Vapour Control Solutions for Product Transfer operation ... · PDF fileVapour Control Solutions for Product Transfer operation: An Overview by ... VAPOUR RECOVERY SYSTEM ... (unit

© 2011 by John Zink Company

CLEAN COMBUSTION. CLEAR SOLUTIONS.™ CLEAN COMBUSTION. CLEAR SOLUTIONS.™

Vapour Control Solutions for Product Transfer operation:

An Overview by

Marco Puglisi Manager Process and Product Development



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 is a registered trademark of John Zink Company, LLC in the United States and various other foreign countries worldwide. ADCON and ADAB are trademarks of John Zink Company, LLC.

___________________ are patented in the U.S. and various other foreign countries.



PETROLEUM PRODUCTION, REFINING AND DISTRIBUTION SYSTEMS (Sources of organic evaporative emissions are indicated by vertical arrows.)

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Crude Storage Tanks

Crude Tanks

Terminal Tanks

Bulk Plant Tanks

Commercial Storage Tanks

Product Tanks

Service Stations



VAPOUR CONTROL FOR DISTRIBUTION FACILITIES

Applications:

Storage Tank Vents Truck Loading Railcar Loading Ship and Barge Loading

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VOC AND REASONS FOR VAPOUR CONTROL

Air + volatile liquids during transfer operation generate Volatile Organic Compounds (VOC)

Volatile Organic Compounds (VOC’s) are involved in an atmospheric photo-chemical reaction.

VOC’s form Ozone, i.e a primary constituent of smog. Ozone can have adverse effects on human health

Legislation driven.

Company Image, PR.

Positive Return on Investment (recovery)



TYPICAL COMPOSITION OF GASOLINE VAPOURS VOL% WT%

AIR 58.1 37.6

PROPANE 0.6 0.6

I-BUTANE 2.9 3.8

BUTENE 3.2 4.0

n-BUTANE 17.4 22.5

I-PENTANE 7.7 12.4

PENTENE 5.1 8.0

n-PENTANE 2.0 3.1

HEXANE+ 3.0 8.0

100.0 100.0



VAPOR COLLECTION METHODS



Fill Pipe Vapor Emissions

Vapors

Product

CARGO TANK

SPLASH LOADING METHOD



Fill Pipe Vapor Emissions

Vapors

Product

Cargo Tank

SUBMERGED FILL PIPE



Fill Pipe

Vapor Vent to Recovery or Atmosphere

Vapors

Product Cargo Tank

BOTTOM LOADING



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VRU - CURRENT EMISSION SPEC IN THE EMEA REGION

The European directive 94/63/EC estabilishes the max. concentration of VOC emitted from petrol loading activities (in a land based depot) as 35 grams per normal cubic meter in air excluding methane -> Vapour Control system is required

Some countries within the EU have adopted more stringent emission specifications, like:

-> 10 g/Nm^3 emitted ex. CH4 (Italy, Spain, etc.) -> 150 mg/Nm^3 emitted ex. CH4 (German TA Luft I, NeR-2004) -> 50 mg/Nm^3 emitted including CH4 (German TA Luft II)



WHAT TECHNOLOGY TO USE ?

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VAPOUR RECOVERY

VAPOUR COMBUSTION

Recognized Technologies



TYPES OF VAPOUR RECOVERY

Compression Absorption

Lean Oil Absorption

Refrigeration (Condensation)

Membrane

Carbon Adsorption/Absorption (ADABTM) (BDT : BEST DEMONSTRATED TECHNOLOGY)

(MACT : MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY)



INLET VAPOR

VAPOR HOLDING

TANK

COMPRESSOR ABSORBER

LEAN ABSORBENT

RICH GASOLINE ABSORBENT

AIR VENT

PUMP

DEAREATOR

PUMP

SATURATOR 250 PSIG

2 PSIG

COMPRESSION-ABSORPTION VAPOUR RECOVERY SYSTEM



INLET VAPOR

VAPOR HOLDING

TANK

COMPRESSOR ABSORBER

LEAN ABSORBENT RICH GASOLINE ABSORBENT PUMP

DEAREATOR

PUMP

SATURATOR

MECHANICAL REFRIGERATED

COOLER

2 PSIG

250 PSIG

35°F

AIR VENT

COMPRESSION-CHILLED ABSORPTION VAPOUR RECOVERY SYSTEM



COMPRESSION-ABSORPTION VAPOUR RECOVERY SYSTEM Advantages:

Simplicity of design

Disadvantages:

Does not meet current emission standards

High pressure operation

Requires compression of flammable vapors

Vapor holder and saturator required

Deareator required

Measurement of recovered product is difficult



PUMP

INLET VAPOR

ABSORBER

VENT AIR

RECYCLE

STRIPPER PUMP

RECOVERED PRODUCT

HEATER

PUMP

REFRIGERATED COOLER

REFRIGERATED CONDENSER

RECEIVER

RICH OIL

LEAN OIL

0 °C 7 barg

0 °C

LEAN OIL MAKEUP

HEAT EXCHANGER

ABSORPTION WITH RICH OIL REGENERATION VAPOR RECOVERY SYSTEM



ABSORPTION WITH RICH OIL REGENERATION VAPOR RECOVERY SYSTEM Advantages: Can meet most current emission standards Low pressure operation No vapor holder required Disadvantages: Very high utility costs Requires source of heat for rich oil regeneration Complex design Lean oil degradation, losses, and makeup Refrigerant losses and makeup Poor operating experience



INLET VAPOR

0 °C -70 °C -100 °C

MECHANCIAL REFRIGERATED

PRE-CONDENSER

MECHANICAL CASCADE


LIQUID NITROGEN CONDENSER

DECANTER

WATER

RECOVERED PRODUCT

PUMP

VENT AIR

CONDENSATION TYPE VAPOUR RECOVERY SYSTEM



CONDENSATION TYPE VAPOUR RECOVERY SYSTEM Advantages: Can meet most current emission standards Direct measurement of recovered product Low pressure operation, no vapor holder required Disadvantages: High capital, utility, liquid nitrogen, and maintenance costs Complex cascade type refrigeration design, requiring

special expertise and knowledge Refrigerant losses and makeup Frost formation requiring defrost cycles Disposal of contaminated water



INLET VAPOR

VACUUM PUMP

AIR VENT

PUMP

A B

RECYCLE ADSORBER ADSORBER

-20°C MECHANICAL


RECEIVER

RECOVERED PRODUCT

CARBON ADSORPTION-CONDENSATION (ADCON™) VAPOUR RECOVERY SYSTEM



CARBON ADSORPTION-CONDENSATION (ADCON™) VAPOUR RECOVERY SYSTEM Advantages: Like ADAB, can be designed to meet all known emission standards No vapor 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 Higher utility consumption Frost formation in condenser coil, defrost cycle, water disposal, etc. Refrigerant losses and makeup



INLET VAPOR

AIR VENT

COMPRESSOR

ABSORBER

PUMP

LEAN GASOLINE ABSORBENT

RICH GASOLINE

ABSORBENT

A

B

MEMBRANE Modules

PUMP VACUUM PUMP

MEMBRANE VAPOR RECOVERY SYSTEM



MEMBRANE VAPOUR RECOVERY SYSTEM

Advantages: Highest emission control efficiency, meets almost all known emission

standards Reduced Plot Plan requirement Electricity is only utility Disadvantages: Operation at higher pressure to overcome membrane delta P: Safety

issue with potential explosive vapours & regular pressure vessels inspections by 1/3rd party

Higher capital cost (unit shall be in stainless steel due to membrane sensitivity to rust)

Higher power consumption (higher operating costs) Higher maintenance cost (more rotating equipment to maintain) Measurement of recovered product requires special equipment (as

ADAB)



INLET VAPOR

VACUUM PUMP

ABSORBER

LEAN GASOLINE ABSORBENT

RICH GASOLINE ABSORBENT

AIR VENT

PUMP A B

RECYCLE

ADSORBER ADSORBER

PUMP

CARBON ADSORPTION-ABSORPTION (ADAB™) VAPOR RECOVERY SYSTEM



CARBON ADSORPTION-ABSORPTION (ADAB™) VAPOR RECOVERY SYSTEM Advantages: Worldwide acceptance as the standard for gasoline vapor recovery Many years of proven and favorable experience Highest emission control efficiency, meets almost all known

emission standards Lowest vapor recovery capital and operating costs Relatively simple to operate and maintain; no special expertise

required Near ambient pressure and temperature operation, no vapor holder,

no refrigeration Electricity is only utility Disadvantages: Measurement of recovered product requires special equipment



ACTIVATED CARBON

Important Features:

High mechanical strength

Low pressure drop

High adsorption capacities

Low rententivity (easy to regenerate)

Low reactivity



CARBON ADSORPTION/ABSORPTION (ADABTM)

Two Types of Systems:

Dry Vacuum Pump Regeneration

Liquid Ring Vacuum Pump Regeneration



ADAB™ Adsorption / Absorption Liquid Ring Vacuum Pump

Major Components: Carbon Beds MOVs Vacuum Pump Separator Absorber Circulation Pumps Seal Fluid Pump Seal Fluid Cooler

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LIQUID RING SYSTEM ADVANTAGES Proven in over 1100 systems worldwide

Tolerant of solid and liquid slugs (more indicated in crude loading operation)

Vacuum pumps available in wide capacity range

Lower capital cost for large systems



Liquid Ring Vacuum Pump





ADAB™ ADSORPTION / ABSORPTION Dry Vacuum Pump

Major Components: Carbon Beds MOVs Vacuum Pump Absorber Circulation Pumps

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DVP – OPERATING PRINCIPLE

1. Inlet 2. Exhaust 3. Water Jacket 4. Screw 5. Oil

6. Gas Path 7. Timing Gears 8. Bearings 9. Shaft Seals 10. Oil Seal



DRY SYSTEM ADVANTAGES

Reduced power consumption

Ethylene glycol seal fluid and associated components are eliminated (biofuels)

Greater flexibility to handle variety of products





System Performance 99%+ recovery efficiency

1-35 grams VOC per Nm3 vapour vented

Can be designed to meet TA Luft standard of 150 mg/Nm3

Recovered product varies with inlet hydrocarbon concentration typically 1-2 liters per 1000l loaded





VAPOUR RECOVERY SYSTEM ADVANTAGES

Can be installed in a hazardous area

No ignition source

Positive return on investment

No trade off pollutants (CO2, NOx, CO)

No supplemental fuel



Vapour Combustion Systems



TYPES OF VAPOUR COMBUSTION DEVICES

Open flame combustors

Enclosed flame combustors

Flares

Thermal Oxidizer systems



ENCLOSED VAPOUR COMBUSTOR



STANDARDS FOR SAFETY Flashback Protection:

Certified detonation arrestors

Anti-flashback burners

Reliable, stable, energy efficient pilots

Multiple burner stages for high turndowns



ADVANTAGES OF VAPOUR COMBUSTION SYSTEMS

99%+ removal efficiency

Can handle multiple products simultaneously

Effectively controls methane and ethane

Lower capital cost than VRU

Easy to install, operate, and maintain



VRU/VCU – PROCESS DESIGN PARAMETERS 1/3

Instantaneous Flow: Maximum Liquid loading rate of products into ship tankers > Pressure Drops in the piping and VRU. Loading Profile: Distribution of the loaded quantity over time –

Q15 min, Q1h, Q4h, Qday. True Vapour Pressure: It quantifies the tendency of product to

migrate to the vapour phase. This is not a standard property as crude oil quality is not standard and many crude oil types are present in the market. Crude Oil Properties and Composition: Density, Viscosity,

Molecular Weight, Pour Point, presence of wax, etc.

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Crude Oil Vapour Composition: In particular methane and ethane with very low boiling temperature (= gas at atmospheric conditions) are difficult to be recovered > typically no CH4 is required (by law) to be recovered and approx 50% of the C2H6 can be recovered. Emission Levels: average percentage of VOC recovered all

over the loading operation. Typical values are in the range of 85-95% recovery rate. Max Pressure at ship tankers: to determine whether a vapour

blower would be required, PVRV sizing, etc. Inerted/Non inerted ship tankers: having mainly an impact on

Safety requirements and ATEX classification.

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Growth Factor: while liquid product is loaded into a ship tanker, the product evaporates and such vapours add to the air volume being displaced by the loading. As a result for every m^3 of liquid loaded more than one m^3 of vapour is expected to be generated. Growth factor depends on the products vapour pressure and typically range from 10 to 25%. Temperature: the maximum temperature of the product being

loaded; the maximum temperature of the absorbent being used. H2S content in the crude oil vapours: If this concentration is

considerable, then a “sacrificial” carbon bed guard might be installed upstream the VRU inlet to avoid elemental sulphur formation / corrosion issues in equipments / bad odor through vent.

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VRU – SINGLE DRY VACUUM PUMP

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Gasoline Truck Loading – USA 440 m3/hr



VRU – THREE DRY VACUUM PUMPS

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Gasoline/Diesel Truck Loading – France 1400 m3/hr



VRU – SIX DRY VACUUM PUMPS / 4 BEDS

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Gasoline/Ethanol Ship Loading – Belgium 4000 m3/hr



MARINE VRU, UK

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



MARINE VRU – LRVP + Booster Blowers

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Naphta Ship Loading – UAE 10,000 m3/hr



MARINE VRU

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



MARINE VRU, UK

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



THANK YOU

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CLEAN COMBUSTION. CLEAR SOLUTIONS.™

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Vapour Control Solutions for Product Transfer operation ... · PDF fileVapour Control Solutions for Product Transfer operation: An Overview by ... VAPOUR RECOVERY SYSTEM ... (unit