Speaking at the inaugural UAE Climate Tech summit, COP28 President Designate Sultan Ahmed Al Jaber called upon the oil and gas industry to phase out methane emissions by 2030 and align in favour of comprehensive net-zero emission plans by or before 2050.
Methane is a powerful greenhouse gas responsible for around 30% of the rise in global temperatures since the Industrial Revolution; it is the second largest contributor to global warming after CO2. More than half of global emissions stem from human activities in three sectors: agriculture, waste and fossil fuels.
Methane tends to leak into the atmosphere undetected from drill sites, gas pipelines and other oil and gas equipment. It has more warming potential than carbon dioxide and breaks down in the atmosphere faster, so reining in methane emissions can have a more immediate impact on limiting climate change.
EPA's new policies would ban routine flaring of natural gas produced by newly drilled oil wells, require oil companies to monitor for leaks from well sites and compressor stations and establishes a program to use third party remote sensing to detect large methane releases from so-called "super emitters,".
US officials at the United Nations COP28 climate change conference in Dubai. The United States and other nations attending the summit are expected to detail how they will achieve a 150-country pledge made two years ago to slash methane emissions by 30% from 2020 levels by 2030.
The market is enormous: the natural gas flared and vented is equivalent to the energy needs of France and Germany.
The market segments include oil and gas, landfill gas, bio gas, shale gas, large scale to produce diluents to transport heavy oil to the US market. In Canada, the Alberta Energy Regulator is shutting in wells that can’t meet the emission objectives.
According to Global Methane Assessment Study do in 2021 – which, assessed and integrated the climate and air pollution costs and benefits from methane mitigation – methane action would prevent nearly 1 million premature deaths due to ozone exposure, 90 million tonnes of crop losses due to ozone and climate changes, and about 85 billion hours of lost labour due to extreme heat by 2050. This would generate roughly USD 260 billion in direct economic benefits through 2050.
More than three-quarters of methane emissions from oil and gas operations and half of emissions from coal can be abated with existing technology, often at low cost. Tackling methane emissions is one of the most cost-effective ways to reduce greenhouse gas emissions. Around USD 75 billion in spending is required to 2030 to deploy all methane abatement measures in the oil and gas sector in the IEA’s net zero scenario, the report finds. This is equivalent to less than 2% of the income generated by the oil and gas industry in 2022.
Reducing methane emissions from the energy sector is one of the best – and most affordable – opportunities to limit global warming in the near term. Early actions by governments and industry to drive down methane emissions need to go hand-in-hand with reductions in fossil fuel demand and CO2 emissions.
Tackling methane emissions is one of the most cost-effective ways to reduce greenhouse gas emissions. Around USD 75 billion in spending is required to 2030 to deploy all methane abatement measures in the oil and gas sector in the IEA’s net zero scenario, the report finds. This is equivalent to less than 2% of the income generated by the oil and gas industry in 2022.
Our patent integrates the micro-refinery unit (MRU) with existing oil facilities that already have trained personnel.
The technology to convert methane (and coal) to fuel was first developed by Fischer and Tropsch in the 1920s. Germany used this technology in World War II as they had no petroleum. The first step to produce fuels is to make syngas – a mixture of carbon monoxide and hydrogen. In the second step, (Fischer-Tropsch synthesis), the CO and H2 react to long chain hydrocarbons, waxes, and light gases.
The problem with gas-to-liquid technology is CAPEX and OPEX. Small scale units are uneconomic, especially if you only build one. Operators cost as much as $2 million per year for specialty chemical plants. However, if you build hundreds, costs can come down exponentially – The patent application we filed address both CAPEX and OPEX.
The MRU technology applies a catalytic partial oxidation (CPOX) step in a milli-second reactor. This compact reactor costs a fraction of steam methane reforming (SMR) because it is exothermic rather than endothermic and so heat management is much simpler.
The first step in addressing cost is to train operators that are already there. Second, integrating the MRU with existing facilities means that there are fewer unit operations to invest in: flare, oil storage, water treatment. All these facilities already exist and so this could reduce the cost of an MRU by a factor of 2.
The third element is reducing CAPEX by building mass manufacturing capability.
This technology provides this economic alternative with an expected payback in 12 to 18 months. So, this would trigger a huge demand for the units as companies would be obliged to buy it. We estimate that a unit could sell for $1,000,000 USD.
The price of crude oil has been hovering around $90/bbl (WTI). The diesel fraction produced through the Fischer-Tropsch process has a higher API gravity, which commands a higher price (10 % to 20 %) than low API gravity crude. Assuming a price of $100/bbl and the unit operates 330 $ per year, the net sales from a unit is $330 000. The target manufacturing cost will be less than $300 000 and we anticipate selling the unit at more than $500 000 so profit from each unit will be $200 000. We anticipate building facilities to produce one unit per day, so revenues would be $150 million per year and the profit would be $60 million per year.
Rather than selling units, some junior oil companies have offered to share the production if we were to able to produce oil from wells that were shut-in. Assuming that the unit can bring a marginal well back online and they produce 5 bbl/d oil and 100 MCF (thousand cubic feet per day) of natural gas, the total revenues would be close to $500 000 per year. The orphan inventory Alberta stood at 8000 wells several years ago. If we assume that 1000 have this minimal capacity, the total revenues would be $50 million/y.
In Canada, oil rigs are allowed to flare gas for 72 h during well completion to evaluate the oil/gas in-place. Sometimes this is not enough time. Since the MRU is mobile, we can bring the unit to the well head and convert the natural gas to diesel, which give reservoir engineers more data to estimate the productivity. There are about 750 oil rigs operating in Alberta. Assuming 200 rigs rent the well for 100 days per year, the total revenues at $3000/day, would be $30 million/year
PEnG has consulted for dozens of start-ups and multinational corporations, including Total, Arkema, ExxonMobil, Johnson-Matthey, Velan, Lavergne Group, and Haldor-Topsoe. PEnG's founder has worked for DuPont in the United States, Spain, and Switzerland (starting in 1990). In the US, he managed a laboratory to qualify 200 000 kg of catalyst for the commercial plant design, operations and technology marketing development. The gas-to-liquids process developed has all of the elements of past industry experience in catalysis manufacture, reactor design, operation, and scalability. PEnG’s the patent holder of the MRU technology has managed $20 million in research funding to develop Li-ion batteries with multi-national corporation that makes catalysts. PEnG has collaborated with major oil companies on developing technology to reduce CO2 emissions and granted a joint patent on similar technology.
2015 Clariant supplied CPOX catalyst for the first step
2016 Canadian Journal of Chemical Engineering publishes the article "Micro-syngas technology options for GtL". Co-authors include Jan Lerou, Bill Green (MIT), Ceramatec.
2016 Theo Fleisch (World Bank Global Gas Flare Reduction initiative) endorses GTL technology at the NSERC Connect conference in Calgary, AB
2016 PEnG organized the Canadian Gas Flare Reduction Initiative: industry, academia, gov’t
2017 NSERC awards Gregory a Tier 1 Canada Research Chair (CRC) to develop a pilot plant: CFI grant =$600 000, CRC=$200 000/year over 7 years
2019 S. Jaffer (VP Corporate Science and Technology Projects, Total), suggests offshore wells
2020 PEnG presents the project to the Government of Alberta Energy Caucus
2022 MRU mechanically complete
2022 Topanga Resources offers to test MRU on site in Peace River
2023 PEnG & Global Oil & Gas Recovery Corp. colaborate to address the flaring and abandoned oil and gas wells available in the USA and Canada
2023 PEnG relocated the MRU pilot plant out of the lab and on to a trailer for oil field upgrades
(1) Install our reactor in the trailer ($30 000 - 1 month) COMPLETED
(2) Certification from the RBQ ($20 000 - 2 months) COMPLETED
(3) Synthesize 200 kg of catalyst ($40 000 - 2 months) COMPLETED
(3) Test individual components of the reactor with controlled gas bottles ($100 000, 8 months)
(a) purchase a methane compressor and install the unit ($60 000 - 4 months)
(b) ship unit out to Peace River, AB install unit at battery unit ($100 000 - 3 months)
(c) conduct extensive tests varying conditions to identify the optimal ($200 000- 6 months)
(4) Modify the reactor design to minimize costs (particularly for the first step - $75 000- 6 months)
(5) Engage Genfabco on constructing 10 reactor units ($600 000 - 6 months)
(6) Purchase all ancillary equipment to build 10 units ($6 000 000 - 1 year)
(7) Hire electricians, technicians to instrument the reactors ($1 000 000 - 1 year)
(8) Install the 10 units at existing oil battery facilities, train individuals ($500 000 - 1 year)
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