They call
them Service Lighters or SL's for short.
In reality they are pretty ugly vessels, looking like a cross between a
coastal tanker and a barge. The mate
meets you at the top of the gangplank and leads you to the captain's quarters,
where the air conditioning hits you like a plunge into the swimming pool.
This is Belém, a seaport in northern
After greeting you, the captain issues curt instructions
for the boat to depart and then enquires "How much do you know about the
Methane Mining Operation?"
Just start
from scratch, if you don't mind
"Well, it all stems from Global Warming, and a
couple of discoveries made back in 2000:
The first was that the Amazon was a CO2 sink,
as opposed to the wisdom of the day which held that mature forests were carbon
neutral. Well, as we all know now, the
missing carbon was being 'exported' down the rivers and deposited, along with a
good bit of silt, as debris in the outer Amazon delta and beyond. Here is decomposed anaerobically to methane
and CO2.
The second discovery was that, in deeper water still,
much older methane had been stored in the seabed as Methane Hydrate… this is a
crystal which forms when the pressure is high and the water is
cold. Unfortunately, when the
temperature rises, it becomes unstable and dissociates to become methane gas
and water once more. The methane of
course, re-enters the atmosphere as a powerful greenhouse gas; a scenario which
the scientists call 'positive feedback', and stood to amplify the effect of
Global Warming by a large factor.
Well, if you put these scientific factors together with
a couple of economic ones, ie that Brazil was desperately short of energy and
that the World Carbon Trading Bank was offering a substantial bounty for
methane mining, and you don't need a crystal ball to see the outcome. Our company BMR (Brazil Methane Reclamation) was founded
within 6 months.
So we have two mining teams, the first, called
'Low-Pressure or LP Methane Miners', work in the relatively shallow waters of
the delta; they harvest wood debris and low-pressure methane. The second, called 'High-Pressure or HP
Methane Miners', work in the deeper offshore waters and harvest high-pressure
methane locked up in hydrate. We Service Lighters are just runners for the LP Miners,
but it's quite exciting enough for me", he finishes with a grin.
By now we're skimming across the light brown water of a river
mouth: What speed are we doing?
"55 knots. This boat, although it looks slow, is
designed to plane on the relatively calm coastal waters, and of course, we're
empty now. We have to slow down a bit
with TIRs behind."
You let that one pass.
Are we at the sea already?
"No way!" the captain laughs "this is the
Point where the
There is a smudge of vegetation just visible on the
horizon ahead through the heat haze.
And how far
away is that?
"Oh, the river is only about 20km wide at this
point, although this is only one of the branches. The entire Amazon delta is about 300km
across"
He sounds casual, but you think you can detect a certain
pride in his voice
So how far is
it to the sea then? "From
here, about 100km"
Good
Lord! The scale of the place is amazing!
"So", he continues, driving the point home,
"our shallow water concession extends some 250km from the coast and totals
just under 95,000 square kilometres, or to put it in
perspective, about three times the area of all the oilfields in the world
combined"
Wow!
"And, it is hundreds of metres deep in places,
whereas the average oil-bearing strata may only be a few metres thick"
The captain has obviously been well educated and is
pleased to be able to show off his knowledge.
"An SL's job is to collect the gas and wood from
the miners and deliver it to LP Central, hence the interesting design of this
ship"
and where is LP Central?
"It's located in 40m of water and is about 20km
south of the geometric centre of the concession"
and what happens to it there?
"Some of the wood is burnt in a power plant to make
electricity, and some is exported. The
gas is compressed to pipeline pressure and the heavier fractions (LPG) are
extracted; quite a lot is converted to hydrogen. Gas, hydrogen and electricity currently go to
the Belém area and are gradually being introduced
into the whole of Pará province"
and what about the CO2
produced?
"Don't worry, it all collected and sent for ocean
sequestration. All the major users
return their CO2 to LP Central.
Minor consumers use hydrogen."
Our boat has been speeding along for a couple of hours
by now, and the captain explains that she is one of three high-speed SL's which
often do the Belém run, taking wood and LPG back to the shore and bringing
containers of supplies out to the miners.
There are also six GL's (Gas Lighters) which just ferry gas from the gas
Miners to the GLS's (Gas Loading Stations) and return
with hydrogen.
What is a Gas
Loading Station?
"Well, the miners are on the move all the time, so
you can’t run a fixed pipeline to them.
However, it would be uneconomic to ship the gas all the way to Central,
so the GLS's are a compromise. They are transfer points from the SL's to a
pipeline system. Each GLS has six Gas
offloading Pillars and three Hydrogen loading Pillars… but you will see all
that later!"
And how many GLS's are there?
"There are currently three, but a fourth will be
opened in a couple of years time, as the working area
expands."
What is the
wood used for?
"Well, a huge amount of wood is used for cooking in
a town the size of Belém with a population of nearly 2 million, not to mention
the rest of
Recently, however, there has been increased demand for
quality 'mined wood' from furniture makers.
Apparently its 'well seasoned' and 'green
label' characteristics make it a very popular export commodity. Most of the wood comes out as flakes, but
sometimes usable logs are found".
and the LPG?
"Well, vehicles mainly… but look, there's our first
LP Miner coming up. This one's a wood
miner so we're going to take some wood and gas aboard; no point in running
around empty"
He is pointing at an island ahead with several houses on
it. There's a jetty with a small coaster
loading, but we're headed for a mooring on the other side.
"As I was saying," said the captain "it's
more like a cottage industry; he's selling his mined logs plus a lot of
firewood, to the coaster who will no doubt be taking them to Belém."
As you get nearer you realise that the island has sheer
concrete sides. It is several hundred
metres in diameter and has a hill, trees and several sizeable huts on it. In the centre is a derrick, and visible in
the distance are some grey canopies. The
captain has been talking on the radio.
"Sebastiao invites us aboard"
Leaving the crew to deal with the gas loading, he leads
the way to a building with a straw roof close to the dock; this is the
Office. The heat is intense and you are
pleased to find that the inside of the building is cool and modern. Apparently the straw roof is just low-tech
insulation and shade.
After introductions, Sebastiao, who looks to be mostly
Amazonian Indian, points at his 'Methane Mining Permit' on the wall.
"Welcome to the 'São Manuel'. This is a family
business, started by my father who still works occasionally although he is
formally retired. The whole family lives
on board, that is myself, two brothers, one sister and
all our various families! The vessel is
leased from the Brazilian government and can work anywhere in the Amazon
concession, subject to our depth limitations, of course. We have a diameter of
350 metres and three workstations. We
can operate in up to 35 metres of water and hold 13 Million standard cubic
metres of Methane gas, including our blimps.
On a good day we also produce 20 thousand tons of wood
flakes". He points at a 'flake'
about half a metre square and a quarter thick!
It is dense and hard to lift off the deck.
Seeing your puzzled expression, he suggests it might be
easier to look at the facilities. He
leads the way to a further room
"This is the control centre, responsible for rig
safety, stability, manoeuvring and overall command. This diagram shows the entire rig, and as you
can see it is like a squat cylinder with a closed top, divided up into cells
approximately 50 metres across. The
larger octagonal cells contain gas and the small squares are ballast. The outer gas cells are closed at the base,
and can be pressurised to 10 bar; the inner cells are open at the bottom and
contain the workstations. As the inner cells
fill with gas, the whole rig floats, although we always hug the bottom for
stability.
There are 15 Drill stations controlled by 3 men, and 3
Grab stations normally controlled by the fourth. We also have a deep drill bit, but that is
rarely needed. We work 24 hours per day,
so we have to have 3 crews. Altogether, with dayshift workers, like myself, maintenance and support, there are 24 people
permanently employed here"
Why so many
drill stations?
"Well, our target is to recover 90% of the wood
buried in the top 100m of the river bed.
That means we drill 6m dia holes at approx. 15m centres. Our rig works a 200m track, hence 15
stations. But you will see more if we
visit one."
This involves a short walk to the first of a line of low
circular huts. Again it is cool inside.
"Yes, the gas expands when it leaves the ground. The result is a cool rig; all we have to do
is keep these work stations insulated."
The workstation is a circular set of consoles with a
huge revolving chair in the centre. Set
into the arms are several levers and buttons.
"The operator keeps five drills working
simultaneously; which requires a high level of training and concentration. Each drill, or Stinger, is a six-metre
diameter hollow tube with cutting edges, like a huge hole-cutting bit. It works its way into the mud slicing through
any trees en route. There is a central
lance ahead of the Stinger which penetrates gas pockets and measures their pressure
characteristics to avoid breaking in too fast.
It is all automated, so the human input is really just tweaking!"
What happens
if you hit a really big gas pocket? you want to know.
"Ah, that has been anticipated. Before the area is released to us, a gas
miner has already worked the patch. We
carry one deep drill just in case they have missed a pocket. In that case, we would turn into a static rig
for a while, but it is very rare."
and the wood; what happens to that?
"On the downstroke, we cut through it and dice
anything within the stinger. The flakes
are carried up with the drilling water which circulates down the outside and up
the middle of the stinger. Then on the
upstroke (stinger retracting), the water flow is reversed, rotation stops and 3
metre long bristles extend from the tip of the stinger to drag large bits of
wood out. These are recovered by the
Grab stations as the rig moves forward."
How deep do
you go?
"The Stinger is telescopic and will extend to 120
metres below base. However the mud
usually firms up at about 80 metres, and any wood
below that depth is considered locked in.
Maybe one day, it will be economic to go back for it, but it's not
urgent from the Greenhouse Gas angle."
and what powers the whole thing?
"We have a bank of Hydrogen-powered Fuel Cells
which delivers hydraulic power (very high pressure water) to all the
workstations, and supplies electricity for general use."
where do you get the Hydrogen?
"It is shipped from LP Central in special
blimps. We aim to leave nothing
environmentally unfriendly behind us.
The alluvium is filtered for wood debris and the water surface within
the rig skimmed for oil. The latter is
actually quite a valuable by-product!
Sometimes we can also sell a barge or two of rich alluvium if somebody
wants to improve their soil quality."
But what
incentive is there to keep things so clean?
"Well basically we are the custodians of the Amazon
delta, and protectors of the overall ecosystem. Most of us are locals and it
makes sense to look after your own backyard and after a while it becomes a
matter of pride. Then again, we are
checked periodically by the inspectorate (Brazilian Government and the World
Carbon Trading Bank), and our license is capable of being revoked if we are
polluting. Would you like to look at the
wood handling?"
Certainly.
We make our way to a further hut, 100m away. Inside it is the normal blissfully cool
atmosphere, but the lighting is subdued.
Two women are seated on swivel chairs on a circular stage in the centre
of the room. They have masks on and are
moving their arms in a peculiar clawing manner.
It looks like some form of macabre slow-motion mime routine.
"This set-up is the latest in Virtual
Reality", says Sebastiao, "the girls are cutting and sorting the wood
in the chambers beneath. Feedback is via
computer enhanced sonar to their goggles and acoustically to their
headphones. Maria, over there is
cutting… see the extended forefinger?
Juanita is stacking."
Sure enough, one of the figures appears to be lifting
invisible objects with either hand. Her
arms are encased in long gloves, supported from the ceiling by wires.
"Normally there is only one VR operator who works
between the three Grabs. At present,
however, we are preparing logs for the coaster and need two ops."
and how do the operators know which
logs are usable?
"It's all
done by our instruments. The good logs
are identifiable by their frequency response to ultrasound; the computer
displays it all in false colours - look in this headset." he fastens some
goggles to your head. At first it's just
a confusing array of near horizontal shapes and colours, blue red and green
outlines with moving white vertical arms.
Sebastiao suggests that you move your head around and
suddenly your brain clicks into 3-D recognition; head movement changes your
apparent position of view and you can now see the outlines of trees and
branches stacked in a heap. The white
tool with the glowing red tip is obviously the cutting blade; it moves through
the logs inexorably working in tandem with a couple of clamping tools. Your smile must have given away your
awareness.
"The green ones are the ironwoods. That's what we are looking for. Occasionally we get some ebony and that shows
up yellow. If you were seated on the
stage where the girls are, you would also feel the vibrations caused by the
tools working - also another useful sensory feedback.."
It seems so
graceful, like ballet
"indeed", agrees
Sebastiao "underwater is an ideal environment to handle timber. Those trees are huge and would weigh over 50
tons on land, but underwater they're only about 3 tons and we can manipulate
them easily. Furthermore they cut like
butter, although once the wood dries out it is almost impossible to even mark
it. The shippers try to keep it wet
until it hits the factories. There they
have learned how to handle it… I know because my uncle owns one." he adds
assuredly.
You emerge from the goggles and look cautiously around;
the room does not move.
"Want to see the end product?"
The Captain of the SL interrupts, "I think, Sebastiao, that we should be on our way, unless there are
any last questions?"
There are many things that you would like to ask, but
one major item is still unclear.
How do you
move this huge vessel?
"Easy! We
are always attached to the bottom via the stingers; while drilling there are at
least three stingers engaged and by varying the pressure on these we can adjust
our depth and attitude. To move, we retract all but one end stinger and rotate
about it. Inserting the other end
stinger allows us to swivel the opposite way.
A bit like the front end of a giant tortoise. Crude but effective!"
He smiles and offers his hand.
"but I see you need to be off. Nice to meet you".
On the way out we call in at the Office to check and
sign the loading papers, but soon we are back on board the SL. There have been some changes in our
absence. The SL is now attached to a
huge floating sausage, grey-green with an orange stripe down the side. It is a 'Towed Inflatable
Reservoir' (TIR), normally referred to as a 'blimp'.
"The orange stripe means medium pressure methane -
all the 6's written down the stripe refer to the pressure rating: 6 barG ." advises the Captain. "The Natural Gas
Liquids (NGL) has been loaded onto tanks on board, and that, of course, is
80,000 tons of wood flakes". He
points at the hold which is full of what looks like grey-black building blocks
in a towering heap.
Where did all
that come from?
"The TIRs were ready
loaded - we just swapped them for empty ones.
The wood skips are floated into the rear docking bay. We dropped off a return skip with an empty
TIR and also a tank of LPG for transport use.
Turnround time is less than one hour."
This time the Service Lighter eases away from the jetty
with her strange cargo trailing behind her and heads off at an acute
angle. "We have to head up wind
until we reach full speed. Always got to keep the blimps downwind of us".
Gradually the speed rises and the sausage, which had
been bouncing around a bit, stabilises nicely.
What size is
the TIR?
"That's our standard 50m diameter by 400m
long. It holds about 4½ Million Standard
Cubic Metres of methane. The skin is
50mm thick carbon fibre reinforced polypropylene. When deflated it is 50m dia
by 100m long and fits neatly into an empty skip"
But isn't
methane lighter than air?
"Well, yes, at atmospheric pressure that's
right. However that blimp is compressed
to 6 bar, which means the methane in it is four times
the density of air. The Hydrogen blimps
normally need a bit of water ballast though, especially if the weather is a bit
bumpy."
After this pronouncement, the captain goes silent. The figures certainly need some
digesting. The captain suggests
lunch. For you it is a chance to ask
some more questions.
So how many
miners are there altogether?
"There are currently eight wood miners and about forty
gas miners. Four more Gas Miners are
commissioned every year, so the whole operation is continually expanding. Currently we are at 60% of expected peak
production.", he replies, "the target is to remove all 'surface
methane' from the Amazon basin in 50 years, then continue to mine the wood as
long as we need the material. There are
wood reserves there for about two thousand years."
Amazing! That takes some thinking about…. a project
which is so large that it takes 25 years from inception to reach peak
production and then continues for 2000 years!
And are all
the miners the size of the 'São Manuel'?
"Yes, she's a standard miner, size wise, perhaps a
bit more automated than most. The gas
miners are simpler; they only make small holes and consequently cover the
ground faster, but they are the same size.
Of course, each miner is designed for its own depth limit - it's never
more than a few metres off the bottom, so it can't sink."
But doesn't
gas mining disturb the sediment and cause later methane outgassing?
"Ah, they've thought of that. The gas miners (as distinct from the wood
miners) only make 6" holes and then plug them as the drill bit comes
out. That way, any later gas
accumulations stay put. The wood miners,
of course do disturb the sediment somewhat, but in this river that is situation
normal. In fact, the fish enjoy the
released nutrients and the miner families and their friends eat
well." He points towards a bulging
plastic bag on the floor. "Supper".
Three quarters of an hour away, the next stop is GLS3
(Gas Loading Station Gamma, you remind yourself). The captain points towards a group of blue
flashing lights, but nothing else is visible.
"Here, look at the radar scan"
A circle of points is visible,
two of the points are winking. 'Those 2
are the Hydrogen Loading Pillars, the other 4 Gas Discharge. It's enhanced radar,
of course, the LP's emit a signal which the radar thinks is a reflection. The pillars are labelled a,b,c etc. clockwise from the North. We're going in to LP-3b."
He issues some unintelligible orders!
"As we slow down we need to come into the wind;
that will bring us parallel with the moored blimps, of course, they all act
like weather vanes"
We execute a slow left-hand turn. The captain seems to be talking to himself.
"Radio beacon detection on!
Each post transmits at a unique frequency.
We have to keep deliveries up in all weathers!"
We are approaching the first moored blimps attached to
their Loading Pillars by the neck. The
first one looks to be full sized, but the second is less than half as long,
with visible corrugations in the skin.
You would like to ask the captain, but he is concentrating.
"Steady as she goes, speed 5 knots, extending tow
rope"
The 6 Loading Pillars are all visible now, like a ring
of marine mushrooms.
"That's our target.
The Loading Pillars rotate and you always approach them on the port
side"
The pillar labelled LP-3b sticks straight out of the
sea. As you get closer, you notice there
is a notch out of the right-hand side just below eye level.
Our TIR has fallen away to stern as the towrope is paid
out. We pass the pillar, drop speed
still further and execute a sharp turn to the left. The towrope wraps itself around the pillar
and is caught in the notch. We are still
moving away from the pillar but the TIR is not following anymore.
"Tow rope clear," says the Captain,
"that's it now, over to the automatics."
He looks at my blank face and explains. "The notch in the pillar grabs the rope,
and pulls it out of our inertial winch until it releases from us. It then reels
the rope in, working from the centre and pulling the blimp onto the discharge
nozzle. See!"
Sure enough, the blimp is slowly nuzzling up to LP-3b.
and what's up with that
half-collapsed blimp?
"The core-rope, which is effectively an extension
of the towrope, extends right through the axis of the blimp to the rear
dome. The pillar pulls steadily on this
rope thus keeping the blimp pressure up by reducing its length. There's a kind of spider inside which
controls the blimp's shape."
Is the
station manned?
"Not in the conventional sense - it's under remote
control from Central; each LP has its ccTV
camera. Also, there is always a support
vessel on hand to sort out handling problems, help the maintenance crew plus
keep an eye on security."
How is
maintenance carried out… there appears to be no way to even access the pillars?
"They are unhooked and replaced in their entirety…
think of them as light bulbs, and you've just about got it, except that they
are overhauled not thrown away."
Where is the
power source?
"A pipeline from Central provides hydrogen which is
converted by fuel cells to electricity.
Pumps provide hydraulic power (compressed water) to the LP's. The Power Complex is subsea in the centre of
the ring; well out of harm's way."
The captain suggests some coffee and a snack. A beer would have been welcome, but it looks
as though the vessel is dry!
Skimming our way across the light brown water, we soon
eat up the 90 kilometres to LP Central.
"There she is", says the captain "we'll
be there in half an hour".
A structure is visible, rising out of the open water.
"Now to offload the containers, and you, of
course"
We make our way slowly towards Central. It seems to get bigger and bigger until our
ship is dwarfed beneath it. A platform
crane swings over and the crew run to attach the slings which are already in
place on the containers. Off they go,
one at a time.
"You will notice that there is hardly any
swell" says the captain " there is a Wave
Barrier upweather of the complex, and it normally provides us with mill-pond
conditions. Not so vital for containers,
but essential for the wood dock. It's
over there."
He points at an opening in the massive structure with a
gantry sticking out.
"We are going to reverse under the gantry, attach
the slings, ballast down so the wood skips float clear of the docking bay, then
pull away. The gantry crane drags the
floating skips under the platform then lifts them one at a time into the drying
area."
"and that" says the
captain, "will be the end of our trip, but first we need to offload
you"
He gives you a firm handshake and bids you
farewell. The mate leads you to the
man-riding capsule, where you are the only traveller in a 6-person padded
module. After the initial acceleration
as the crane lifts you off the deck, there is hardly any sensation as you cross
the gap. The view through the portholes is breathtaking! There is activity all around.
"Welcome to LP Central" the door swings open and a friendly
face looks in "follow me, please, the OIM is expecting you". The boss is obviously known as the 'Offshore
Installation Manager' in true oil-rig fashion!
In fact the whole thing reminds you of your time in the
The offices are cool and efficient. The OIM has a corner location with
magnificent views to the North and East.
Having greeted you he is keen to get down to BMR business.
"When this project kicked off in 2004, there was
little appreciation of the effect it would have on the Brazilian economy and
even the local culture."
This is obviously a well-rehearsed speech.
"It was not easy - it took three years of
feasibility studies before the financing was secured and detailed design could
proceed. By 2013, construction started
and the first gas was processed by LP Central in 2016, fed by the first 2
miners via Gas Loading Station Alpha.
Since that time we have been building miners at a rate
of four per year, and extending our zone of operations accordingly.
By 2029 we expect to have enough Gas miners
- 74 in total - to work out our gas concession within the 80 years of
the original charter."
What is the
current production situation?
"Well, today we process the output from 40 gas and
8 wood miners in the Amazon delta, and although that is a simple statement, the
whole thing becomes quite complex and sometimes needs a good bit of juggling
between our various clients. We
basically have four products, each of which can be described in three stages."
The OIM seems to have an orderly mind; he ticks the
items off on his fingers.
"Firstly we have wood.
Wood is a growing market. We started with 3 Wood Miners, which were
enough for our initial needs. That was:
1a the first use of wood - 52 thousand
tons of it is burned daily here for power.
An equivalent sized conventional power station would burn 45 thousand
tons of coal per day just to produce the electricity, never mind the Hydrogen
…. next
1b We
started sending wood down the coast to various power plants (45 thousand tons
daily). Currently that occupies another
2 Wood Miners…. then
1c the last use of wood is for
export. Exports are getting stronger,
both in bulk wood flakes (90 thousand tons daily) and reclaimable timber (123
thousand cubic metres daily). To put
that in perspective, it's as much as the wood production of the whole of the
Grand total ten Wood Miners."
We look out of the window towards East; it certainly is
a grand view. The wave barrier appears as a busy port with five large ships and
numerous smaller moored on the near side.
It is hard to appreciate that it is 5 kms away and itself over 2kms long!
The lesson continues:
"Secondly we have River Gas
The Gas that arrives here is a mixture of Methane and
the heavier fractions plus 10% CO2.
It is processed in three stages:
2a It
is offloaded at one of the GLS's from the TIR's at a constant pressure of 6 bar;
a hydraulic winch tensions the core rope to compress the blimp… but you have
seen that!
2b Back
at Central, the gas is further compressed and cooled to remove the NGL (Natural
Gas Liquids).
2c Then
it is converted to a mixture of Hydrogen and Electricity in the Oxycell
process"
"Thirdly we have Electricity
We are a major power station. The juice we make here supplies the whole
Belém area via an underwater superconducting cable. It is government policy to keep the Amazon
area as clean as possible so this offshore power plant is a blessing. Our electricity production meets three
criteria:
3a Under
average load conditions we produce 5 Gigawatts of electricity. That's equivalent to two or three central
power stations; but we have an advantage…
3b During
light load times, say 2 Gigawatts, we reduce the hydrogen flow to the Fuel
Cells and store the excess under the platform for later use.
3c And
under heavy load conditions, we can put that stored hydrogen back through our
extra bank of PEM cells to produce 10 Gigawatts of power. That's an overall turndown ratio of 5:1,
which is unheard of for a central unit… and we can adjust to load changes in
minutes!"
The OIM is obviously proud of his installation. He glows with enthusiasm.
"Fourthly we have our miscellaneous products, again
there are three:
4a NGL
(Natural Gas Liquids) which is split to recover propane, butane etc. which is
then called LPG (Liquid Petroleum Gas). This is sent to the mainland as vehicle
fuel, powers our boats and is used on the miners for various purposes. Total exports 4 thousand tons per day.
4b Hydrogen
is produced in vast quantities in the OxyCell process. Some of it (currently 3 thousand tons per
day), is used by the miners and GLS's as a zero
emissions fuel. The rest is delivered to
the mainland by pipeline. This has been
a progressively expanding market for us.
4c Carbon
Dioxide - all CO2 produced is recovered and pumped down a pipeline
for sequestration in the deep ocean, where it joins the underlying ocean currents and is
locked up in the form of hydrates. The
scientists say it will not re-emerge for some centuries. All the Carbon in the
River Gas is recovered; the total liquefied and sequestered is 250 thousand
tons per day, that's 90 million tons per year!"
The figures are amazing. The OIM is beginning to sound
like a salesman, which come to think of it, must be part of his job. He hands you a schematic with the figures on
it, saying
"That sheet gives you all the data you need on LP
Central" <see
attached>
How will you
utilise the additional River Gas, as further miners come on line?
"Aha! That is where the Northern Platform comes
into the picture. Up 'til now, we have
been expanding our onshore energy supply (Hydrogen and Electricity) as the
Government has been progressively closing the 'old-tech' power utilities. However, the entire region has now been
converted, and further expansion will be very gradual.
So from next year, Northern Platform will start taking
gas for Aluminium smelting, and will ramp up its operations to match future gas
availability. It will also use advanced
Oxycell to facilitate CO2 recovery, producing Electricity and
Hydrogen as intermediate products. This
gives us the opportunity, without the commitment, to deliver more power to the
mainland by diverting it from Northern Platform. A very flexible
solution!"
The OIM glows again!
'Why aluminium?', you want to know.
"Smelting is a pretty power-hungry process. Bauxite is plentiful in the region, and there
are several onshore operations, using hydro-power. The Government is keen to expand the
business, but cannot afford further environmental impact onshore. Out here, however, we can control things
better. All by-products will be recycled."
How do the
economics of Methane Mining work? you ask.
"Well, the original investment was funded half by
the Brazilian Government and half by the World Carbon Trading Bank… in fact, most of the revenue from the CO2
sequestration (which at $10 per tonne is worth a lot) goes to pay for the WCTB
loan. Likewise the gas export is taken
by the Government in return for its loan. However, our operating costs are well
covered by the electricity and NGL sales, leaving a reasonable profit.
What has surprised us though, is the wood export. We had half expected originally that we might
have to 'bury' the excess wood in the deep water where it would not rot, as a
form of carbon sequestration. However,
in the event it has proved a popular fuel with a green image, although we
insist on the recipients recovering the CO2 from any use of the
fuel.
The quality of the reclaimed hardwood tree trunks has to
be seen to be believed. We are exporting
more cubic metres of furniture quality timber from here than is produced by any
other country in the world… and all without felling one tree from the
rainforest! Nature did all the work for
us centuries ago.
So overall the economics are good enough for us to
finance the next installation ourselves; the new Aluminium Plant at HP Central
will be a $1½ billion phased investment."
You have a lot more questions. The OIM seems happy to oblige.
How do you
store the hydrogen you mentioned?
"The rig is located over a gas field; there is a
deep reservoir which we can use as a gas buffer, and a shallower depleted
reservoir where we store hydrogen."
How many jobs
has the Methane Mining created?
|
§
380 on Central plus 85 on the
Wave Barrier and 8 on tugs. |
|
473 |
|
§
74 Miners with say 24
operators plus families |
|
2476 |
|
§
9 SL crews of say 8 men |
|
72 |
|
§
75 at the shore base,
including administration |
|
75 |
|
Grand Total
3,100 in round numbers:- all skilled jobs |
|
3096 |
Plus, of course, all the
spin-offs. You must
have seen whole families on those miners, and the timber trade is flourishing,
and of course tourism is way up now that the area is 'clean and green', and the
local people have taken renewed pride in looking after their environment. Altogether, a significant contribution to the
local economy"
What about
the impact of the CO2 on the ocean?
"Here in Central, we are on the continental shelf
and the water is only 40m deep, but within 100km it has plunged to over 4000
metres. The liquid CO2 is
released into this abyss and forms a stable crystalline hydrate which floats
away like snow in the current. We have
found 'hydrate glaciers' forming in valleys downstream of the discharge point,
and have every hope that it will be down there for a long time, or at least
until it's needed in the atmosphere again to counteract a future ice age! There are no volcanic vents in the region and
we have never observed any animal life to be affected by the deposits. We keep a constant eye on proceedings with
underwater robots"
What happens
when the gas runs out?
"Good question!
You must remember that our priority here is to gather up methane which
is in danger of leaking into the atmosphere, especially in view of rising
temperatures and more extreme weather.
Consequently we are only mining the top 200m or so of the river
sediment. In places it is more than 500m
thick, and there is reason to suspect that there is more gas the further down
you go. So after the first pass we will
probably do the following, or a combination of all four:
a) Extend
the concession into more remote areas - by then we will be able to show that
our techniques are not environmentally damaging - there is about the same area
again to be mined.
b) Rework
the first concession at a greater depth.
c) Harvest
the methane hydrate from the deeper waters along this stretch of the coast.
d) Use
a greater proportion of wood in the gasification process.
The miners are designed to have a 200 year life, and
there seems to no danger of running out of gas before then."
You mention Hot Cells and PEM cells, what are these?
"Aha, they are both forms of Fuel Cell; the Hot
Cells are Solid Oxide fuel cells (SOFC's) which operate best at about 1000°C as
distinct from the Proton Exchange Membrane (PEM) cells which run fairly
cool. But the best person to answer that
sort of technical question is the Production Manager who is going to take you
on a quick tour which is arranged for
You make your way along seemingly identical
corridors. The OIM is commenting all the
way things like "Radio room", "First Aid",
"Security". We are in the
living quarters at one end of the platform with the heli-deck on top, well
removed from the process plant at the other end.
The mess is light and spacious; various groups are at
tables eating and chatting. A tall
dark-haired man comes over to our table by the window. "Thought
I may as well introduce myself, although it's a few minutes early yet;
Francisco Gomes, Production Manager."
You are soon on first name terms; it's easy to get along
with this man, although also clear that he would not tolerate fools gladly.
"OK, so while we have the luxury of sitting here in
the cool, let's get you up to speed on the OxyCell Process, the heart of our
operation. Here's a simplified
diagram"
The OIM makes his excuses; he has heard this many times
before! "If you want to reclaim all the CO2 from
your combustion process, it is easier if you avoid getting Nitrogen mixed into
it. Most combustion processes use air
and end up with an exhaust containing at least 8 Nitrogens
for every CO2… complicated and costly to separate." OK, so how
does OxyCell avoid that? "Well it does it in two ways: 1. The
combustion process is carried out in a Fuel Cell, a Solid Oxide Fuel Cell to be
precise. SOFC's are able to transform most liquid or
gaseous hydrocarbons into electricity.
They run at between 500C - 1000C, which means that their 'waste heat' is
quite useful, but for us they have a very important quality; they work by the oxygen
ions crossing the electrolyte rather than the hydrogen ions (protons). That means that CO2 exhaust is
generated on the fuel side of the cell ie. not mixed
with the Nitrogen in the air. 2. Oxygen
is used for the final combustion. It's
expensive stuff to make, but as we only need it for the tail end of the process
(13% of the total Oxygen input), it's quite tolerable" He looks at your puzzled expression. "Here, look at the diagram. Hot air enters one side of the SOFC cell and,
because of the nature of the solid oxide electrolyte dividing the two side of
the cell, the oxygen ions migrate through to react with the hydrocarbon fuel,
so stripped air (90% Nitrogen) emerges. Charged ions migrating means current flowing, so electricity is
generated at about 55% efficiency while the rest of the energy is liberated as
heat with the reaction products.
So on the other side of the cell, you put methane, hydrogen and carbon
monoxide in, and get out CO2, H2O, heat, plus a bit of unburnt fuel. Normally recovery of this heat and fuel would
be an unwanted problem. Here, however,
it leads into a conventional steam cycle with topping Gas turbine, which
despite years of evolution has only just managed to attain 40% efficiency. Some of the electricity from the Hot
cells goes straight into the electrolysis unit to generate the Oxygen. The ELEC unit runs at 20 bar
and 200°C, at which temperature the dissociation energy of the water is
lower. The O2 and H2
are also generated at high pressure, saving energy in filling the hydrogen
storage reservoir." So what is
the resultant effect on the exhaust? "It consists of water and CO2 only; easy
and cheap to separate!" In addition, the intermediate production of Hydrogen
means that we can store it for conversion to electricity in our PEM cells
whenever we want. Moreover, PEM cells
are relatively cheap, so to put in an extra bank or so is an option which
allows us to generate, for a few hours per day, more than double our average
output; essential for the local lifestyle here!
Off peak, of course, we are recharging our hydrogen reservoir." Ah, hence the turndown ratio that the OIM was talking
about. You want to sound as if you have
learnt something! How about the
fixed load requirement?
you ask, pointing at the top right of the
diagram. "In our situation that is the Hydrogen compression
load, as long as the H2 keeps flowing, the energy requirement is
just about constant." He looks at
his watch. "But now we should be going to have a look round
before it gets too dark" It's a hot and tiring tour; Francisco shows you
everything, some of it familiar and some completely alien. "Of course," he says afterwards "it was
tempting when the plant was built to stick to conventional technology, after
all, a conventional power station with flue gas treatment would have
worked. However, the WCTB and the
Brazilian government thought this should be a flagship project even if it cost
a bit more… and their courage has paid off - the extra efficiency more than
pays for the additional investment, and we have proved the technology, such
that the Northern platform will be even better." Tell me about
the Northern Platform, please "Interesting. It's not a platform in the conventional sense, it's more an artificial island. Aluminium production is normally quite a
messy business, using a lot of water and producing heaps of waste. Well, here there's as much water as you
want", he waves his arm around, "and the waste is consolidated and
used to extend the island. Make more
island, and you can enlarge the plant!
Export couldn't be easier and cheap fuel is abundant. Of course, the zero emissions policy does add
to the cost, but when it's built in from the start, it's not that much. In fact, because other producers are now having to pay a 'pollution premium', it means that
our output should be highly competitive." You have one last question before turning in. The Wave
barrier, what happens there? "OK, really it's another whole project in itself,
but I'll make it quick". He thinks
for a moment. "As you know, it is a floating port and a barrier
at the same time. It extracts the energy from the waves,
leaving nothing to 'rock the boat', hence it's stability. Physically it is a vast concrete structure
2kms long and 500m wide, consisting of a large number of hexagonal cells, open
at the bottom. The deck, although flat-looking, actually slopes down from 25m
above water level at the outer edge to only 10m at the calm inner edge. It generates all its own electricity and
motive power for dynamic positioning.
Sometimes it has to change location in order to keep us in its wave
shadow, and it does this almost indiscernibly, taking all the moored ships with
it so that loading can continue unhindered. To prevent heave in extreme weather
conditions, it can put down 'anchors' along its leading edge; just like giant
augers which embed themselves into the alluvium. This is only required once or twice a year,
and then generally as a safety measure rather than necessity. It is
completely self-sufficient, and we wouldn't notice it unless it wasn't there
one day! That's it
in a nutshell." Well,
that's been a marvellous introduction, but I really think bed is calling now. With a
cheery "Good Night", the Production Manager leaves you at your cabin
door. It has been quite a day! Roger Clark
STEP 2000


