Innovation of pilot OTSG skid design and construction to simulate field conditions for corrosion and erosion

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The Southern Alberta Institute of Technology (SAIT) and Canada's Oil Sands Innovation Alliance (COSIA) are collaborating to innovate pilot lab-scale once-through steam generators (OTSGs) through a novel design and construction configuration of part of the process. This new design is required to improve steam quality, increase energy efficiency and reduce environmental impacts. OTSGs convert boiler feed water (BFW) of poor quality, non-potable water to high-quality steam required for in-situ resource recovery. The elevated concentrations of dissolved organic and inorganic impurities and residual organo-metallic species present in the BFW cause scaling and fouling. This causes corrosion and erosion in the OTSG tubes, leading to their premature failure. The objective of this new applied research project is to assist the development, construction, operation and testing of a novel hybridized prototype metal test coupon and heater on the pilot test rigs at SAIT. This new research project will focus on two novel and important inclusions through the design and construction of: (i) metal test coupons and (ii) a heater with superior heat exchange capacity to hybridize the pilot skids and simulate the field OTSG conditions for erosion and corrosion. This innovation will entail a systematic investigation to determine the composition and the effect of scale and fouling in retarding heat transfer and the erosion and corrosion mechanisms that foster their residence on the surface of the metals under the deposits.