i s a exchanger. It may, however, prove necessary t o
process where the tube ends a r e expanded develop a lay-up procedure f o r shutdowns.
mechanically from t h e i n s i d e t o an i n t e r f e r e n c e
f i t w i t h t h e tube sheet. Thus, leakage o f h i g h S u l f i d e s a r e present i n t h e engine f u e l gas
pressure isobutane i n t o t h e low pressure exhaust t o t h e e x t e n t o f 22 ppm. These would be
gas would r e q u i r e a f a i l u r e o f one o r more o f expected to be converted t o (SO), i n the
the seal welds, which i s considered h i g h l y engine. The engine a l s o forms (NO), from t h e
unlikely. Furthermore a leakage o f isobutane a i r i t ingests, amounting t o about 0.3% o f t h e
i n t o t h e o u t l e t ( c o l d ) chamber would merely exhaust gas stream. I n an aqueous s o l u t i o n ,
result i n a discharge o f isobutane t o t h e these two components would form s u l f u r i c and
atmosphere, as t h e 300OF discharge temperature n i t r i c a c i d r e s p e c t i v e l y . This problem has been
i s below t h e i g n i t i o n temperature o f isobutane. avoided d u r i n g o p e r a t i o n by u s i n g t h e standard
A leakage o f isobutane t o t h e 1130OF i n l e t boiler practice of maintaining the o u t l e t
chamber would be expected t o combust upon temperature above 300oF, which keeps a l l o f
contact with the h o t gas. However, t h e t h e H20 i n t h e exhaust i n t h e vapor s t a t e .
combustion engine manufacturer p r e d i c t s t h a t t h e During shutdown, however, t h e small amount of
(unreacted) oxygen c o n t e n t o f t h e exhaust gas water vapor present i n t h e heat exchanger would
w i l l be o n l y 2%. Thus, t h e magnitude o f t h e be expected t o condense, and small q u a n t i t i e s o f
possible combusti on would be s i g n i f i c a n t l y a c i d would be formed. I f i t i s deemed
l i m i t e d , and temperature increases i n s i d e t h e necessary, t h i s c o u l d be avoided by a simple a i r
heat exchanger would n o t be expected t o be purge of the heat exchanger tube side
excessive. i m e d i a t e l y f o l l o w i n g shutdown o f t h e engine.

Isobutane leakage g r e a t e r than t h a t usable All of t h e heat exchanger p a r t s which

f o r combustion w i t h t h e l i m i t e d oxygen would be contact the exhaust gas a r e made o f 304
expected t o pass up t h e stack t o t h e atmosphere, stainless steel. This i n c l u d e s t h e tubes, tube
but it will be below the autoignition sheet, and i n l e t and o u t l e t chambers (heads).
temperature when i t reaches t h e atmosphere. Thus c o r r o s i o n i n general would n o t be expected
t o be a s i g n i f i c a n t problem. The temperature a t
The most l i k e l y l o c a t i o n f o r an isobutane which s i g n i f i c a n t s c a l i n g would take place i s
l e a k i s t h e heat exchanger j o i n t between t h e l i s t e d a t 1650oF, which i s s i g n i f i c a n t l y above
s h e l l and tubesheet. This i s a b o l t e d flanged t h e gas i n l e t temperature o f 1130oF. Only t h e
j o i n t , which sees t h e f u l l o p e r a t i n g pressure of i n l e t chamber w i l l see t h e 113OOF temperature
t h e isobutane (266 p s i g ) . Such j o i n t s are The i n l e t s i d e o f t h e tubesheet, t h e second
common p r a c t i c e f o r many heat exchangers. A h o t t e s t piece, w i l l see a maximum temperature o f
scenario could be created that thermal about 256OF. Corrosion i s t h e r e f o r e n o t
d i s t o r t i o n o f t h e tube sheet ( u n l i k e l y ) would expected to present a s i g n i f i c a n t problem
c r e a t e an isobutane l e a k which would i g n i t e on (Lawford, 1988).
the hot surface (under i n s u l a t i o n ) o f t h e
exhaust gas i n l e t chamber o r p i p i n g . The
p o t e n t i a l damage from i g n i t i o n o f such a l e a k i s Status
d i f f i c u l t t o assess, because i t would depend
upon t h e q u a n t i t y o f leaked isobutane which had A t t h e w r i t i n g o f t h i s paper t h e HPS i s
accumulated i n t h e area o f t h e heat exchanger under c o n s t r u c t i o n . By t h e time t h i s paper w i l l
before i g n i t i o n , which would i n t u r n depend upon be presented t h e HPS should have been completed
t h e magnitude and d i r e c t i o n o f breezes a t t h e and t e s t i n g i n i t i a t e d . The Eaton Operating
HPS s i t e . W i t h i n t h e u n l i k e l y event t h a t such a Company (EOC) i s t h e o p e r a t i n g company under
l e a k would develop and be i g n i t e d , t h e most c o n t r a c t t o DOE a t t h e Pleasant Bayou Well. The
l i k e l y s i t u a t i o n i s t h a t a steady s t a t e flame I n s t i t u t e o f Gas Technology i s under c o n t r a c t t o
would be established, emanating from t h e leak. EOC to operate the production surface
Metal temperatures adjacent t o t h e flame w i l l be f a c i l i t i e s , and t h e Ben H o l t Company i s under
l i m i t e d by water deluge from t h e f i r e p r o t e c t i o n c o n t r a c t t o EOC t o c o n s t r u c t and operate t h e
system. The isobutane supply t o t h e heat HPS.
exchanger would be l i m i t e d by c l o s i n g i n l e t and
discharge valves, and t h e f i r e w i l l burn i t s e l f
o u t by exhausting t h e isobutane a v a i l a b l e t o t h e P r e l i m i n a r y Economics o f
leak. This p o t e n t i a l a c c i d e n t i s one which Pleasant Bayou Conversion
should be evaluated i n t h e s a f e t y r e p o r t .
( Lawford, 1988). A r e c e n t review o f economics o f energy forms
from t h e geopressured resource suggests t h e
following comparison of costs t o produce

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electrical energy from a Pleasant Bayou type
resource (Negus-de Wys et al. , 1989).
Cost to Produce
Form Method $/ kWh
Gas Gas Engine 0.07
Thermal HPS or-off-the shelf 0.32
technology
The costs to produce electrical energy from
both the gas and hydraulic energy fall within
the range set as the Geopressured Program goal,
6-10 cents/kWh (level ized 1986 constant
dol 1 ars) . However, the conversion of
geopressured thermal energy to electricity is
high. Increased efficiency and lower cost for
technology are needed to meet the Program's
objective.
With advanced technology (assuming an
increased efficiency of 100%) the cost to
produce electricity from thermal energy in a
Pleasant Bayou type resource can conceivably be
reduced to 16 cents/kWh. This estimate is
predicated on a flow rate of 20,000 barrels per
day, 23 scf/bbl methane content, 278oF brine
wellhead temperature, a 970 kW plant, and a
10-year plant and reservoir life (Negus-de Wys,
et al. , 1989).
When gas, hydraulic and thermal are
considered as an energy package, the overall
cost to produce becomes about 15 cents/kWh.
Thus, the capital cost and efficiency of thermal
conversion remain an anchor on the economic
viability of geopressured thermal conversion.
Direct use of the thermal energy could enhance
the economic viability in using this energy
form.
CONCLUSIONS
It is anticipated that the Pleasant Bayou
HPS will have been constructed and be in the
testing phase at the time of this presentation.
This is the first actual conversion of
geopressured-geothermal energy to electricity.
The Pleasant Bayou HPS will provide measurements
of the increase in efficiency obtained by using
the waste heat from the high temperature exhaust
gas in the power cycle to heat the evaporator.
An economics review concludes that both
geopressured gas and hydraulic energy conversion
to electricity are within the program's desired
cost to produce range (6 to 10 cents/kWh).
However, the thermal conversion for a Pleasant
Bayou type resource with off-the-shelf
technology falls well above the goal (32
cents/kWh), but could be brou ht closer with
advanced technology (16 cents/kWhq.
Taken as an energy package, the gas,
hydraulic, and thermal energy from a Pleasant
Bayou type resource results in an estimated
2178
1 II
average cost to produce of about 15 cents/kWh
with off the shelf technology (Negus-de Wys, et
al., 1989).
The future possibilities for the
geopressured-geothermal resource could include
the following:
1. Conversion of geopressured gas to
electricity through use of a gas
engine, resulting in a cost-to-produce
of about 7 cents/kWh. This may be of
interest to independent oil and gas
operators.
2. Conversion of geopressured hydraulic
energy to electricity through use of a
hydraulic engine, resulting in a
cost-to-produce of about 8 to 10
cents/kWh.
3. Research on advanced technology to
increase efficiency and reduce cost to
convert geopressured thermal energy to
electricity.
4. Direct use projects for cascading
utilization of geopressured thermal
energy tailored to regional markets and
needs. The concept of total energy use
makes the geopressured-
geothermal resource more economically
viable.
5. Other direct uses of geopressured
thermal energy such as the recovery of
medium to heavy oil.
ACKNOWLEDGMENTS
The author wishes to acknowledge the
considerable information received from reports
by R. Miller, Eaton Operating Company, EPRI, and
H. Coffer. These all contributed to the
development and review of the HPS at the
Pleasant Bayou Well. Additionally, the author
wishes to thank Dr. Carl Bliem, and Ms. S.
Stiger, for reviewing the manuscript.
The Geopressured-Geothermal Program is
sponsored by The Department of Energy under
contract No. DE-AC07-76ID01570.-
REFERENCES
Gas Processors Suppliers Association,
Engineering Data Book, 1987, Tenth Edition,
Tulsa, Oklahoma, pp 24-32.
HPS Test Plan, 1989, modified by INEL, for
Geopressured-Geothermal Report to DOE.
D. F. Keeley and J . R. Meriwether, 1985,
Aromatic Hydrocarbons Associated With Brines
I
From Geopressured We1 1s , i n Geopressured-
Geothermal Energy, proceedings o f t h e S i x t h U.S.
Gulf Coast Geopressured-Geothermal Energy
Conference, E d i t o r s : Myron H. Dorfman and Robert
A. Morton, Pergamon Press.
J. Negus-de Wys, S. G. S t i g e r , M. Plum, D.
D. Faulder, C. J. Bliem, and B. C. Lunis, 1989,
Geopressured-Geothermal Resource Economics
Summary.

J . Negus-de Wys, ( i n press), P r o p e r t i e s o f

Geopressured Brines and Wells i n t h e G u l f Coast
and Opportunities for Industrial/Research
P a r t i c i p a t i o n , Proceedings f o r t h e Geothermal
Review V I 1 i n San Francisco.

W. M. Z a r e l l a , R. J. Mousseau, N. D.
Coggeshall, M. S. N o r r i s , and 6. J. Schrayer,
1967, Analysis and S i g n i f i c a n c e o f Hydrocarbons
i n Subsurface Brines. Geochim Cosmochim Acta,
-
31, 1155-1166

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