Vapour Control on Crude Oil Loading - Platts · Vapour Control on Crude Oil Loading ... Lean Oil Absorption Refrigeration (Condensation) ... Vapour Recovery System

Vapour Control

on Crude Oil

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Challenges & Technological Developments

Marco Puglisi

Manager Process and

Product Development

©2013 John Zink Company, LLC 2 CONFIDENTIAL AND PROPRIETARY

Notice

► The information contained in these materials is for informational purposes only and is provided “AS IS”, without warranties of any kind. Your use of the information contained herein is at your sole risk. We expressly disclaim any express or implied representations, warranties or guaranties, including without limitation, the implied warranties of merchantability and fitness for a particular purpose. We will have absolutely no liability (whether direct, indirect or consequential) in connection with these materials (and/or the information contained therein) including without limitation, any liability for damage to person or property. We also reserve the right the make subsequent changes to the materials without prior notice. For purposes of this notification, “We” includes John Zink Company, LLC and its affiliates and their respective employees, partners, principles, agents and representatives, and any third-party providers or sources of information or data.

► JOHN ZINK HAMWORTHY COMBUSTION is a trade name of John Zink Company, LLC. JOHN ZINK and JZ are registered trademarks of John Zink Company, LLC in the United States and various other countries. HAMWORTHY COMBUSTION is a registered trademark of Hamworthy Combustion Engineering, Inc. in the U.K. and various other countries. ADCON, ADAB, and ACE are trademarks of John Zink Company, LLC.


Petroleum Production, Refining and

Distribution Systems

Crude Storage Tanks

Crude Tanks

Terminal Tanks

Bulk Plant Tanks

Commercial Storage Tanks

Product Tanks

Service Stations

► Sources of organic eVaporative emissions are indicated by vertical arrows.


Distribution Facilities

Vapour Control Applications

►Applications:

►Storage Tank Vents

►Truck Loading

►Railcar Loading

►Ship and Barge

Loading

4


Crude Oil Transportation

Oil Transportation and Major Chokepoints ► From storage and loading operations roughly 3.2 billion cubic

meters of air/hydrocarbon Vapours (VOC) are generated per

year, equivalent to 5.2 million cubic meters of liquid crude

oil if recovered.

► In 2005 2.4 billion tons of crude oil was moved by ship,

which is roughly 62% of all crude oil produced


Example: Stabilised crude from Middle East

Composition Of Crude Oil Vapour

VOL% WT%

AIR/INERT 68.0 51.7

METHANE 0.3 0.1

ETHANE 0.3 0.2

PROPANE 7.9 8.7

I-BUTANE 2.2 3.2

n-BUTANE 10.2 14.9

I-PENTANE 2.9 5.3

n-PENTANE 4.5 8.2

HEXANE+ 3.7 7.7

100.0 100.0

1 m3 of such Vapours do contain 1.2 liters of liquid VOC !


Economic Opportunity

Environmental Concerns

What are VOCs?

► Volatile Organic Compounds (VOCs) are organic compounds that are involved in atmospheric photochemical reaction.

Why Vapour Control?

► VOCs form Ozone which is primary constituent in smog

► Ozone has adverse effects on human health and vegetation. ► Crude oil price at 120 $/bbl

► Recovery is also an attractive economic opportunity

► For every 1,000 m3 of crude oil loaded into a ship there is the potential to recover the equivalent of $700


What Technology To Use?

8

Vapour RECOVERY

Vapour COMBUSTION

Recognized Technologies


Types of Vapour Recovery

►Compression Absorption

►Lean Oil Absorption

►Refrigeration (Condensation)

►Membrane

►Carbon Adsorption/Absorption (ADAB™/ ADCON™)

►BDT : Best Demonstrated Technology

►ACE™ (Adsorption + Conversion + Energy)

► New technological development, Patent Pending


INLET

Vapour

VACUUM

PUMP

ABSORBER

LEAN GASOLINE

ABSORBENT

RICH

GASOLINE

ABSORBENT

AIR VENT

PUMP

A B

RECYCLE

ADSORBER ADSORBER

PUMP

Vapour Recovery System

Carbon Adsorption-Absorption (ADAB™)



Carbon Adsorption-Absorption (ADAB™)

Advantages:

► Worldwide acceptance as the standard for gasoline Vapour recovery

► Many years of proven and favorable experience

► Highest emission control efficiency, meets almost all known emission standards

► Lowest Vapour recovery capital and operating costs

► Relatively simple to operate and maintain; no special expertise required

► Near ambient pressure and temperature operation, no Vapour holder, no refrigeration

► Electricity is only utility

Disadvantages:

► Measurement of recovered product requires special equipment

► Does not recover the light ends (methane, ethane)


Crude Oil Ship Loading – UK 16,000 m3/hr

Marine VRU, UK


Marine VRU, UK


Crude Oil Ship Loading – Sweden 6,000 m3/hr

Marine VRU, Sweden


Marine VRU, Sweden


INLET

Vapour

VACUUM

PUMP

AIR VENT

PUMP

A B

RECYCLE ADSORBER ADSORBER

COMPRESSOR

RECEIVER

RECOVERED

PRODUCT


Carbon Adsorption-Condensation

(ADCON™)



Carbon Adsorption-Condensation

(ADCON™)

Advantages:

► Like ADAB™, can be designed to meet almost all known emission standards

► No Vapour holder required

► Only electricity required to operate

► Direct measurement of recovered product

Disadvantages (relative to ADAB™):

► Higher capital and operating costs

► More complex design requiring higher maintenance cost

► Does not recover the light ends (methane, ethane)



ACE™ (Adsorption + Conversion + Energy)

ELECTRIC

POWER

INLET

Vapour

VACUUM

PUMP

AIR VENT

PUMP

A B

RECYCLE ADSORBER ADSORBER

COMPRESSOR

RECEIVER

RECOVERED

PRODUCT

STEAM

BOILER GENERATOR

(Patent Pending)


Adsorption + Conversion + Energy (Patent Pending)

ACE™

The idea of this new technological development in Vapour Control is

born combining the synergies and experiences of John Zink and

Hamworthy Combustion

Over 30 years’ experience in

Vapour Control

► More than 1600 systems supplied

worldwide

Over 40 years’ experience in

Marine Combustion Equipment

► Nearly 60 installations in

FPSO/FSO since 1991


Process Sketch Summary

ACE™

LIQUID VOC

STORAGE TANK

WEAK GAS

(INERT GAS,

METHANE

AND SOME

ETHANE)

VENT GAS FROM OIL STORAGE TANKS

(INERT GAS AND VOC VAPOURS)

STEAM TURBINE

DRIVEN

ELECTRICAL

GENERATOR

VOC

SEPARATION

EVAPORATOR

SEA

WATER IN

FRESH

WATER OUT

VOC

LIQUIFACTION

CONCENTRATED

VOC VAPOUR LIQUID VOC

BOILER

BRINE DISPOSAL


Utility Generation System When Loading

ACE™

BOILER, STEAM

TURBINE GENERATOR,

EVAPORATOR

CUSTODY TRANSFER

SYSTEM

SINGLE POINT MOORING

BUOY (SPM 1)

FUELLING AND VAPOUR

RETURN HOSES

SUBSEA HOSESOFFSHORE PIPELINES

VAPOUR FROM SPM 1

OIL TO SPM 2

OIL TO SPM 3

VAPOUR FROM SPM 2

VAPOUR FROM SPM 3

OIL TO SPM 1

MAIN OIL TERMINAL

SEAWATER SUPPLY

SEAWATER RETURN

FRESHWATER

OUTPUT

ELECTRICITY OUTPUT

OFFSHORE LOADING

RICH

GAS IN

WEAK GAS OUT

TO BOILER CARBON

ADSORPTION

SYSTEMGAS

BLOWER

LIQUID VOC

STORAGE

TANK

LIQUID VOC TO

BOILER

BRINE DISPOSAL


Utility Generation System When Not Loading

ACE™

BOILER, STEAM

TURBINE GENERATOR,

EVAPORATOR

CUSTODY TRANSFER

SYSTEM


BUOY (SPM 1)

FUELLING AND VAPOUR

RETURN HOSES


MAIN OIL TERMINAL

SEAWATER SUPPLY

SEAWATER RETURN

FRESHWATER

OUTPUTELECTRICITY

EXPORTED

CLOSED

VALVE

CARBON

ADSORPTION

SYSTEMGAS

BLOWER

LIQUID VOC

STORAGE

TANK

LIQUID VOC TO

BOILER

BOILER, STEAM

TURBINE GENERATOR,

EVAPORATOR

CUSTODY TRANSFER

SYSTEM


BUOY (SPM 1)

FUELLING AND VAPOUR

RETURN HOSES


MAIN OIL TERMINAL

SEAWATER SUPPLY

SEAWATER RETURN

FRESHWATER

OUTPUTELECTRICITY

EXPORTED

CLOSED

VALVE

CARBON

ADSORPTION

SYSTEMGAS

BLOWER

LIQUID VOC

STORAGE

TANK

LIQUID VOC TO

BOILER

BRINE DISPOSAL


Marine version, FPSO/FSO

ACE™

WEAK GAS

(INERT GAS, METHANE

AND SOME ETHANE)

VOC

SEPARATION

VOC

LIQUIFACTION

CONCENTRATED

VOC VAPOUR LIQUID VOC

LIQUID VOC

STORAGE TANK

ZERO VENTING

VENT HEADER

VENT RISER -

CLOSED

OIL LOADING

BOILER

FUEL GAS

(IF AVAILABLE)

FUEL

OIL

VENT

GAS

LIQUID VOC

RETURN TO

STORAGE TANK



Adsorption + Conversion + Energy

(ACE™)

It addresses new market requirements in Vapour control for large crude oil land based export facilities and marine production facilities

(FPSO and FSO)

Advantages and WHO shall be interested:

► It effectively addresses light ends VOC emission (methane, ethane): Terminals where strict environmental regulations apply on VOC emission

► It transforms a «waste» into high value outputs (steam, electric power, sweet water): Terminals/facilities not owning the crude stored and loaded; FPSO/FSO where steam and electric power is highly valuable


Cost/Revenues Analysis

The application: Land base facility, crude oil ship loading; 20,000 m3/h 50 million tons of crude per year

Summary of the ACE VRU cost:

► Estimated Installed power: 5500 kW

► Estimated Consumed power: 4200 kW

TOTAL EQUIPMENT COST (Ex-works): 25-30 M$

Summary of the Revenues:

► E-power production: 30 MW

► Revenues from net e-power export: ► 25,000 kW x 8,300 oper. h/year x 0,06 $/kWh = 12 M$

► 25,000 kW x 8,300 oper. h/year x 0,10 $/kWh = 20 M$

TOTAL Estimated Revenues: 12-20 M$/year


Vapour Combustion Systems


Types of Vapour Combustion Devices

► Open flame combustors

► Enclosed flame

combustors

► Flares

► Thermal Oxidizer systems


Marine VCU

How does Vapour Combustor work?

VOC Vapours pass through shutdown valves and detonation arrestors into combustion chamber with assist gas burners for flame temperature and assist air for mixing and proper combustion.


Standards for Safety

Flashback Protection:

► Certified detonation arrestors

► Anti-flashback burners

► Reliable, stable, energy efficient pilots

► Multiple burner stages for high turndowns


Advantages

Vapour Combustion Systems

►99%+ removal efficiency

►Can handle multiple products

simultaneously

►Effectively controls methane and ethane

►Lower capital cost than VRU

►Low electricity consumption

►Easy to install, operate, and maintain


Marine VCU Installed in Crude Oil Loading - 19,080 m3/hr Turkey

Marine VCU


Questions?

©2012 John Zink Company, LLC 34

Thank You

Documents

Vapour Control on Crude Oil Loading - Platts · Vapour Control on Crude Oil Loading ... Lean Oil Absorption Refrigeration (Condensation) ... Vapour Recovery System