Fracture criterion and control plan on CO2 pipelines: Theory analysis and full-bore rupture (FBR) experimental study

Pressurized pipelines are the most reliable and cost-effective option for the long-distance transportation of CO₂ from an emitter to an onshore storage site. Propagating or unstable factures are considered catastrophic pipeline failures, resulting in a massive escape of inventory within a short period of time. The decompression curve for CO₂ exhibits a large drop in decompression wave speed at the phase transition pressure, leading to a higher driving force for crack propagation. The study of fracture control plans is very important for assessing the possibility of fracture propagation and preventing unstable fracturing along CO₂ pipelines. Three full-bore rupture (FBR) experiments were performed using an industrial-scale (258 m long, 233 mm inner diameter) CO2 pipeline with initial CO2 states of gaseous, dense and supercritical phases, respectively. The relation between the decompression velocity and the pipeline fracture propagation velocity was analyzed during the process of buried CO2 pipeline release. A fracture propagation criterion was established for the buried CO₂ pipeline. For the gaseous CO₂ leakage, the pressure plateau corresponding to the decompression wave velocity only appeared near the closed end of the pipeline. For the dense CO₂ leakage, the pressure plateau corresponding to the decompression wave velocity was observed near the saturation pressure after rapid decompression. For the supercritical CO₂ leakage, the pressure plateau corresponding to the decompression wave velocity was observed in the stage when the supercritical CO₂ transformed into the two phases of gas and liquid. Compared with the gaseous and dense CO₂, for the supercritical CO_2, the initial decompression wave velocity was the smallest, and the requirement of the pipeline safety factor was the highest.     

Reducing the risk level for pipelines transporting carbon dioxide and hydrogen by means of optimal safety valves spacing

In many countries where electricity generation is based on their natural resources of fossil fuels a need arises to implement new power engineering technologies that allow carbon dioxide capture. Simultaneously, efforts are made to find new energy carriers which, if fired, do not involve carbon dioxide emissions. Hydrogen is one of such fuels with this future potential which is now becoming increasingly popular. Obviously, this means that the two gases mentioned above – carbon dioxide and hydrogen – will be produced in large quantities in future, which in many cases will necessitate their transport over considerable distances. If a pipeline failure occurs, the transport of the gases may pose a serious hazard to people in the immediate vicinity of the leakage site. This paper presents an analysis of the possibility of reducing the level of risk related to pipelines transporting CO₂ and H₂ by means of safety valves. It is shown that for a 50 km long and a 0.4 m diameter pipeline transporting gas with the pressure of 15 MPa the individual risk level can be reduced from 1·10⁻⁴ to 6.5·10⁻⁷ for CO₂ and from 1·10⁻⁶ to 6·10⁻¹⁰ for H₂. The social risk can be diminished in similar proportions.     

A risk assessment methodology for high pressure CO2 pipelines using integral consequence modelling

This paper presents a risk assessment methodology for high pressure CO₂ pipelines developed at the Health and Safety Laboratory (HSL) as part of the EU FP7 CO2Pipehaz project. Until recently, risk assessment of dense phase and supercritical CO₂ pipelines has been problematic because of the lack of suitable source term and integral consequence models that handle the complex behaviour of CO₂ appropriately. The risk assessment presented uses Phast, a commercially available source term and dispersion model that has been recently updated to handle the effects of solid CO₂. A test case pipeline was input to Phast and dispersion footprints to different levels of harm (dangerous toxic load and probit values) were obtained for a set of pipeline specific scenarios. HSL's risk assessment tool QuickRisk was then used to calculate the individual and societal risk surrounding the pipeline. Knowledge gaps that were encountered such as: harm criteria, failure rates and release scenarios were identified and are discussed.     

Release and dispersion behaviour of carbon dioxide released from a small-scale underground pipeline

The development of carbon capture and storage (CCS) brings challenges for safety issues regarding carbon dioxide (CO₂) transmission pipelines. Once a pipeline is punctured or full-bore ruptured, the leaked CO₂ is hazardous to personnel and the environment. Small-scale devices were established with the aim of studying the release and dispersion behaviour of gas and liquid CO₂ from a punctured underground pipeline. A sandbox was built to simulate the underground conditions. The parameters of the sand used in the experiments were tested. CO₂ concentrations on the ground and temperatures around the release orifice in the sand were analysed. The results indicate that in the CO₂ gas release experiments, the CO₂ concentration on the sand surface decreases with increasing horizontal distance in the form of a power function. CO₂ concentrations in upward release are slightly larger than those in horizontal release at the same location but are obviously bigger than values in downward release. The temperature-drop region is much smaller than that in air. A frozen ice ball can be generated near the release orifice during the gas phase of the CO₂-release process. In the liquid phase of CO₂-release experiments, a large amount of dry ice is generated near the release orifice. Dry ice can only be generated in the area close to the release orifice, especially in the near-field area.     

Fuzzy optimization of multi-period carbon capture and storage systems with parametric uncertainties

Carbon capture and storage (CCS) is an important technology option for reducing industrial greenhouse gas emissions. In practice, CO₂ sources are easy to characterize, while the estimation of relevant properties of storage sites, such as capacity and injection rate limit (i.e., injectivity), is subject to considerable uncertainty. Such uncertainties need to be accounted for in planning CCS deployment on a large scale for effective use of available storage sites. In particular, the uncertainty introduces technical risks that may result from overestimating the limits of given storage sites. In this work, a fuzzy mixed integer linear program (FMILP) is developed for multi-period CCS systems, accounting for the technical risk arising from uncertainties in estimates of sink parameters, while still attaining satisfactory CO₂ emissions reduction. In the model, sources are assumed to have precisely known CO₂ flow rates and operating lives, while geological sinks are characterized with imprecise fuzzy capacity and injectivity data. Three case studies are then presented to illustrate the model. Results of these examples illustrate the tradeoff inherent in planning CCS systems under parametric uncertainty.     

Risk assessment methodology for high-pressure CO2 pipelines incorporating topography

This paper presents a risk assessment methodology for high-pressure CO₂ pipelines developed at the Health and Safety Laboratory as part of the EU FP7 project CO2Pipehaz.Traditionally, consequence modelling of dense gas releases from pipelines at major hazard impact levels is performed using integral models with limited or no consideration being given to weather bias or topographical features of the surrounding terrain. Whilst dispersion modelling of CO₂ releases from pipelines using three-dimensional CFD models may provide higher levels of confidence in the predicted behaviour of the cloud, the use of such models is resource-intensive and usually impracticable. An alternative is to use more computationally efficient shallow layer or Lagrangian dispersion models that are able to account for the effects of topography whilst generating results within a reasonably short time frame.In the present work, the proposed risk assessment methodology for CO₂ pipelines is demonstrated using a shallow-layer dispersion model to generate contours from a sequence of release points along the pipeline. The simulations use realistic terrain taken from UK topographical data. Individual and societal risk levels in the vicinity of the pipeline are calculated using the Health and Safety Laboratory's risk assessment tool QuickRisk.Currently, the source term for a CO₂ release is not well understood because of its complex thermodynamic properties and its tendency to form solid particles under specific pressure and temperature conditions. This is a key knowledge gap and any subsequent dispersion modelling, particularly when including topography, may be affected by the accuracy of the source term.     

The extreme carbon dioxide outburst at the Menzengraben potash mine 7 July 1953

Carbon dioxide is an asphyxiant and an irritant gas. An extreme outburst of carbon dioxide took place 7 July 1953 in a potash mine in the former East Germany. During 25 min, a large amount of CO₂ was blown out of the mine shaft with great force. It was wind still and concentrated CO₂ accumulated in a valley leading to multiple asphyxiation casualties. Based on a review of concentration-response relationships, the location of victims, and other information, it is concluded that concentrations of 10-30% carbon dioxide may have occurred 450 m from the point of release for at least 45 min. It is concluded that 1100-3900 tonnes of CO₂ were blown out of the mine shaft, possibly with intensities around 4 tonnes/s. It is also concluded that the large majority of the gas escaped as a near-vertical high-velocity jet with only little loss of momentum due to impingement. The release was modelled using PHAST. Output from the model is inconsistent with the asphyxiation harm observed. The high-momentum release is predicted to disperse safely and never reach the ground. Carbon dioxide capture and storage (CCS) schemes will involve handling and transportation of unprecedented quantities of CO₂. Case histories to date include sudden releases of CO₂ of up to 50 tonnes only, far too small to provide a suitable empirical perspective on predicted hazard distances for CCS projects. The 1953 outburst contributes to filling this gap.     

Simulation study on near-field structure and flow characteristics of high-pressure CO2 released from the pipeline

The accidental release of high-pressure carbon dioxide (CO₂) can cause serious damages to both humans and pipeline equipment. Therefore, it is of great significance to have a deeper understanding about the release characteristics of high-pressure CO₂ for improving the safety level of Carbon Capture and Storage (CCS) technologies. Both industrial-scale and laboratory-scale studies have been carried out to predict the release behaviors. In recent years, computational fluid dynamics (CFD) simulation has become a crucial method to study the instantaneous changes and microscopic details of the fluid behaviors. In this paper, the simulation method was employed to study the near-field structure and flow characteristics of high-pressure CO₂ released from pipelines. The Peng-Robinson Equation of State (EOS) was used to compute the thermodynamic properties of high-pressure CO₂, and SST k-ω model was applied to simulate the structure and physical parameters of the under-expanded jet. In addition, the multi-phase mixture model was introduced to study the phase transition. The non-equilibrium liquid/vapor transition is modeled by introducing ‘source terms’ for mass transfer and latent heat. Compared to the experimental results, the simulation results showed good agreement. Furthermore, the influences of operating conditions, including different stagnation pressure, stagnation temperature, and nozzle size, were analyzed.     

The influence of impurities on the transportation safety of an anthropogenic CO2 pipeline

Transportation safety is a key aspect of carbon capture and storage (CCS), which is a major technology used to reduce greenhouse gas emissions. Supercritical CO₂ pipelines have been certified as an optimised choice for CO₂ transportation. The results of this study show that the Peng–Robinson (PR) equation of state is recommended for analysis of the properties of supercritical CO₂. The influence of nonpolar and polar impurities on the two-phase region and the location of the sharp discontinuity in the density are found by analysing the ternary phase equilibrium and physical parameters using the PR equation of state. A transitional area between the supercritical phase and the dense phase, where the density changes abruptly, is defined as the quasi-critical region. This study describes the functional relation between the temperature and the pressure that defines the quasi-critical line by calculating the partial derivative equations and then determines the effect of impurities on the quasi-critical region of transported CO₂. Operational recommendations for pipeline transportation of flue CO₂ are developed using a pipeline operated by Sinopec as an example, demonstrating the influence of impurities in flue CO₂ on saturation pressure for control and prevention of fractures in CO₂ pipelines.     

Evaluation of multi-phase atmospheric dispersion models for application to Carbon Capture and Storage

A dispersion model validation study is presented for atmospheric releases of dense-phase carbon dioxide (CO₂). Predictions from an integral model and two different Computational Fluid Dynamics (CFD) models are compared to data from field-scale experiments conducted by INERIS, as part of the EU-funded CO₂PipeHaz project.The experiments studied consist of a 2 m³ vessel fitted with a short pipe, from which CO₂ was discharged into the atmosphere through either a 6 mm or 25 mm diameter orifice. Comparisons are made to measured temperatures and concentrations in the multi-phase CO₂ jets.The integral dispersion model tested is DNV Phast and the two CFD models are ANSYS-CFX and a research and development version of FLACS, both of which adopt a Lagrangian particle-tracking approach to simulate the sublimating solid CO₂ particles in the jet. Source conditions for the CFD models are taken from a sophisticated near-field CFD model developed by the University of Leeds that simulates the multi-phase, compressible flow in the expansion region of the CO₂ jet, close to the orifice.Overall, the predicted concentrations from the various models are found to be in reasonable agreement with the measurements, but generally in poorer agreement than has been reported previously for similar dispersion models in other dense-phase CO₂ release experiments. The ANSYS-CFX model is shown to be sensitive to the way in which the source conditions are prescribed, while FLACS shows some sensitivity to the solid CO₂ particle size. Difficulties in interpreting the results from one of the tests, which featured some time-varying phenomena, are also discussed.The study provides useful insight into the coupling of near- and far-field dispersion models, and the strengths and weaknesses of different modelling approaches. These findings contribute to the assessment of potential hazards presented by Carbon Capture and Storage (CCS) infrastructure.     

Corrosion behavior of steels for CO2 injection

The process chain for Carbon Capture and Sequestration (CCS) includes tubing for injection of CO₂ into saline aquifers. The compressed CO₂ is likely to contain specific impurities; small concentrations of SO₂ and NO₂ in combination with oxygen and humidity are most harmful. In addition, CO₂ saturated brine is supposed to rise in the well when the injection process is interrupted. The material selection has to ensure that neither CO₂ nor brine or a combination of both will leak out of the inner tubing. In this comprehensive paper the investigated materials range from low-alloy steels and 13% Cr steels up to high-alloy materials. Electrochemical tests as well as long term exposure tests were performed in CO₂, in brine and combination of both; pressure was up to 100 bar, temperature up to 60 °C. Whereas the CO₂ stream itself can be handled using low alloy steels, combinations of CO₂ and brine require more resistant materials to control the strong tendency to pitting corrosion. The corrosion behavior of heat-treated steels depends on factors such as microstructure and carbon content. For different sections of the injection tube, appropriate materials should be used to guarantee safety and consider cost effectiveness.     

Flammability of hydrocarbon and carbon dioxide mixtures

The effect of carbon dioxide (CO₂) concentration on the ignition behaviour of hydrocarbon and CO₂ gas mixtures is examined in both jets and confined explosions. Results from explosion tests are presented using a 20 l explosion sphere and an 8 m long section of 1.04 m diameter pipeline. Experiments to assess the flame stability and ignition probability in free-jets are reported for a range of different release velocities. An empirically-based flammability factor model for free-jets is also presented and results are compared to ignition probability measurements previously reported in the literature and those resulting from the present tests.The results help to understand how CO₂ changes the severity of fires and explosions resulting from hydrocarbon releases. They also demonstrate that it is possible to ignite gas mixtures when the mean concentration is outside the flammable range. This information may be useful for risk assessments of offshore platforms involved in carbon sequestration or enhanced oil recovery, or in assessing the hazards posed by poorly-inerted hydrocarbon processing plant.     

Modelling three-phase releases of carbon dioxide from high-pressure pipelines

This paper describes the development and experimental validation of a three-phase flow model for predicting the transient outflow following the failure of pressurised CO₂ pipelines and vessels. The choked flow parameters at the rupture plane, spanning the dense-phase and saturated conditions to below the triple point, are modelled by maximisation of the mass flowrate with respect to pressure and solids mass fraction at the triple point. The pertinent solid/vapour/liquid phase equilibrium data are predicted using an extended Peng–Robinson equation of state.The proposed outflow model is successfully validated against experimental data obtained from high-pressure CO₂ releases performed as part of the FP7 CO2PipeHaz project (www.co2pipehaz.eu).The formation of solid phase CO₂ at the triple point is marked by a stabilisation in pressure as confirmed by both theory and experimental observation. For a fixed diameter hypothetical pipeline at 100 bar and 20 °C, the flow model is used to determine the impact of the pipeline length on the time taken to commence solid CO₂ discharge following its rupture.     

Thermodynamic method for the prediction of solid CO2 formation from multicomponent mixtures

The increase in GHG concentration has a direct effect on global climate conditions. Among the possible technologies to mitigate GHG emissions, CCS is being accepted to gain emission reduction. Such technology also involves cryogenic CO₂ capture processes based on CO₂ freeze-out or where the formation of solid CO₂ must be avoided. Captured CO₂ is usually transported in pipelines for the reinjection.The risk associated to the release of CO₂ is due to the changing temperatures and pressures the system may experience, which can lead to the deposition of solid CO₂ where it must be avoided. Prolonged exposure to dry ice can cause severe skin damage and its resublimation could pose a danger of hypercapnia. It is, thus, necessary to build up a tool able to predict the conditions in which CO₂ can freeze-out.A thermodynamic methodology based on cubic EoSs has been developed which is able to predict solid–liquid–vapor equilibrium of CO₂ mixtures with n-alkanes or H₂S which are usually found in equipment for acidic gas, mainly natural gas, treatment.The focus is a detailed analysis of the method performances when more than two components are present since, for such a case, literature does not provide significant modeling results.     

Inherently Safer Design for low-temperature process during depressurization: An industrial case study

The exploitation of a low-quality gas field with high CO₂ concentration is more viable through liquid CO₂ produced from cryogenic distillation technology. Despite the bright potential of the technology, there are deficiencies in handling high concentration of CO₂ at low temperature and high pressure during the blowdown condition. This study focuses on the CO₂ blowdown at a cryogenic pilot plant designed to manage high concentrations of CO₂ in the feed gas, high pressures, and low temperatures. A comprehensive design review and risk assessment using Inherent Safer Design (ISD) indexes were carried out in this study. The ISD was performed to identify the current risk level, and the critical parameters that may cause solid CO₂ formation in the piping or equipment as well as to identify mitigation measures to avoid the temperature to drop below the CO₂ freezing point during blowdown. The present findings confirmed that the initial pressure and temperature, as well as CO₂ concentration are key parameters towards significant impact on blowdown conditions. Therefore, the reduction of the feed gas pressure from 80 bar to 70 bars has minimized the Joule Thomson (JT) effect during blowdown and avoided the CO₂ solid formation in the system. Moreover, the relocation of the blowdown valve at the downstream heater resulted in a higher final temperature above the CO₂ freezing point. The ISD indexes confirmed that the cryogenic facilities are inherently safer during blowdown with the mitigation measures adopted.     

Experimental study on the minimum explosion concentration of anthracite dust: The roles of O2 mole fraction,inert gas and CH4 addition

The explosion characteristics of anthracite coal dust with/without small amount of CH₄ (1.14 vol %) were investigated by using a 20 L spherical explosion apparatus with an emphasis on the roles of oxygen mole fraction and inert gas. Two methods based on overpressure and combustion duration time were used to determine the minimum explosion concentration (MEC) or the lower explosion limit (LEL) of the pure anthracite coal dust and the hybrid coal-methane mixtures, respectively. The experiment results showed that increasing oxygen mole fraction increases the explosion risk of coal dust: with increasing oxygen mole fraction, the explosion pressure (P_ex) and the rate of explosion pressure rise ((dp/dt)_ex)) increase, while MEC decreases. The explosion risk of anthracite dust was found to be lower after replacing N₂ with CO₂, suggesting that CO₂ has a better inhibition effect on explosion mainly due to its higher specific heat. However, the addition of 1.14% CH₄ moderates the inhibition effect of CO₂ and the promotion effect of O₂ on anthracite dust explosion for some extent, increasing explosion severity and reducing the MEC of anthracite dust. For hybrid anthracite/CH₄ mixture explosions, Barknecht's curve was found to be more accurate and conservative than Chatelier's line, but neither are sufficient from the safety considerations. The experimental results provide a certain help for the explosion prevention and suppression in carbonaceous dust industries.     

Accounting for the effect of concentration fluctuations on toxic load for gaseous releases of carbon dioxide

In Great Britain, advice on land-use planning decisions in the vicinity of major hazard sites and pipelines is provided to Local Planning Authorities by the Health and Safety Executive (HSE), based on quantified risk assessments of the risks to the public in the event of an accidental release. For potential exposures to toxic substances, the hazard and risk is estimated by HSE on the basis of a “toxic load”. For carbon dioxide (CO₂), this is calculated from the time-integral of the gas concentration to the power eight. As a consequence of this highly non-linear dependence of the toxic load on the concentration, turbulent concentration fluctuations that occur naturally in jets or plumes of CO₂ may have a significant effect on the calculated hazard ranges. Most dispersion models used for QRA only provide estimates of the time- or ensemble-averaged concentrations. If only mean concentrations are used to calculate the toxic load, and the effects of concentration fluctuations are ignored, there is a danger that toxic loads and hence hazard ranges will be significantly under-estimated.This paper explores a simple and pragmatic modification to the calculation procedure for CO₂ toxic load calculations. It involves the assumption that the concentration fluctuates by a factor of two with a prescribed square-wave variation over time. To assess the validity of this methodology, two simple characteristic flows are analysed: the free jet and the dense plume (or gravity current). In the former case, an empirical model is used to show that the factor-of-two approach provides conservative estimates of the hazard range. In the latter case, a survey of the literature indicates that there is at present insufficient information to come to any definite conclusions.Recommendations are provided for future work to investigate the concentration fluctuation behaviour in dense CO₂ plumes. This includes further analysis of existing dense gas dispersion data, measurements of concentration fluctuations in ongoing large-scale CO₂ release experiments, and numerical simulations.     

Suppression of flame propagation in a long duct by inertia isolation with inert gases

Experimental studies were done with a small pipe with a diameter of 0.043 m and a large pipe with a diameter of 0.49 m to demonstrate the flame propagation suppression with inertia isolation in a long duct. Tests were carried in an ignition section containing propylene/air mixture near stoichiometric concentration and generating a peak flame propagation speed of approximately 100 m/s. The ignition section is connected to a section filled with an inert gas, another section with flammable mixtures, and finally a sufficiently long, ambient section to accommodate flame propagation. The critical length of the inert gas section required for successful suppression of flame from the igniting the flammable section is found to be 0.6 m for CO₂ and 0.9 m for N₂ in the large pipe and 0.2 m for CO₂ and 0.3 m for N₂ in the small pipe. Additional tests with a 3 m of ignition section and peak flame propagation speed of 225 m/s showed that the critical length for successful suppression by CO₂ is only increased slightly to 0.9 m, confirming that the suppression is a result of inertia isolation rather than inert gas dilution. Finally, application of the results in responding to large-scale leak into a long, underground duct is discussed.     

Economic assessment of inherently safe membrane reactor technology options integrated into IGCC power plants

Pd/alloy-based (Pd/Cu, Pd/Au) membrane reactors embedded into Integrated Gasification Combined Cycle (IGCC) plants (IGCC-MR) enable the storage and/or use of the energy value of H₂ to produce electricity while the CO₂ enriched retentate exit stream becomes particularly suitable for high pressure CO₂ capture-sequestration. There is undoubtedly a lack of operating experience associated with IGCC-MR plants, and therefore, sound process intensification principles/practices should be followed not only to enhance process system performance but also to ensure process safety and economic feasibility of an IGCC-MR plant. Motivated by the above considerations, a comprehensive process economic assessment framework for an inherently safe membrane Pd/alloy-based reactor integrated into an IGCC plant is proposed. In particular, a detailed Net Present Value (NPV) model has been developed to evaluate the economic viability of an IGCC-MR plant where the membrane reactor module design conforms to basic inherent safety principles. Sources of irreducible uncertainty (market, regulatory and technological) are explicitly recognized such as the power plant capacity factor, Pd price, membrane life time and CO₂-taxes due to future regulatory action/policies. The effect of the above uncertainty drivers on the project's/plant's value is studied through Monte Carlo methods resulting in detailed NPV-distribution and process economic outcome profiles. The simulation results derived suggest that in the presence of (operational, economic and regulatory) uncertainties, inherently safe membrane reactor technology options integrated into IGCC plants could become economically viable. In particular, comparatively more attractive NPV distribution profiles are obtained when concrete safety risk-reducing measures are taken into account through pre-investment in process safety (equipment).     

Power system planning with emission constraints: Effects of CCS retrofitting

Today, the world's energy needs are still supplied mainly from fossil fuel based resources. This is true for electricity generation as well, thus making the power sector responsible for 45% of greenhouse gas emissions. The present climate crisis has made it necessary to minimise emissions in power generation, with low-carbon energy sources taking on greater significance in recent years. However, most low-carbon sources have inherent problems, like intermittency and high capital expenditure. A suitable alternative is carbon capture and storage (CCS) technology which allows continued fossil fuel-based electricity generation at much lower rates of emission. Two approaches are possible in the deployment of CCS technology. The first is to introduce new power plants equipped for carbon dioxide (CO₂) capture, while systematically shutting down existing coal power plants. Another is to retrofit existing power plants for CO₂ capture. These approaches are compared in this work. The study shows that allowing CCS retrofitting of existing power plants can reduce the overall cost requirement significantly. In addition, a sensitivity analysis is also done to study the effect of nuclear energy on the overall energy mix.