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At least 109 records · Page 6

NETL Well Integrity Workshop: Identifying Well Integrity Research Needs for Subsurface Energy Infrastructure

Wells are a critical component of subsurface energy infrastructure. Ensuring the integrity of wells as engineered pathways for the safe extraction, injection, and storage of fluids in the subsurface is key to maximizing the effectiveness and resilience of that infrastructure. Addressing well integrity issues in a technically robust manner that promotes environmental sustainability and social equity is also an important focus of the United States (U.S.) Department of Energy’s (DOE) Office of Fossil Energy and Carbon Management. Industry best practices, regulatory standards, modern monitoring data acquisition and control systems, and decades of research and development have dramatically improved the performance and reliability of wells for hydrocarbon extraction and underground injection in the oil and gas industry. Yet, important innovation is required to improve and ensure well integrity performance in engineered geologic systems where operational environments (fluid composition, temperature, pressure, and/or stress conditions) and long functional life cycles of well systems present unique challenges. Additionally, work is needed to understand and manage the long-term integrity and risks associated with legacy wells—especially those located adjacent to and presenting hazards for new subsurface activity.

02 PETROLEUM↗

In-Situ Pipeline Coatings for Methane Emissions Mitigation and Quantification from Natural Gas Pipelines

Addressing the current health of the nation’s existing 3 million miles of pipeline infrastructure is key to preventing further climate change. In 2020, natural gas production exceeded 34 trillion cubic feet (Tcf). Roughly 75% of natural gas consists of methane (CH 4 ), which is up to 25 times more powerful than carbon dioxide (CO 2 ) at trapping heat within the atmosphere over a 100-year period, and studies from the Environmental Defense Fund (EDF) estimate approximately 2% of all the natural gas produced will be lost during normal operations due to unaddressed leaks. This does not even consider the risks of major disaster due to pipeline failure, or the losses and extra fuel costs incurred due to corrosion and scale deposits in under-maintained pipelines. The objective of the proposed research is to demonstrate the protection capabilities and economic benefits of Oceanit’s internal pipe surface treatment, known as DragX™. DragX™ is a chemically resistant, water-and-oil repellent nanocomposite system that can be readily applied in-situ on natural gas transmission and distribution pipelines with a minimum of surface preparation. This makes it an ideal candidate for in-place retrofitting and refurbishment of existing pipelines without the need for expensive extraction and replacement. DragX™ is also able to significantly reduce the surface roughness, and subsequently, the frictional drag forces within a pipeline, improving throughput, decreasing energy costs of pressurization and pumping, and allowing for longer pipeline operation without interruption, reducing the methane emitted during pipe isolation and venting. As part of this project, Oceanit has utilized the Department of Energy’s support to fully develop, de-risk and prove the DragX™ core technology is both economically viable and commercially desirable to pipeline operators and energy companies alike. DragX™ material properties were optimized in this effort both for ease of applicability, to provide value in certain key parameters, and was demonstrated on pilot applications exceeding 2 miles in length. Beyond the already field demonstrated applications, this innovative nanocomposite surface treatment has the potential to be the backbone for CO 2 and Hydrogen transporting pipeline infrastructure. The learnings from this project could accelerate the deployment of surface treatment technologies related to the energy transition infrastructure, thus benefitting the clean energy initiatives in the United States and all around the world.

03 NATURAL GAS↗

Implications of climate change mitigation strategies on international bioenergy trade

Most climate change mitigation scenarios rely on increased use of bioenergy to decarbonize the energy system. Here we use results from the 33rd Energy Modeling Forum study (EMF-33) to investigate projected international bioenergy trade for different integrated assessment models across several climate change mitigation scenarios. Results show that in scenarios with no climate policy, international bioenergy trade is likely to increase over time, and becomes even more important when climate targets are set. More stringent climate targets, however, do not necessarily imply greater bioenergy trade compared to weaker targets, as final energy demand may be reduced. However, the scaling up of bioenergy trade happens sooner and at a faster rate with increasing climate target stringency. Across models, for a scenario likely to achieve a 2 °C target, 10–45 EJ/year out of a total global bioenergy consumption of 72–214 EJ/year are expected to be traded across nine world regions by 2050. While this projection is greater than the present trade volumes of coal or natural gas, it remains below the present trade of crude oil. This growth in bioenergy trade largely replaces the trade in fossil fuels (especially oil) which is projected to decrease significantly over the twenty-first century. As climate change mitigation scenarios often show diversified energy systems, in which numerous world regions can act as bioenergy suppliers, the projections do not necessarily lead to energy security concerns. Nonetheless, rapid growth in the trade of bioenergy is projected in strict climate mitigation scenarios, raising questions about infrastructure, logistics, financing options, and global standards for bioenergy production and trade.

09 BIOMASS FUELS↗

Fiber-optic sensor packaging assessment and benchmarking for embedded sensing applications

Fiber optic-based sensing for non-destructive evaluation (NDE) and structural health monitoring of various infrastructure and energy assets is an increasingly important sensing scheme. Because of their immunity to electromagnetic interferences, versatility in sensing mechanisms and designs as well as capability for distributed sensing, the fiber optic sensing is of great interest for embedding within infrastructures using advanced manufacturing methods. However, the protection of fiber optic sensors during advanced manufacturing-based embedding is an important aspect for infrastructure monitoring in practice. While successful installation of fiber optic sensors has been accomplished through application of epoxy or adhesives on infrastructure surfaces, there has been only limited investigation of fiber protection packaging schemes which are compatible with in-situ repair techniques such as the metallic cold-spray. With increasing interest and importance of cold spray-based repair processes, the integration of fiber optic sensors simultaneously during the repair is equally important. In this work, we focus our efforts on investigating various types of packaging schemes for their compatibility and integrability on the surfaces of metallic structures such as oil and gas pipelines during an in-situ repair coating. First, we consider sandblasting using silica sand particles of various size for optical fibers on the surface of a metallic coupon as a useful proxy test of sensor packaging stability. Structural damage of packaging is characterized by means of optical microscopy and the optical integrity of embedded fiber optic cables is examined using optical backscatter reflectometry (OBR). In addition, initial investigation of metallic cold-spray embedded fiber optic cables under various packaging on metallic substrates is also considered with early conclusions and future directions.

Fiber-optic sensors, Sensors packaging, Metallic C↗

Findings on subtask 3.3 – applicability of automated brine chemistry determinations for treatment and recovery processes through facility automation/modularization: engineering design study

Under the Energy & Environmental Research Center’s (EERC’s) ~$\$$22 million Phase II Brine Extraction and Storage Test (BEST) Program, a multimillion-dollar brine treatment technology test bed facility was established in western North Dakota to provide a platform for evaluating developing technologies and approaches for brine treatment and volume reduction. The initial facility, and associated research effort, was funded by the U.S. Department of Energy (DOE), with in-kind contributions provided by several industry participants and the state of North Dakota. Since its opening, the Brine Technology Test Facility (BTTF) has supported performance evaluations of desalination technologies capable of treating high-salinity produced water (PW) and enabled data collection for multiple approaches of PW management and critical material recovery. As part of the decommissioning process for the original project, facility ownership and liability were transferred to Select Water, which is providing the EERC with a continuing site access option for state or federal research and/or commercial technology development. This report documents the findings from a design study conducted by the EERC and the engineering firm that was originally contracted to design and construct the facility (Advanced Engineering and Environmental Services, LLC [AE2S]) that evaluated the current status of BTTF and its systems and developed a retrofit design to increase the facility’s capabilities through automation and modularization of its PW treatment infrastructure. The proposed retrofit will provide DOE and industry with an expanded range of conditioned PW that can be produced at the facility for evaluating fit-for-purpose water treatment technologies, online instrumentation for brine chemistry determination, and systems that recover critical materials like lithium and magnesium. The current facility consists of an 9600-square-foot facility that includes a 40-foot by 65-foot Class 1, Division 2-rated demonstration area and associated control rooms and lab-ready space capable of sourcing oil and gas PW and wastewater from industrial sources or tailoring brine compositions up to 300,000 mg/L total dissolved solids (TDS) and supplying them at rates up to 25 gpm for extended-duration technology demonstrations. The colocation of the facility with Select Water’s water management facilities allows for access and unloading of more than 10,000 bbl/day of trucked water delivered to site and associated access to on-site Class I and Class II brine disposal wells and nearby hazardous waste landfills operated and/or contracted by Select Water to dispose of concentrate and/or effluents associated with the testing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Wyoming Carbon Blueprint A Roadmap for Statewide Carbon Capture and Storage

Wyoming stands at a pivotal point in defining its energy future, and the Wyoming Carbon Blueprint positions the state to lead the nation in carbon management through a coordinated buildout of carbon capture, transportation, utilization, and geologic storage. Building on Wyoming’s long history as a major producer of coal, oil, and natural gas, and supported by favorable policies, skilled labor, and robust subsurface resources, the Blueprint outlines a pathway to develop one of the world’s first open-access carbon hubs capable of capturing between 10 and 25 million tonnes of CO₂ per year within five years, and up to 45 million tonnes within a decade. In doing so, it advances the concept of “No Carbon Left Behind”: a statewide strategy that prevents stranded CO₂ by aligning capture, transport, and storage systems into a single coherent infrastructure network.

54 ENVIRONMENTAL SCIENCES↗

Monitoring pipeline integrity of underground gas storage facilities using membrane-based electrochemical sensors

Effective monitoring of internal corrosion risk is crucial to ensuring the safety and longevity of natural gas pipeline infrastructure. While electrochemical sensors are commonly used to assess corrosion rates and corrosion indicators in aqueous fluids, they are rarely used in gas pipelines as these fluids lack the ionic conductivity needed for electrochemical measurements. The inclusion of ion-conductive membranes into electrochemical sensors can extend their functionality into humidified gas streams, providing critical information about emerging corrosion events that are common during withdrawal season in pipeline systems downstream from underground storage facilities. In parallel, new protective films, like those obtained through cold spray coating, are being developed to protect oil and gas pipelines and recover losses in structural integrity due to corrosion damage. Herein, we demonstrate how membrane-based electrochemical sensors (MBES) can be used to monitor fluid corrosivity by examining their response to changes in water content for a wide range of fluid compositions. It was found that MBES readings were highly sensitive to water content changes with membrane conductivity measurements varying from 10 –6 to 10 –1 S cm -1 , and corrosion rate measurements which varied from 10 –7 to 1 mm y -1 . Electron microscopy confirmed that the self-healing characteristics of metal coating films were still active despite their inclusion into an MBES probe. In conclusion, these findings indicate that membrane-based corrosion monitoring can be expanded to monitor coated-pipeline materials and provide early detection of emerging corrosion upsets relevant to underground gas storage facilities.

Electrochemical sensor↗

Carbon Intensities of Refining Products in Petroleum Refineries with Co-Processed Biofeedstocks

Petroleum refineries increasingly seek to generate fuels with lower carbon intensities (CIs; a measure of life cycle greenhouse gas [GHG] emissions per unit of energy of fuel; well-to-wheel [WTW]) to meet growing demand. Co-processing refers to a process that adds biomass-derived feedstocks to the fossil-based feedstocks of existing petroleum refinery process units. With the use of biofeedstocks, it is expected that co-processed fuels would have lower CIs than their petroleum counterparts without requiring changes in the existing infrastructure for producing, transporting, and using fuels. To quantify the GHG emissions reduction benefits of co-processing, this study uses a linear programming model to simulate petroleum refinery conditions with and without co-processing. The co-processing cases include three biofeedstocks (soy oil, tallow, and used cooking oil or UCO) used as 10 vol.% of the feedstock to a hydrotreater or hydrocracker since these lipid-based feedstocks have favorable properties to be treated in a hydrotreater or hydrocracker. In addition, we considered pyrolysis oil used as 10 vol.% of the feedstock to a fluid catalytic cracking (FCC) unit in the modeled refinery due to its higher oxygen content compared to other lipid-based feedstocks. Life cycle analysis (LCA) using two distinct approaches—process-level energy allocation and a refinery-level marginal approach—has been conducted for each case. The LCA results using process-level allocation show that there are no noticeable changes in emissions or energy use impacts at the facility level. The life cycle GHG emission reductions of co-processing cases are mainly related to the fraction of biogenic carbon embedded in each fuel product. For example, co-processed jet fuels (a mixture of fossil and biogenic fuels) made via hydrotreating or hydrocracking have higher biogenic carbon, which results in jet fuel CI reductions of 3.9%–8.6% compared to the CI of baseline petroleum jet fuels on a WTW basis. However, analysis of co-processed pyrolysis oil in an FCC shows that a higher fraction of biofeedstocks (29%) becomes process emissions (i.e., CO and CO 2 ), mainly due to the oxygenates in pyrolysis oil, and so it generates less renewable fuel than biofeedstocks co-processed via hydrotreating or hydrocracking. Using the refinery-level marginal approach, the changes in energy use and emissions of co-processing cases compared to the petroleum-only baseline case are allocated to the changes in fuel production (assuming renewable fuels). This approach generates the life cycle GHG emission values of co-processed renewable fuels, which are comparable to the CIs of standalone biofuel production pathways. However, as this approach relies on a rough assumption that product yields and emissions from co-processing units on fossil feedstocks remain the same with and without biofeedstock inputs, co-processing cases like FCC pyrolysis oil may generate quite skewed results.

02 PETROLEUM↗

Catalytic Bio-crude Production in a Novel, Short-Contact Time Reactor

RTI has developed a catalytic fast pyrolysis (CFP) process to produce biomass-based hydrocarbon replacement fuels. From a technology perspective, this advanced biofuels process produces liquid transportation fuels that can leverage capital expenditures in the existing petroleum distribution infrastructure. From a business perspective, this technology does not face potential market limitations caused by oxygenate blend limitations for light duty vehicle applications. A promising catalyst has been developed with excellent potential for deoxygenation to produce a hydrocarbon-rich biocrude that is more suitable for upgrading with traditional hydroprocessing technology. The role of the catalyst is to control the chemistry during biomass pyrolysis to produce a biocrude in a single step that has lower oxygen content and is more thermally stable than conventional biomass fast pyrolysis oil. Catalyst properties are optimized to minimize gas and coke production and improve catalytic deoxygenation and biocrude yields. Results from this project have demonstrated that biocrudes from catalytic fast pyrolysis contain <20 wt% oxygen, with the organic fraction as low as 12% oxygen. These oxygen numbers are > 50% lower compared to traditional fast pyrolysis oils. The biocrude produced from our CFP process can be upgraded to gasoline range hydrocarbons. A very conservative approach for upgrading included a preliminary stabilization step followed by a hydroprocessing step. The oxygen content in the upgraded product was decreased by 97% (to less than 3wt %) from the oxygen content of the biocrude sample. Additionally, the acid content was reduced by 99% from the acid content of the biocrude sample. In an optimized integrated process, the CFP step and the hydroprocessing (upgrading) step need to be carefully balanced to maximize the input biomass energy that is recovered in the finished biofuels. Hydrogen utilization and carbon recovery during both catalytic biomass pyrolysis and biocrude upgrading need to be optimized to maximize energy recovery in the finished biofuel. A nominal 1 ton per day (TPD) catalytic biomass pyrolysis system was designed based on the laboratory experimental data. The system was designed to achieve the short residence times (0.5–2 sec) and high heat transfer rates required for maximum liquid biocrude yields while optimizing process integration to maintain catalyst activity by continuous regeneration. The catalytic biomass pyrolysis reactor is a continuously circulating single-loop transport reactor design that is flexible enough to allow sensitivity studies around temperature, residence time, biomass feed rate, and catalyst-to-biomass ratio (i.e., catalyst circulation rate) for process optimization. For a nominal 100 lb/hr feed rate of dry biomass, the products include ~25 lb/hr char and coke, ~20 lb/hr permanent gases, and ~55 lb/hr condensable vapors. Pyrolysis temperatures are 350–600°C, and the system is operated close to ambient pressure. Production of the catalyst developed within the project was scaled up to provide enough material (200kg) for bench-scale testing. The 1TPD bench-scale unit was fabricated, installed and commissioned with this project. Biocrude samples from wood were produced in this unit with the CFP catalyst with material balance > 90%. The intermediate biocrude yields and chemical composition compare well with previous laboratory results and a hydroprocessing strategy for upgrading the resulting biocrude was developed. The experimental results obtained within this project were used to develop a process model for a 2000 TPD commercial facility. Detailed flow sheets were developed for all major unit operations in the process and provided a basis for an economic analysis to develop capital and operating costs. Estimates of the biofuel production costs were used to develop internal rates of return for the yields and compositions measured for the current state of technology at the end of this project and for the yields anticipated for an optimized (nth plant) scenario as additional process improvements are made.

09 BIOMASS FUELS↗

Alabama Carbon Storage: Data Sharing and Engagement (Final Report)

This report is the final technical report on Alabama Carbon Storage: Data Sharing Engagement (ACS:DSE) project activities. The goals of the ACS:DSE project are to compile geologic, geophysical, infrastructure, and other relevant CCUS datasets for the study area and develop a geologic model of the study area; develop an online platform to serve data to stakeholders; engage with the public, students, and industry to educate them about CCUS and the data platform; and ensure energy and environmental justice is central to all aspects of the project. Datasets compiled and expanded include formation depths and elevations, digital geophysical well logs, reservoir properties, geologic structures, and geologic models. The geologic data were used to create a three-dimensional geologic model, structure grids, structure contour maps, and fault trace maps. In addition to downloadable datasets, links to CCUS relevant regulatory agencies (e.g., OGB, U.S. Environmental Protection Agency) and sources for infrastructure and educational information were included on the website Educational materials on CCUS for use by K-12 teachers were produced as part of the ACS:DSE project.

01 COAL, LIGNITE, AND PEAT↗

Alabama Carbon Storage: Bringing Data to the People

The Gulf Coastal Plain of Alabama has proven potential for geologic carbon storage and current interest in the area for large carbon capture and storage (CCS) projects is high. Extensive CCS relevant data exist in the records of the Geological Survey of Alabama and State Oil and Gas Board of Alabama, however, most of this data is not publicly available or is scattered in separate databases, file cabinets, and tables in publications. The “Alabama Carbon Storage: Data Sharing and Engagement” (ACS-DSE) project seeks to accelerate the responsible development of large CCS projects in the Gulf Coastal Plain of Alabama and offshore in state waters through a publicly accessible database of geologic carbon storage models and data across the region. The ACS-DSE draws on the over 150 years of geologic research and over 20 years of experience in CCS research to place relevant geologic, geophysical, and infrastructure data on a single web platform. Datasets available will include formation depths and elevations, geologic structures, reservoir properties, digital well logs (LAS files), existing penetrations, and geologic models. In addition to downloadable datasets, links to CCS related regulatory agencies and other sources of information will be included (for example, Class VI UIC permitting regulations and pipeline regulations). By making these datasets and models available in commonly used formats on a public website, the project will increase transparency in decision making and decrease the data acquisition time for industry.

01 COAL, LIGNITE, AND PEAT↗

Grid-Scale, Long-Term Energy Storage: Repurposing Hydrocarbon Reservoirs, Resources, and Infrastructure to Store CO 2 and Heat (Mid-Project Progress Report)

The purpose of this project is to create a viable business case for CO 2 capture, use, and storage (CCUS) by enabling grid-scale, long-term energy storage in mature hydrocarbon reservoirs and saline aquifers. Our CCUS approach, called the Earth Battery, is based on patents issued to Lawrence Livermore National Laboratory on Multi-Fluid Geo-Energy and Earth Battery Systems and to the University of Minnesota and TerraCOH, Inc. on CO 2 Plume Geothermal (CPG). Excess energy can be used to compress and store CO 2 and hot brine underground in permeable formations, including: (1) saline aquifers suitable for geologic CO 2 storage (GCS) and (2) hydrocarbon reservoirs, the focus of this project featuring a pilot test in a mature oil and natural gas (NG) field. Excess energy can come in the form of excess electricity from the grid or excess NG that does not have a market. It can also come in the form of excess heat from other sources, such as from the heat of air or CO 2 compression or from a nearby base-load power plant or solar thermal energy (STE) facility, when heat is not needed to generate electricity from those sources.

15 GEOTHERMAL ENERGY↗

Evaluation of Performance Variables to Accelerate the Deployment of Sustainable Aviation Fuels at a Regional Scale

An increase in jet fuel consumption and its associated emissions across the world have led to the need for alternative technologies to produce sustainable aviation fuels (SAF). One option to produce SAFs is to utilize waste or biomass-based feedstocks that has the potential to reduce greenhouse gas emissions by 50% or more compared to conventional jet fuel. However, there is a lack of understanding of how the synergistic effects of key performance variables could hinder or help the deployment of aviation fuels on a regional scale. Here, we assess the implications of key variables-including type and quantity of waste/biomass feedstock availability near the airport, cost of SAF production, life cycle greenhouse gas (GHG) emissions, policies, and fuel/infrastructure logistics-on the deployment of SAF at Chicago's O'Hare International Airport. We consider three ASTM International-approved SAF technologies (Hydroprocessed Esters and Fatty Acids, Fischer-Tropsch, and Alcohol to Jet) that can be blended up to 50% with petroleum-based jet fuel. Results from our analysis show that woody biomass-based Fischer-Tropsch technology has the lowest fuel production costs ($2.31-$2.81/gallon gasoline equivalent) of all pathways, and it reduces life cycle GHG emissions by 86% compared to conventional jet fuel despite the higher availability of crop residues compared to either woody biomass or fats, oils, and greases. Also, infrastructure is available at O'Hare International Airport to blend SAF with Jet A fuel through three terminals directly connected to the airport via pipelines. Our sensitivity analysis shows renewable fuel incentives and feedstock price to be key performance variables affecting the production cost and deployment of SAF.

alcohol-to-jet↗

Findings from the NETL Well Integrity Workshop: Insights for multiple subsurface energy operations

Wells are a core aspect of subsurface energy infrastructure. Ensuring the resilience of that infrastructure relies on the integrity of wells as engineered pathways that safely extract, inject, and store fluids in the subsurface. To identify areas where focused research can yield new insights to improve integrity and extend the operational life of wells, the United States (US) Department of Energys (DOE) National Energy Technology Laboratory (NETL) organized and hosted a workshop on well integrity research needs in May and June of 2021. The three-day workshop consisted of six technical sessions and 18 presentations from international well integrity experts on topics of geologic storage of carbon dioxide, natural gas, and hydrogen, as well as hydrocarbon and geothermal energy production. There were over 350 registrants from more than 10 countries, 4 major oil & gas companies, 14 US states, 8 US DOE National Laboratories, US Departments of Interior, Transportation, and Energy, and regulators from eight of ten US Environmental Protection Agency (EPA) regions and US EPA headquarters. Through presentations, moderated discussions, and an attendee survey several important areas for future research were identified. In this presentation, we highlight the findings of the NETL well integrity workshop and discuss future well integrity research needs.

carbon capture utilization and storage (CCUS)↗

Onshore U.S. Carbon Pipeline Deployment: Siting, Safety, and Regulation

Carbon capture, utilization, and storage (CCUS) technology has significant potential to reduce greenhouse gas (GHG) emissions and mitigate the impact of climate change, particularly in hard to decarbonize industrial and commercial sectors. CCUS involves capturing carbon dioxide (CO 2 ) from industrial processes or power generation and utilizing it for other purposes, such as enhanced oil recovery (EOR), or storing the captured CO 2 underground. CCUS technology can reduce the environmental impact of continued fossil fuel use while smoothing the transition to a low-carbon economy. CCUS can create new economic opportunities, such as the development of new industries and job creation, and can enhance energy security by diversifying energy sources. For these reasons, enabling CCUS has become a key objective of the Biden-Harris administration’s clean energy policy and has received bipartisan support. Despite its environmental and economic potential, CCUS faces multiple barriers to widespread deployment. One of the main challenges is the high cost and technical difficulty of implementing and operating large-scale CCUS infrastructure. CCUS remains a relatively expensive way to reduce carbon emissions (e.g., compared to solar photovoltaic technology’s displacement of coal generation). Additionally, financial incentives and supportive policies like those enacted to support solar photovoltaic development, especially at the state level, are inconsistent or nonexistent, which can discourage investment in CCUS projects. There are also technical challenges associated with safe and secure underground CO 2 storage and the development of new carbon utilization technologies. Public opposition to various aspects of CCUS technologies, ranging from concerns that CCUS will extend reliance on fossil fuels to CCUS infrastructure being sited in disadvantaged communities, is a growing challenge. This paper focuses on another significant barrier to broad CCUS deployment: the need for considerable expansion of the dedicated land-based CO 2 pipeline network in the United States to meet CCUS goals and the unique regulatory challenges to its development. To reach carbon emissions targets in the United States by 2050, CCUS technology will need to be supported by tens of thousands of miles of CO 2 pipelines. Estimates range from a minimum of roughly 29,000 pipeline miles (according to a 2020 Great Plains Institute study) to 66,000 pipeline miles (as per a 2021 Princeton University–led study). As of October 2022, however, the U.S. Department of Transportation (U.S. DOT) reports fewer than 5,400 miles of U.S. pipelines carrying CO 2 . This deficit—and what it means for the prospect of moving substantially larger quantities of CO 2 from source to use or storage—threatens to stifle the development of CCUS projects and technologies identified as an important tool to meet emissions targets. The current regulatory landscape facing CO 2 pipeline development can best be described as uncertain. At the federal level, the U.S. DOT Pipeline and Hazardous Materials Safety Administration (PHMSA) oversees safety regulation of pipelines transporting hazardous materials, including CO 2 upon commencement of operation. However, PHMSA’s definition of CO 2 as “a fluid consisting of more than 90 percent CO 2 molecules compressed to a supercritical state” has not been updated since its 1991 addition to the Federal Register. Because CO 2 can be transported in a gaseous, liquid, or supercritical state (indeed, the physical state of CO 2 can fluctuate within a single pipeline due to environmental changes), doubts persist about the extent of PHMSA’s purview—and raise questions about what, if anything, states should do to address this apparent gap. PHMSA has begun a major revision of its existing rules, but the agency does not expect a first draft before 2024. Economic oversight of CO 2 pipelines is even less clear. The Federal Energy Regulatory Commission (FERC) and Surface Transportation Board (STB)—which regulate the rates of interstate oil/natural gas and non-energy pipelines, respectively—have both declined jurisdiction over interstate CO 2 pipelines. This presumably leaves economic regulation to state and/or local governments, but few if any states have the laws or resources in place to oversee just and reasonable rates. Further, the interstate nature of CO 2 pipeline development creates questions around how different states should align their rate-making decisions. Onshore U.S. Carbon Pipeline Deployment: Siting, Safety, and Regulation Currently, regulatory responsibilities regarding CO 2 pipeline siting and permitting fall to state and local governments. The variety of laws and regulations across the country, however, creates a maze of requirements for pipeline developers to navigate. To secure necessary permits, most states require pipeline companies to be “common carriers” that provide transport service to the public at uniform rates. However, the specific definition of that term varies. Some states require clear evidence that a pipeline services the public, while others automatically deem any pipeline company transporting energy products or hazardous materials to be a “common carrier”—with little consideration for accessibility to third parties. Other states have eschewed common-carrier terminology entirely, placing private and publicly accessible pipelines on equal footing. Much like the variation in common-carrier requirements, laws governing eminent domain authority to secure rights-of-way (ROW) to commence construction on a planned pipeline route differ by state. Several states have no laws or rules governing CO 2 pipelines. In addition to creating questions about whether long-standing rules for other pipelines (e.g., natural gas or petroleum products) apply to CO 2 , this policy vacuum leaves local governments as the sole authority over sections of pipe within their boundaries. With dozens of counties along a given route, the probability of inconsistent regulation of the same pipeline is significant. Even in states with CO 2 pipeline laws in place, local regulatory attempts to address rising concerns over pipeline routing and safety have triggered lawsuits by pipeline companies seeking to delimit areas of federal, state, and local government responsibility. Meanwhile, legislators across the country have introduced bills to restrict the application of eminent domain to CO 2 pipeline projects, which could threaten a key means of securing ROW that companies cannot secure through negotiation with landowners. Taken separately, any of these regulatory issues—the narrow federal definition of CO 2 , FERC’s and STB’s decisions that CO 2 pipelines are not within their jurisdiction, and the considerable variation in state and local governments’ laws regulating CO 2 pipeline technologies—are extremely difficult to resolve. Adding the required scale of CO 2 pipeline expansion and the currently identified narrow window of time in which to reach climate target goals, the task becomes even more difficult—and raises a host of urgent questions for regulators. How should CO 2 be defined in federal regulations to ensure consistent safety standards across the country? What is the potential impact radius of a CO 2 pipeline rupture, and how should that inform local emergency response? In the absence of centralized federal oversight, what should state legislatures do to increase alignment for interstate CO 2 pipeline projects? This paper intends to serve as a primer for regulators and stakeholders who seek to better understand the regulatory challenges and opportunities facing this critical infrastructure.

42 ENGINEERING↗

Advancing Development of Emissions Detection (Final Report)

This document is the final report to the U.S. Department of Energy (DOE for contract DE-FE0031873) awarded to Colorado State University (CSU). CSU and partners at Harrisburg University of Science and Technology, University of Texas Arlington, and University of Texas at Austin organized several testing rounds to provide knowledge focused on advancing the detection capabilities of emissions monitoring devices. With this funding opportunity the research group began by establishing the Advancing the Development of Emission Detection (ADED) program, with the goal focused on enhancing the accuracy, reliability, and field applicability of methane detection technologies. This effort aimed to address the critical challenges of identifying and quantifying methane emissions while enabling industry stakeholders to meet regulatory compliance and environmental sustainability goals. The program engaged with industry, government, and technology stakeholders to promote adoption and consensus on testing techniques for methane detection solutions. Methane, a potent greenhouse gas, contributes significantly to global warming, and the oil and natural gas (O&G) sector is a primary source of methane emissions. Regulatory measures such as leak detection and repair (LDAR) programs have been implemented to address emissions. However, traditional LDAR approaches, reliant on handheld and component-level measurements, are resource-intensive. To address these limitations and move with evolving regulations, advanced methane technologies are emerging. These solutions include ground-based sensors, mobile systems (e.g., drones, vehicles, and aircraft), and satellite-based platforms. They offer innovative capabilities for autonomous monitoring, larger spatial coverage, and emission quantification using methods such as tracer gas techniques and inverse modeling with Gaussian plume analysis. The ADED program began with creating protocols for methane controlled release (CR) testing these continuous monitoring (CM) and survey technologies that detect and monitor methane emissions at O&G facilities. The protocols were then implemented throughout testing of CM and survey devices at CSU’s Methane Emissions Technology Evaluation Center (METEC) facility from 2021 through 2024. As apart of the protocol, solutions that tested under the ADED program installed their solutions at METEC, documented their system under test, and provided detection reports to the METEC team for analysis. The METEC team would provide the solutions with analyzed reports of their emissions and ground truth data of the releases conducted during their testing session. Under the ADED program, CMs were also tested at O&G facilities for a six week test run of challenge release (ChR) releases. The findings from the ADED program underscore the critical role of collaborative research and innovation in tackling methane emissions, offering a pathway for the oil and gas sector to achieve significant environmental and economic benefits. Results from METEC testing saw improvement of performance and accuracy across all solutions over the extent of the ADED experiments. The results also showed a variance in CM solution performance between CRs and ChRs. That variance pushed the team to further analyze the differences between CR testing environments and field conditions. With the drive from regulations and that variance in field conditions, the ADED team began designing a new CR testing protocol and additions to the METEC testing facility. The METEC team is furthering the progress made through the ADED program with awarded funding from DE-FE0032276. This funding pushes the development of METEC’s addition with new equipment, allowing for an updated facility layout. METEC still facilitates for traditional facilities, with a legacy pad, while expanding an new design based on how O&G infrastructure has Final Report - Contract Number: DE-FE0031873 been changed over the last decade. Throughout the ADED program the team has also been working with international partners to ensure staying in the trend globally. International partners have been essential in moving the new protocol forward to implement into CR testing at the METEC facility in Spring 2025.

42 ENGINEERING↗

Feature Extraction for Pipeline Defects Inspection Based Upon Distributed Acoustic Fiber Optic Sensing Data

Fiber-optic distributed acoustic sensing (DAS) is becoming an increasingly important tool for real-time monitoring of energy and civil infrastructure structural health such as pipelines. We present a systematic theoretical study of the potential for DAS to be directly coupled with guided ultrasonic waves typically used in conventional acoustic non-destructive evaluation (NDE) methods for real-time pipeline health monitoring. We are referring to this innovative new NDE technique as ultrasonic guided wave and optical fiber sensor fusion. In the practical application of DAS coupled with guided ultrasonic waves, the structural design of (1) the specific guided waves excited, (2) the physical installation of the acoustic transducers and the fiber optic sensors, and (3) the functional performance specifications (gauge length, sensitivity, Etc.) of fiber optic DAS have an important influence on overall capabilities of the monitoring system. Meanwhile, physics-based analysis of acoustic waves is still a challenge due to the complex nature of the Lamb wave when it propagates, scatters, and disperses in the presence of structural defects. In this work, we simulate carbon steel pipes relevant for oil and gas pipeline applications with diameters of approximately 6-12” and wall thickness of 0.5” as the objects to be monitored. By establishing and implementing these capabilities, we seek to pursue an in-depth study on structural parameter optimization of DAS network, measurement range, and signal processing with an ultimate goal of increasing the sensitivity and efficacy of DAS to defect identification for various modes of corrosion expected in practice. To study the characteristics of scattered acoustic waves and performance of DAS for defect identification, we simulated the response of DAS for multiple pipe structures, defect types, and DAS sensor network configuration using finite element software Ansys, then the properties of signal response are extracted to construct defect-sensitive features. The raw data simulated, and the associated features extracted can ultimately be utilized as annotated training data to benchmark various designs for DAS applications, guided acoustic excitation sources, and learning model parameters to enhance early detection of potentially problematic defects.

Pipeline Defects Inspection, Fiber-optic sensors, ↗