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3/7/16 Page 1Authorization Process for Pressure Assisted MultiPoint Ground Flares
Authorization Process for Pressure Assisted MultiPoint Ground Flares
Anne Inman, P.E.Technical SpecialistOperational Support SectionAir Permits DivisionTexas Commission on Environmental Quality
3/7/16 Page 2Authorization Process for Pressure Assisted MultiPoint Ground Flares
Overview of Regulatory Authorization Process for MPGF• Federal Regulation Applicability
• AMEL Introduction and Streamline Framework
• Project Scope and Background
• Performance Demonstration
• Monitoring and Operating Conditions
• Public Notice Proposal and Final Decision by EPA
• State/Regional Parallel Authorizations
3/7/16 Page 3Authorization Process for Pressure Assisted MultiPoint Ground Flares
Federal Regulatory Applicability• 40 CFR 60, Standards of Performance for New Stationary Sources
(NSPS) – 88 Subparts A-OOOO
• 40 CFR 61, National Emission Standards for Hazardous Air Pollutants (NESHAPs) - 22 Subparts A-FF
• 40 CFR 63, National Emission Standards for Hazardous Air Pollutants Source Categories (a.k.a. Maximum Achievable Control Technology) (MACT) – 134 Subparts A - HHHHHHH
3/7/16 Page 4Authorization Process for Pressure Assisted MultiPoint Ground Flares
Federal Regulatory Applicability• NSPS, NESHAPs, MACT regulate sources and mandate emission
limitations
• Flares are a common control with design & operating specifications • 40 CFR §60.18 and 40 CFR §63.11
• Continuous Pilot
• Net Heating Value
• Flare Tip Velocity
• Smokeless
3/7/16 Page 5Authorization Process for Pressure Assisted MultiPoint Ground Flares
Pressure Assisted Multi-Point Ground Flares (MPGF)Flare systems:
• Characterized by one or more flare headers and groupings
• Operate at high pressures
• Varying stream characteristics and flows
• 99%+ Destruction Rate Effectiveness (DRE) for VOCs and HAPs
• Cannot meet flare tip velocity requirements in federal regulations §60.18(c) or §63.11(c)
3/7/16 Page 6Authorization Process for Pressure Assisted MultiPoint Ground Flares
Alternate Means of Emission LimitationsAMEL IntroductionFCAA §111(h)(3)
• Alternative Means of Emission Limitation (AMEL)
• Satisfy Administrator (EPA – not delegated)
• Achieve equivalent emission reduction
• Each regulated air pollutant and subpart
• Notice and opportunity for public hearing
• EPA Authorization
3/7/16 Page 7Authorization Process for Pressure Assisted MultiPoint Ground Flares
MPGF AMELs by EPADocket EPA-HQ-OAR-2014-0738• Proposal Dow and Exxon – 2/13/2015 FR pgs 8023-30
• Approval Dow and Exxon, Proposal OCC – 8/31/2015 FR pgs 52426-35
• Streamline Framework Proposal – 8/31/2015 FR pgs 52435-36
• Pending Actions at EPA: OCC (1), CPCHEM (2), R&H (2)
3/7/16 Page 8Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMELs Streamline Framework• Submit AMEL request to EPA
• Copy corresponding state/tribal/local permitting programs and agencies
• Each request stands-alone (documentation)
• Must have all needed information to satisfy EPA Administrator
3/7/16 Page 9Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL Project Scope and Background• Identify site, company, permits, reference IDs
• Describe processes and operational conditions which generate emissions
• Details of typical and worst-case waste gas compositions, flows, profiles
• Anticipated start of construction and operation
3/7/16 Page 10Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL Project Scope and Background• MPGF utilization (routine operations, planned MSS, upsets, etc.)
• Applicable NSPS, NESHAPs, MACT standards
• Authority to request AMEL (FCAA plus subparts)
3/7/16 Page 11Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF• Identify burner manufacturer, design, specifications (type,
geometry, size)
• Describe operational scenarios (low pressure, high pressure)
• Details on capacity, rows/stages, burners, pilots per stage, staging curve
• Include any unique design or operational details
3/7/16 Page 12Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance • Must achieve equivalent control (DRE)
• Most stringent applicable standard• VOC
• HAPs
• Individual constituents
• Demonstration options• Test
• Engineering assessment
3/7/16 Page 13Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance Demonstration Testing• Test
• PFTIR and Extractive
• Specific manufacturer and design
• Representative fuel/waste gas OR Worst-case substitute
• Minimum 3 runs
• Report
3/7/16 Page 14Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance DemonstrationTest Report Contents• Test description
• Protocols and methodologies
• Quality assurance/quality control
• Raw field and laboratory data
• Summary report sheets
• Calibration standards and curves
• Date, time, duration
3/7/16 Page 15Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance DemonstrationTest Report Contents• Fuel/waste gas composition and justification
• Highest operating pressure/sonic velocity conditions
• Visible emissions observation forms
• Calculate average DRE and combustion efficiency
• Flowrates and velocity of gas
• Calculate NHVcz and/or LFLcz of gas
3/7/16 Page 16Authorization Process for Pressure Assisted MultiPoint Ground Flares
Gas Net Heating Value in Combustion Zone (NHVcz)
𝑁𝐻𝑉%& = (𝑥*𝑁𝐻𝑉*
+
*,-
• Based on compositional analysis data
• NHVcz = Net heating value of flare vent gas (Btu/scf).
• i = Individual component in flare vent gas & n = Number of components in vent gas
• xi = Concentration of component i in flare vent gas, volume percent.
• NHVi = Net heating value of component i
3/7/16 Page 17Authorization Process for Pressure Assisted MultiPoint Ground Flares
Gas Lower Flammability Limitin Combustion Zone (LFLcz)
𝐿𝐹𝐿01 =1
∑ 𝜒*𝐿𝐹𝐿*
+*,-
• Based on compositional analysis data
• LFLcz = Lower flammability limit of flare vent gas, volume fraction
• i = Individual component in flare vent gas & n = Number of components in vent gas
• xi = Concentration of component i in flare vent gas, volume percent.
• LFLi = Lower flammability limit of component i
3/7/16 Page 18Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance DemonstrationTest Report Contents• MPGF burner tip pressure
• Waste gas temperature
• Meteorological conditions
• Observed flameouts
• Results analysis and summary
3/7/16 Page 19Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance DemonstrationEngineering Assessment• Demonstrate effectiveness by prior testing
• Similar equivalent burner
• Representative fuel/waste gas OR worst-case substitute
• Address all other factors
• Include supporting documentation/prior tests
• Persuasive conclusions
3/7/16 Page 20Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance DemonstrationEngineering Assessment
Equivalent burner destruction/combustion effectiveness • Design principles of burner type
• Burner size
• Burner geometry
• Air-fuel mixing
• Combustion principles to assure smokeless operation
• Spectrum and variety of operating conditions
3/7/16 Page 21Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance DemonstrationStability Testing
Key Importance – Lit, Stable Flame and Smokeless
Conduct long-term stability test• Spectrum and range of operating conditions
• Representative or worst-case waste gas stream
• Smokeless operation
• Stable flame to flameout point
3/7/16 Page 22Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance DemonstrationStability Testing• Design and complete test
• Purpose to determine point of flame instability and flameout
• Stable minimum 5 minutes• Highest operating pressure/sonic flow conditions
• Most challenging composition
• Document all relevant conditions and parameters
3/7/16 Page 23Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance DemonstrationStability Testing• Replicate results
• Minimum and maximum operating conditions• At least 15 minutes at each condition
• At least 3 test runs
• At or above NHVcz or below LFLcz• Highest operating pressure/sonic flow conditions
• Most challenging composition
• Document and report all relevant conditions and parameters
3/7/16 Page 24Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance DemonstrationCross Lighting• Design and complete test
• Purpose to show all stages will light under range of conditions• Vary operating pressure / velocity
• Appropriate design and installation spacing and pilot locations
• Boundaries• At least 3 test runs at each condition
• NHVcz or LFLcz
• Minimum of 3 burners must light in each stage
3/7/16 Page 25Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance DemonstrationCross Lighting• Report Contents
• Description of the testing
• Protocol of test methodology
• Test method QA/QC parameters
• Time, length, and duration of the test
3/7/16 Page 26Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance DemonstrationCross Lighting• Report continued…..
• Waste gas composition
• Waste gas temperature
• NHVcz and/or LFLcz of the gas tested
• Velocity (or Mach speed ratio) of the waste gas tested
3/7/16 Page 27Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance DemonstrationCross Lighting• Report continued…..
• Burner tip pressure
• Whether successful cross-light was observed over all of the burners
• Length of time it took for the burners to cross-light
• Maintaining a stable flame after a successful cross-light
• Duration of stable flame observed
3/7/16 Page 28Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Performance DemonstrationOther Reduction Considerations• Alternatives to flaring or flare reduction measures
• Evaluate flare gas recovery
• Justify MPGF utilization
3/7/16 Page 29Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Operating Conditions• Each stage equipped with at least two (2) pilots
• No visible emissions when operating
• NHVcz ≥ 800 Btu/scf
• LFLcz ≤ 6.5 vol %
3/7/16 Page 30Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Monitoring• Install, operate, calibrate, maintain, record data, record
downtime & out of compliance periods
• At all times:• Pilot flames on each stage present (thermocouple)
3/7/16 Page 31Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Monitoring• Receiving material
• Downtime for maintenance, instrument adjustments, calibrations (max 5%)
• Component concentrations in vent gas (LFLcz) or measure, calculate and record heating value of vent gas (NHVcz)
• Monitor vent gas flow rate
• Pilot flame / opacity video camera
• Pressure monitors on main header, each staging valve
3/7/16 Page 32Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL MPGF Review• EPA staff will review details of request
• Provide all documentation
• Request for Information – respond promptly to avoid delays
• Draft site-specific AMEL approval or disapproval
3/7/16 Page 33Authorization Process for Pressure Assisted MultiPoint Ground Flares
AMEL Notice and Action• Publish proposal in Federal Register
• 30-day comment and hearing request period
• EPA evaluates all comments
• Publish final AMEL in Federal Register• Approval or Disapproval
• Revisions to AMEL conditions as proposed
• Respond to comments
3/7/16 Page 34Authorization Process for Pressure Assisted MultiPoint Ground Flares
State/Tribal/Regional Authorizations
• Each state/region/tribe/local government has different requirements
• Actions possible• Amend or Revise New Source Review Permits
• Administrative Revision to Federal Operating Permits
• Alternate Method of Compliance or Control (AMOC) Requests
• Public notice and comment/hearing opportunities
• Plans may parallel or be different than EPA AMEL
• May process simultaneously or consecutively
3/7/16 Page 35Authorization Process for Pressure Assisted MultiPoint Ground Flares
Anne Inman, P.E.Air Permits Division, TCEQ
Mail Code 163P.O. Box 13087
Austin, TX 78711