Hybrid Solar-Fuel Cell Low Emissions Pneumatic Solution
Approved for funding through ERA and Sustainable Development Technology Canada’s (SDTC) joint call in 2017, Calscan Energy Ltd demonstrated a Near Zero Emissions Well Control System (NZE WCS) to eliminate methane emissions from pneumatic equipment at off-grid oil and gas well sites. By its completion in 2021, the project successfully deployed NZE WCS units at 11 field sites in Alberta and confirmed reliability of the electric linear actuator and the solution’s ability to eliminate methane emissions from pneumatic control systems.
Calscan’s NZE WCS is a solar-fuel cell pneumatic equipment solution designed to eliminate methane emissions at off-grid oil and gas well sites. The NZE WCS integrates a new electric linear actuator and related components into their solar powered “bear” control system. The hybrid power generation provides electricity using solar power and incorporates a novel solid acid fuel cell (SAFC) from SAFCell, utilizing industrial grade on-site methanol, to add reliability to remote sites without always having access to ample solar resources. This ultra-low-emissions well control system and power generation package aims to achieve a net greenhouse gas (GHG) reduction of 99% compared to traditional pneumatic devices, create cost efficiencies for drop-in solution to meet reduction targets, and effectively electrify brownfield and greenfield off-grid oil and gas well sites.
Advanced Commercialization of an Engineered-in-Alberta Solution
The project demonstrated that the electric linear actuator and related controls can successfully replace pneumatic equipment and operate with high reliability, thus advancing commercialization of these core components. Work was done to improve cold weather performance of the SAFC methanol fuel cell; however, at the time of project completion, further testing was required to ensure power supply reliability for remote off-grid applications. The project developed improvements to the design such as adding a fail-safe controller and uninterrupted power supply, which increases the system’s adoptability. Tourmaline, one of the largest leading natural gas producers in Canada, has now standardized designs to utilize Calscan’s system for its new wells. Calscan now offers three different models of electric linear actuators.
What’s next?
By early 2022, Calscan had successfully deployed over 200 electric linear actuators in the field with orders for several hundred more. Calscan signed a distribution agreement with Advent Technologies to supply the SAFCell developed methanol fuel cell in Canada. Together they continue to develop, field test, and deploy the fuel cells whilst Calscan continues to market the NZE WCS components without the fuel cell to existing and new oil and gas customers. Calscan is shifting its focus to supplying components, such as the electric linear actuators, to fabricators instead of designing and engineering complete packages for end users. This is partly because they have found a greater cost-benefit for greenfield applications than brownfield retrofits.
This continues to be a viable and compelling solution to reduce methane emissions from pneumatic devices today, with significant commercial potential.