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High Displacement, Consistent Quality Among the Results
This summer, Alamo Pressure Pumping successfully used field gas to power a fleet of Cat® Tier 4 Final Dynamic Gas Blending™ (DGB™) engines on a frac site near Midland, Texas.
Raw associated gas was gathered from an adjacent pipeline, cleaned using GTUIT mobile gas processing systems and delivered directly to the Cat 3512E DGB U.S. EPA Tier 4 Final and Tier 2 engines on site. Over the course of the eight-day demonstration, the DGB engines averaged 77% diesel displacement and reached peak displacement of 85% — delivering significant fuel savings and emission reductions compared to using diesel only or trucking in compressed natural gas (CNG) or liquified natural gas (LNG).
The results exceeded expectations for Alamo and producer CrownQuest Operating, which went into the project with little confidence of success based on past associated gas processing experiences.
“Frac operations have tried different types of gas conditioning in the past, and the issue is always achieving consistency with changing gas quality and ambient conditions,” says Brian Cebull, president and CEO of GTUIT. “There’s all kinds of variability and engines don’t like variability. But our technology is able to keep up with the dynamic fuel flow nature of a frac job, and we proved that during this demonstration.”
Cat DGB engines are dual-fuel models that “displace” diesel with compressed natural gas (CNG), liquified natural gas (LNG), pipeline gas or associated gas (also called field or flare gas). Associated gas taken directly from a flare line or gathering line is ideal, because it costs less and generates fewer emissions than CNG or LNG. Whatever type of gas is used, achieving a consistently high displacement rate is the goal for both pressure pumpers and producers — because that means less diesel is burned.
“To achieve the greatest ESG and cost benefits, it only works if you’re displacing diesel all the time,” says Jim Haider, GTUIT’s chief technology officer. “During this demonstration, we were able to hit the exact displacement levels Caterpillar specified for these engines.”
That translates into big cost savings. According to GTUIT’s calculations, direct fueling with associated gas could save more than $225,000 a month compared to diesel — even at today’s low diesel prices — and more than $170,000 a month versus CNG.
When it comes out of the ground, field gas contains all sorts of contaminants — most of which need to be removed to create usable fuel. Other processing systems rely on compression or direct refrigeration to clean the gas, but they’re sensitive to environmental conditions and can’t achieve consistent gas quality as ambient conditions change. GTUIT’s patent-pending chiller-based technology eliminates this problem.
“With compression-based membrane systems, JT [Joule-Thomson] or direct refrigeration systems, the ambient temperature directly affects the quality of the processed gas,” Haider says. “With our chiller-based system, we don’t have to worry about the outside air temperature. That was critical for this project because we hit the hottest part of summer, the first week of August in Texas.”
The innovative chiller-based system also helps ensure quality gas from the moment a frac job starts up. In a typical frac scenario, the engines come online and begin operating at high RPMs fast — meaning the demand for gas is immediate. Traditional processing systems can’t respond that quickly, but GTUIT’s solution can.
“Because our system uses chiller-based technology, not direct refrigeration, membranes or JT, we can ramp up processing right along with the ramp-up of engine RPMs,” Cebull says. “We’re able to respond and deliver quality gas right from the beginning of the job. In fact, data from this demonstration showed that the first MCF of gas we processed and sent to the engines was just as good as the last.”
Another benefit of employing GTUIT’s patent-pending mobile gas processing units to treat and use associated gas is that it’s much simpler. The typical process used to deliver a molecule of natural gas as CNG or LNG to a DGB engine involves eight steps or more. The Alamo/CrownQuest demonstration required just three. Fewer touches of the gas molecule mean significantly less CO2 production, less truck traffic and its associated emissions, and a safer overall frac site.
“You’re reducing the number of diesel trucks coming and going and eliminating the need for CNG trucks on the site,” Cebull says. “There’s less loading and unloading, less dust and less risk.”
That stood out to Alamo and CrownQuest just as much as the cost-saving and environmental benefits.
“We got a lot of kudos for how our team and our equipment were extremely safe,” Haider says. “Frac sites are complicated and busy operations, and our technology helps deliver a big economic advantage to our customers while improving the total safety environment of the site.”
For more details and results from the eight-day demonstration using Cat Tier 4 Final DGB engines and GTUIT mobile gas processing systems, take a look at this white paper. Ready to explore putting this winning combination to work on your site? Get in touch with your local Cat dealer to get started.
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