Advancing scientific knowledge on fouling, erosion and corrosion in Once Through Steam Generators (OTSGs)

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Canada is well positioned to deliver safe, secure, and reliable energy to markets especially via steam-assisted in-situ production of oil sands deposits. This requires highly economic approaches to produce steam in so-called Once Through Steam Generators (OTSGs) while produced fluids are recycled to minimize the environmental footprint of in-situ oil sands operations. The boiler feed water constituents are prone to cause mineral and organic precipitates upon heating in steam generators and erosion and corrosion often resulting in premature OTSG failure. The objective of this research project is to reduce inorganic and organic fouling and erosion and corrosion in OTSGs to enhance water and energy efficiency and achieve greenhouse gas emission reductions. The research team members from the University of Calgary, the University of Alberta, and SAIT will advance the scientific knowledge about inorganic and organic fouling, erosion and corrosion, and modeling of OTSG systems. A unique aspect of this project is the ability to test the applicability of key findings from laboratory and modeling investigations in two large-scale pilot test OTSG rigs. The inter-disciplinary evaluation and interpretation of the research activities will create for the first time a scientifically based technical operating envelope (TOE) for steam generators. An improved scientific knowledge of boiler feed water limits (e.g. hardness, dissolved silica content, content and quality of organic compounds among others) will enable higher steam qualities of up to 90%. This will result in a more economic and environmentally friendly operation of OTSGs and hence in a significantly increased competitive advantage for oil from Canada's large in-situ oil sands reserves.