37MWe Geothermal, Apas Kiri, Tawau, Sabah, Malaysia

58 Pages·2017·16.95 MB·Indonesian

by  Mark Weiss

DPG-DTEC
Tawau GE Geothermal Proposal
Apas Kiri, Sabah, Malaysia
Created: 2017.09.15 Until: 2017.10.30
Unit 3-2-608, East 3 District, Phone: + 86 28-68730102
New Century Global Center, Fax: [phone]
DPG-DTEC
No. 1700, North Section, http://dpg-dtec.com
Tianfu Ave. Chengdu, China [email protected]
DPG-DTEC
Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Apas Kiri, Sabah, Malaysia ................................................. 6
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ABOUT US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Who We Are .............................................................. 8
What We Do? ............................................................. 8
OUR TEAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GEOTHERMAL RISK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Location - Ring of Fire ...................................................... 10
Project Acquisition ......................................................... 10
Reduced Risk - Known Resource ............................................. 11
RISK MITIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FINANCIAL RISK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FINANCIAL RISK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CASE STUDY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TGE Apas Kiri Geothermal Project
Apas Kiri, Sabah, Malaysia ................................................. 14
Design / Engineering ...................................................... 15
Turnkey Construction & Commissioning ...................................... 15
SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CLIENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PORTFOLIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PROJECT DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Preliminary Work Scope .................................................... 18
Contract Acceptance and Execution .......................................... 18
Detailed Power Plant Design and Enginnering ................................ 18
Phase 1 .................................................................. 18
Phase 2 .................................................................. 18
Phase 3 .................................................................. 18
Equipment Procurement and Construction .................................... 19
Project Completion, Commissioning and Acceptance ........................... 19
Operations and Maintenance ............................................... 19
PROJECT DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Phase 4 .................................................................. 19
Phase 5 .................................................................. 19
Phase 6 .................................................................. 19
TECHNOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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AK-1D Analysis & IBHX Engineering ......................................... 20
TECHNOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TECHNOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Turboden Heat Balance ................................................... 22
Proposed Power Plant Design ............................................... 23
TECHNOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Dual Closed Loop Working Fluid Systems ..................................... 23
TECHNOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Project Cost Savings from Previous Design ................................... 24
Proposed Well Bore and IBHX Engineering ................................... 24
Water Chemistry and IBHX Coating .......................................... 24
Performance and Risk Management Insurance ................................ 24
Drilling and Logging ...................................................... 24
Months .................................................................. 25
TIMELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TERMS & CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Apas Kiri 30 MWe IBHX Generation .......................................... 27
Project ROI ............................................................... 27
BUDGET DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CONTRACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
APPENDIX A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Heat Exchanger Discussion ................................................ 29
Nomenclature ........................................................... 29
Greek Symbols ........................................................... 29
Definitions .............................................................. 29
THERMODYNAMICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Geothermal ORC Power Plant Cycle ......................................... 30
Power Plant Modeling & Simulation ........................................ 31
MODELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
WELL ENGINEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
IBHX Geothermal Well Engineering ......................................... 32
Best Practice Handbook ................................................... 32
Introduction ............................................................. 32
Temperature ............................................................ 33
BEST PRACTICES
GEOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Geology ................................................................ 34
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Geochemistry ............................................................ 34
Drilling practices ......................................................... 34
Well design ............................................................. 34
BEST PRACTICES
WELL DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Casing depths ........................................................... 35
Casing diameters ......................................................... 35
BEST PRACTICES
CASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Casing materials ......................................................... 36
Casing connections ....................................................... 36
Cementation of casings ................................................... 36
BEST PRACTICES
DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Perforated and slotted liner ................................................ 37
Drilling rig and associated equipment ....................................... 37
BEST PRACTICES
DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Drilling fluids ............................................................ 38
Well control ............................................................. 38
BEST PRACTICES
DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Running the open-hole liner ............................................... 39
APPENDIX B
AK-1D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
APPENDIX B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
AK-1D WELL REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
AK-1D - TOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
AK-1D EXECUTIVE SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
AK-1D EXECUTIVE SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
AK-1D INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
APAS KIRI RE
PPA (FIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
APAS KIRI
PPA TOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
AK PPA RECITALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
APAS KIRI PPA
SIGNATURE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
AK PPA
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ANNEXURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
APAS KIRI PPA
LOCATION MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
AK MAP AK1, AK2
WELLPADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
AK COMPLETION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
AK FEED-IN APPROVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
AK FIT APPROVAL CONDITIONS A - F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
AK FIT APPROVAL CONDITIONS G - I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
AK FIT APPROVAL CONDITIONS J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
List of Figures
Figure 1 Schematic of traditional geothermal power generation . . . . . . . . . . 6
Figure 2 Schematic of IBHX geothermal power generation . . . . . . . . . . . . . 7
Figure 3 Apas Kiri project location . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 4 AK-1D test well profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 5 Schematic of IBHX and Turboden geothermal power generation and optional
district heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 6 Schematic of IBHX delivering 315.55°C heat from geothermal source to ORC.
IBHX fluid returns to well at 179.44°C. IBHX reheats working fluid by
136.11°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 7 Turboden Heat Balance Diagram. Represents one of three units per well. 22
Figure 8 Schematic of Aon Risk Management and Risk Mitigation Process and
Flowchart. Strategy combines all contracts, insurance finance and waranties
under one point of management. . . . . . . . . . . . . . . . . . . . . . . 25
Figure 9 Schematic of ORC Mathematical Model . . . . . . . . . . . . . . . . . . . 31
Figure 10 Downhole fluid conditions - BPD . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 11 Casing strings and liner for a typical well. . . . . . . . . . . . . . . . . . . . . 35
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INTRODUCTION
Apas Kiri, Sabah, Malaysia
30MWe Geothermal Power Plant

The 30MWe Apas Kiri Project in Tawau, Sabah, Malaysia is an excellent project for the deployment of our In-Bore Heat Exchange
(IBHX) technology. The project has been under development by Tawau Green Energy (TGE) since 2011 and has already completed
many of the development tasks such as securing a twenty-one (21) year Power Purchase Agreement (PPA) with a FiT fixed at RM
0.45/kWh ($0.11/kWh), grant funds to develop access roads, development of four (4) wellpads and drilling of the first exploration
well, AK-1D.
In addition, TGE has completed extensive subsurface studies including...
• Geology
• Geophysics
• Geochemistry
• LiDAR (light detection and ranging) surveys.
The outcomes from all of these surveys were analyzed and integrated into the Apas Kiri Well Report. GeothermEx Inc, USA and
Jacobs New Zealand produced the report. The Executive Summary and Introduction are included in Appendix B. The complete report
is availble upon request. Their consensus is that seven production wells and four injection wells would be required to support the
export capacity of 30MW. It was also estimated that the overall potential of the Apas Kiri geothermal reservoir could exceed 70MW.
The investor backing TGE in this project pulled their investment in the spring of 2017. This presented an opportunity for DPG-
DTEC to propose our In-Bore Heat Exchange (IBHX) technology as an alternative. We had spoken to TGE early in the year and were
informed that we are welcome to develop a well at Apas Kiri if we bring our own finance. Now, it appears, the whole project has
become available for consideration using the IBHX. We have the opportunity to acquire the project.
There is a wide range of differences between the conventional binary technology originally proposed for Apas Kiri and our IBHX
technology. There is nothing wrong with that, per Se. Enhanced geothermal is a valid technology and the above studies and analysis
show that. However, the technology that we bring to Apas Kiri challenges this old thought and ushers in the new. Geologists
and Engineers that have reviewed the potential of the IBHX in comparison to the development of deep geothermal reservoirs
immediately see the potential.
Take, for instance the studies undertaken at Apas Kiri.
The recommendations are to drill seven production
wells and four injection wells. Our proposed technology
can achieve the same results with one well and exceed
expectations with two production wells and no, zero
injection wells. How can that be, you say? Let me
explain...
The IBHX is designed and engineered to the specific
conditions of each well. But, regardless of well
Figure 1: Schematic of traditional geothermal power generation
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INTRODUCTION
characteristics, the IBHX is a heat exchanger. It operates using a closed-loop organic working fluid. It’s only function is to extract
heat from the formation and transfer that heat to
the turbo generator’s working fluid. Similarly, in a
nuclear power plant, the only purpose of the nuclear
reactor and reactor vessel is to heat a working fluid in
a closed loop. In both these cases, the super-heated
working fluid is then pumped through a secondary
heat exchanger. In the case of the IBHX, this occurs on
the surface in the Turboden turbo generator. A small
amount of heat (~25% - ~45%) is exchanged in this
stage. The hot working fluid still retaining ~55% to
~75% of the heat is returned to the well.
Figure 2: Schematic of IBHX geothermal power generation
Following the laws of thermodynamics, the working
fluid that is returned to the well only needs to be reheated by the delta of the heat used in the secondary heat exchanger. Our
assumption (from the AK-1D well report) is the IBHX outlet temperature is 315°C and that the IBHX working fluid will enter the
Turboden heat exchanger at a temperature of 315°C. The Turboden turbo generator will use 138°C or 44% of the heat from the IBHX
to flash expand the working fluid in the turbo generator. Due to Turboden’s efficiency, the unit does not require much thermal energy.
The IBHX working fluid is then returned directly to the well via the IBHX at a temperature of 177°C. The geothermal formation
only needs to reheat the working fluid by 138°C or the delta of the energy used. The IBHX captures heat the whole length of the
heat producing formation so raising the temperature from 177°C to 315°C is very quick and efficient. This conservative use of the
available heat and subsequent “recycling” of the heat remaining in the IBHX working fluid yields 3x to 4x more thermal energy and is
the differentiating factor between the two types of system designs.
In contrast, the Enhanced Geothermal binary plant design uses the natural fluid in the well. It is passed through a heat exchanger
on the surface and a working fluid is heated just as with the IBHX. However, whether it is water, steam or brine, there are inherent
deficiencies and risks when using the natural fluid in this way...
• Heat extraction is limited to where the formation is producing
• Mineral content that is potentially harmful can build up scale within the heat exchanger, increasing O&M costs
• As scale builds up performance and efficiency decline
• Insufficient pressure and/or brine flow severely limit the amount of energy that can be produced
• Excess heat, ~60% to ~80% is injected far from the borehole and is wasted. It has to reheat as it flows back to the well
The proposal that follows delves into the additional cost savings from the elimination of injection wells and the reduction of the
number of production wells needed. But, if those wells are eventually developed, the Apas Kiri site could produce substantially more
power than was originally estimated using the conventional enhanced geothermal design. Conservatively, as much as 120MW.
We look forward to developing this vast geothermal potential for Malaysia and all of Southeast Asia. We strive to be the lowest cost
energy produced of all sources of energy.
Mark Weiss
Managing Director
DPG-DTEC
TGE Apas Kiri TGE Apas Kiri
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ABOUT US
Having a strong international team helps us
offer both efficient and cost effective geothermal
solutions customized perfectly for our clients
needs.
We are an international collaboration of individuals and
companies that provide high quality, cost effective solutions in
renewable energy project development, engineering, equipment
procurement and construction. We deliver premium renewable
energy solutions throughout the world.
We work with a wide range of valuable suppliers and
technologies in our endeavor to provide our clients with
quality, cost-effective solutions to their energy needs. We have
an experienced and dedicated team of energy professionals.
We are your best choice for a wide range of renewable energy
technology development, engineering and construction services.
We work closely with you in order to understand your business
requirements and utilize the appropriate technology to get you
the best design for your renewable energy system.
Who We Are What We Do?
Our professionals have proven industry and technical experience We focus mostly to transform our client’s energy independence
and use innovative system design and construction techniques dream to a reality by providing quality systems. We help our
along with standard methodologies to provide innovative client’s achieve their business objective on an overall aspect.
energy solutions on time and under budget. We are committed
to delivering excellent services focused on quality of work, cost
control and time management.
• Project Development / Project Management
We strive to improve the quality of our technology offerings
• Conceptual Design / Systems Engineering
and by applying this, unleash the inherent underlying potential
of our system designs. Our vision is to provide first rate, high
• Technology Specification / Technology Procurement
quality power generation solutions to our clients. Meeting these
requirements allows us to exceed our client’s expectations while
• Project Construction / Operations & Maintenance
we expand and propel our professional business growth.
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OUR TEAM
We have a clear understanding of geothermal project development requirements, and we have the
knowledge, skills and experience to successfully complete the proposed project.
Drakon Power Group LLC (DPG) is a unique renewable energy development company. Our goal is
DPG
to provide a versatile integrated project solution, specifically designed to guarantee the success
of the Owner/Investor/Client from per-construction design to O&M for the life of the power
plant. We have built strong relationships with leading renewable technology manufactures and
leverage them to provide our clients with the most cost and energy efficient renewable energy
systems in the industry.
DPG brings a flexible and nearly endless list of available services focused on our client’s project
needs. From simply providing our clients with Tier 1 rated renewable products, to design-build
engineering and construction consulting with onsite support, we deliver quality. In addition, DPG
has the relationships to provide various project financing programs and options. This allows DPG
Project Developer
to assist in bringing any size project to construction and completion.
Dongturbo Electric Company Ltd (DTEC) is an international corporation headquartered in
DTEC
Chengdu, China. With manufacturing bases in Deyang and Kunming, China, we are mainly
engaged in the manufacturing of power & electric equipment, EPCC (engineering, procurement,
construction, commissioning), and export and import business. DTEC also has branches and joint
ventures in Malaysia, Thailand, and Philippines. Our business scope covers EPC, supply equipment
and materials for thermal power including boiler, turbine, generator and their auxiliaries, BOP,
electric and C&I etc; EPC and equipment supply for PV, thermal solar power, Wind & PV hybrid
and energy storage systems; spare parts supply and power plant overhaul and maintenance.
We have established close partner relationship with design institutes, manufacturers, erection

EPCC companies, traders and end customers both in China and all over the world.
DPG and DTEC signed a Memorandum of Understanding
Collaboration
early in 2017 agreeing to cooperate on the development of
geothermal and other renewable energy projects in China
and Southeast Asia. Since our inception as partners, we have Thousands of candles
strived to bring a unique new geothermal heat extraction can be lit from a single candle,
technology to China and Southeast Asia. It is this geothermal and the life of the candle will not
technology that we propose to design and deliver in Malaysia, be shortened. Happiness never
Thailand, Sichuan Provence, Yunan Provence and Tibet, China. decreases by being shared.
We can provide both power generation and thermal heating
as well as Hybrid power and heating applications.
DPG-DTEC [email protected]
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GEOTHERMAL RISK
Location - Ring of Fire Project Acquisition
Geothermal energy as a heat source for electricity generation by the geological risk. The geological risk includes the risk of not
is a renewable energy with many advantages: It is base load finding an adequate resource (short-term risk) and the risk that
energy, it is produced local to where it is consumed and it is the resource naturally declines over time (the long-term risk).
environmentally friendly. The AK-1D exploration well completed at Apas Kiri in August,
2016 indicates a fantastic resource for our IBHX thus the initial
Apas Kiri, in the state of Sabah, Malaysia is surrounded by
short term risk for this project has already declined while the
producing geothermal power plants located in Indonesia and the
long term risk is greatly alleviated by the conservative use of the
Philippines. The Malaysian government has recognized that the
geothermal heat that the IBHX extracts.
Apas Kiri project is the first geothermal project in Malaysia. As
such, they have provided grant money to develop the roads and
well pads. They have granted access to the national park where
the resource is located and they have facilitated the approval
of a twenty-one year PPA with the state-owned power company
for the purchase of the power. The project has been developed
to the level of having the first exploration well drilled yielding
a great deal of data on the available resource. This is presented
in a comprehensive well report that has been provided. Since
much of the CAPEX and OPEX is now known, we can accurately
propose this project.
Typically, the bankability of a geothermal project is threatened
Figure 3: Apas Kiri project location
TGE Apas Kiri
DPG-DTEC
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Geo Proposal