flare recovery system
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FLARE GASRECOVERY SYSTEMS
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LIquidLIquidRIngRIng COmpressorCOmpressorStandard SystemStandard System
GASESGASES
AcidAcid GasesGases OthersOthers
H2SH2S NOXNOX CO2CO2 H2 H2 COSCOS CondensableCondensable HCHC mixturesmixtures
etc.etc.
APPLICATIONAPPLICATION..
PROCESSPROCESS RECOVERYRECOVERY
Topping FlareTopping FlareGasGas FCC Off GasFCC Off Gas VacuumVacuum Steamer Off GasSteamer Off Gas CokingCoking Flash GasFlash Gas
VisbreakingVisbreaking VOCVOC etc. etc. etc. etc.
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WHY INSTALL
A FLARE GASRECOVERY SYSTEM?
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THE ENVIRONMENTTHE ENVIRONMENT
Removal of three types of pollution:
Atmospheric (smoke, SO2, NOx, etc.)
Light
Noise
NB: In many parts of the world continuous flaring is not permitted.
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THE ECONOMIC ARGUMENTTHE ECONOMIC ARGUMENT
Consider a typical plant with continuous flaring of 1 ton/h:
Value of flared gas: 8000 x 1 x $150 = US$ 1,200,000 per year
First Year Operational Costs (Electricity & Water): = US$ 150,000 (approx)
Total installed cost of flare gas recovery system: = US$ 700,000 (approx)
Payback achieved in 8.5 months!
Subsequent yearly operational savings = US$ 1.050,000!
For larger systems the payback is shortened!
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TYPICAL FLARE GAS
RECOVERY SYSTEM& COMPONENTS
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FGRS COMPONENTSFGRS COMPONENTS
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TYPICALTYPICAL FLARE GASFLARE GASRECOVERY SYSTEMRECOVERY SYSTEM
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THECOMPRESSOR
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TYPES OF COMPRESSORTYPES OF COMPRESSORGenerally three types of compressor have been used for flare
gas recovery systems:
Reciprocating, screw and liquid ring
Reciprocating and screw type compressors are more efficient
but they are also more expensive, require more maintenance
and downtime, result in compressed gases being at high
temperature and are not tolerant to condensates being present
in the gas.
For flare gas recovery liquid ring compressors have many
advantages.
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ADVANTAGESADVANTAGESOFOF
LIQUID RING COMPRESSORSLIQUID RING COMPRESSORS
Liquid ring compressors are generally the best to use for flare
gas recovery systems for the following reasons:
Able to handle gases containing condensates
Able to handle gases containing particulates
Able to handle wet gases
Able to handle toxic, flammable and corrosive gases
Works without lubricants
Gas temperature rise is low - 10OC
Because of liquid ring, compressors are inherently safe
System tolerates sudden gas and condensate surges
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DESIGN BASISDESIGN BASIS
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TYPICAL LIQUID RING VACUUM PUMPTYPICAL LIQUID RING VACUUM PUMP
Radial Forces
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THE GARO DESIGNTHE GARO DESIGN
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THE GARO DESIGNTHE GARO DESIGN
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GARO is the preferred supplier of liquid ring compressors due to many
technical advantages.
Double lobe casing to balance radial pressures acting on overhung
impeller with a single mechanical seal.
Noise is dictated by the electric motor
Reduced vibration levels give bearingsa longer life
Potential leakage point with
atmosphere reduced to one mechanicalseal
The mechanical seal is the onlycomponent subject to wear and is easilyreplaced.
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FRONT PULL OUTFRONT PULL OUT
Fast access to compressor
internals without putting the
machine in vertical position.
Lower power consumption
DISTRIBUTION CONEDISTRIBUTION CONE
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CONE & IMPELLER ALIGNMENTCONE & IMPELLER ALIGNMENT
Easy checking of internalclearances without any need toopen the machine (two spannersand a dial gauge are all thatsrequired)
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The GARO machines are customengineered to meet process
requirements. Dimensional changes to
internal components alter the
machines operational capability.
Each size of compressor can be
adjusted to vary pressures, flow rates
and power consumption within a range.This optimizes performance in relation
to the required conditions of service.
Post supply process changes can oftenbe accommodated without the need to
replace the machine.
Casing
Impeller
Cone
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CROSS SECTIONCROSS SECTION
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TYPICAL LIQUID RING COMPRESSORTYPICAL LIQUID RING COMPRESSOR
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MAINTENANCE
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EASY MAINTENANCEEASY MAINTENANCE
OVERHUNG IMPELLEROVERHUNG IMPELLER
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EASY MAINTENANCEEASY MAINTENANCE
OVERHUNG IMPELLEROVERHUNG IMPELLER
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OVERHUNG IMPELLEROVERHUNG IMPELLER
EASY MAINTENANCEEASY MAINTENANCE
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BETWEEN BEARINGS DESIGNBETWEEN BEARINGS DESIGN
TRADITIONAL DESIGNTRADITIONAL DESIGN
Liquid ring compressor AM 850 maintenance costs
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T he table underneath show s the realm aintenance costs of a single stage G aro's co m pressor A M 850 operating
D ate C ause Shut dow n in T otal costs in U SD ,
hours incl. labor costs**
1 7 .0 8 .89 S ulphur rem o val* fro m filter 1 1 8
1 4 .0 9 .89 S ulphur rem o val* fro m filter 1 3 8
18.10.89 Sulphur rem oval* fro m filter, pipe and 1 2 3 0 0
valve upstream filter.
0 7 .1 1 .89 N ew filter installed* 4 8 * * * 4 .9 0 0
1 9 9 0 - - -
0 3 .0 6 .91 M ech. seal rings 8 1 .3 3 01 6 .1 0 .91 S et o f bearings 1 2 * * * 1 .5 4 3
0 5 .0 5 .9 2 M ech. seal gaskests 8 1 7 0
1 6 .1 1 .9 2 N ew filter cartridge 4 9 1 3
1 9 9 3 - - -
2 6 .0 1 .9 4 C o m plete m ech. seal 1 2 * * * 2 .1 4 8
0 9 .0 2 .9 5 R ing + gaskets o f m ech. seal 8 1 .4 5 0
2 1 .0 2 .9 5 R efitting due to w ro ng assem bly 4 1 9 02 0 .0 8 .9 5 S et o f bearings 1 2 * * * 1 .6 8 0
1 9 9 6 - - -
1 2 .0 2 .9 7 M ech. seal 8 3 .2 8 5
2 6 .0 5 .9 7 N ew filter cartridge 4 1 .3 6 1
1 9 9 8 - - -
T otal U SD 19.326
*In 1989 the refinery plant started refining crude oil w ith high sulphur content w hich led to frequent filters
clogging: in N ovem ber 1989 the filter w as rep laced by a self cleaning type.
**1 U S D = 1 ,071 2 E U R O
***D uring general plant shutdow n.
at a refinery p lant in S annazzaro de B urgund i, P avia -Italy- from 1989 up to 1998.
(C o st calcu latio n m eth o d : fro m 17.08.89 u n til 31.12.98 = 112 m o n th s. 19.326/ 112 x12= 2.070 U S D p er y ear.)
U S D 2.070A verage annual cost:
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FLARE SAFETY
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P1 = 0.03 bar g
1000 m3/h
0 am3/h
1 0 0 0
m
3 / h
P2= 0.02 bar g
P3 = 0.01 bar g
P T
1000 m3/h
1000 m3/h
NO BY- PASS REQUIRED
Pilots Only
NORMAL OPERATIONNORMAL OPERATION
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P1 = 0.02 bar g
800 m3/h
0 am3/h
8 0 0 m3
/h
P2= 0.016 bar g
P3 = 0.01 bar g
P T
1000
m3/h
800 m3/h
BY- PASS OPEN
Pilots Only
200 m3/h
REDUCED GAS FLOWREDUCED GAS FLOW
NO GAS FLOWNO GAS FLOW
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P1 = 0,01 bar g
No gas = 0 m3/h
0 am3/h
0 m3 /h
P2= 0,01 bar g
P3 = 0,01 bar g
P T
1000 m3/h
0 m3/h
100% BY- PASS OPEN
Pilots Only
1000 m3/h
PSL
Shut-down of compressor
NO GAS FLOWNO GAS FLOW
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CAPACITIES
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Vol. capacity ^ P 5 ^ P 7 Mod. Flow power cons.
in Tonnes / h bar abs bar abs Garo in m 3/h in kW
Approx. operating conditions
0,4 - 0,8 x AM 400 400 - 800 88
x AB 600 " 107 1200 - 1800 RPM 71 k W - 143 k W Inle t Pr es s. 1 bar abs
0,8 - 1,1 x AM 800 800 - 1100 140 Inlet Tem p. 20 -40 Cx AB 850 " 170 1300 - 1600 RPM 143 kW - 197 kW
Cooling water 30 - 35 C
1,1 - 1,4 x AM 1100 1100 - 1400 185
x AB 1100 " 280 1100 - 1400 RPM 197 kW - 251 kW Frequency 50 Hz
1,4 - 2,0 x AM 1500 1400 - 2000 251 Mol. Weight 15-45 Kg/kmol.
x AB 1500 " 305 900 - 1200 RPM 251 kW - 359 kW
2,5 - 3,0 x AM 2500 2500 - 3200 444
x C 250-6,3 X/SP " 538 800 - 980 RPM 420 kW - 568 kW
*** 4,0 - 5,0 AM/AB 5000 4000-7500 660 - 1200 RPM 430 - 620 Kw *** Double support compressor
System Single or duoble stage Garo compressor ( mech.seals, flushing system, couplings, baseframe )
Garo basic scope of supply as per enclosed annexe 1
Execution: All parts in carbon steel.
Compressor in 316 and other parts in carbon steel ( for H2S )
Other materials required ( S.S., Duplex etc. )
NOTES 1) Garo AB 600-850-1500 can reach 14 bar abs
2) Different eccentricity of the impeller and cone can change performances for each GARO COMPRESSOR TYPE
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AM=Single Stage AB=Double stage
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PLOT SIZE
PLOT SIZE
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PLOT SIZEPLOT SIZE
TWO COMPRESSOR SYSTEMTWO COMPRESSOR SYSTEM G AG A
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TWO COMPRESSOR SYSTEMTWO COMPRESSOR SYSTEMG.A.G.A.
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REFERENCESFLARE GAS RECOVERY
REFERENCE LIST FOR FLARE GAS &REFERENCE LIST FOR FLARE GAS &
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REFERENCE LIST FOR FLARE GAS &REFERENCE LIST FOR FLARE GAS &
HYDROCARBONS RECOVERYHYDROCARBONS RECOVERY SYSTEMSSYSTEMS
1986/1992 AGIP PETROLI, SANNAZZARO DE BURGONDI REFINERY (PV) - ITALYThree liquid ring compressors type AM 850 each handling 850 m^3/h of flare gas from 1 to 4 bar abs
1996 ISAB PRIOLO, COOGENERATION PLANT ERG PETROLI, PRIOLO (SR) - ITALYOne liquid ring compressor type AB 1500 handling 1400 m^3/h of flare gas from 1 to 7 bar abs
1997 AGIP PETROLI, GELA REFINERY (CL) - ITALYFour liquid ring compressors type AB 2500 (former C250-X/SP) each handling 2700 m^3/h of flare gas
from 1 to 6,5 bar abs
1997 AGIP PETROLI, TARANTO REFINERY - ITALYOne liquid ring compressor type AM 2500 handling 2700 m^3/h of flare gas from 1 to 3,8 bar abs
1997 SARAS, SARROCH REFINERY (CA) - ITALYTwo liquid ring compressors type AB 850 each handling 900 m^3/h of flare gas from 1 to 7 bar abs
1998 ITALIA ENERGIA E SERVIZI (I.E.S.), MANTOVA REFINERY - ITALYOne liquid ring compressor type AB 850 handling 900 m^3/h of flare gas from 1 to 7 bar abs
1999 ERG PETROLI, PRIOLO GARGALLO REFINERY, PRIOLO (SR) - ITALYOne liquid ring compressor type AM 1500 handling 1600 m^3/h of flare gas from 1 to 4 bar abs
2000 SHELL, DOCK SUD, AVELLANEDA - ARGENTINATwo liquid ring compressors type AB 850 IX each handling 600 m^3/h of flare gas from 1 to 8 bar abs
2000 SNP PETROM BRANCH PETROBRAZI BRAZI PRAHOVA ROMANIA
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2000 SNP PETROM BRANCH PETROBRAZI, BRAZI PRAHOVA - ROMANIAOne liquid ring compressor type AM 2500 handling 2800 m^3/h of flare gas from 1,05 to 4,05 bar abs
2001 LION OIL, EL DORADO, ARKANSAS - U.S.A.Seven liquid ring compressors type AB 1100 each handling 1200 m^3/h of flare gas from 1,05 to 7,5 bar abs
2001 ADCO, SAHIL - UNITED ARAB EMIRATESOne liquid ring compressor type AB 850 IX handling 450 m^3/h of flare gas from 1 to 6,5 bar abs
2001 REPSOL YPF, ESCOMBRERAS, CARTAGENA - SPAIN
One liquid ring compressor type AB 850 handling 950 m^3/h of flare gas from 1,05 to 7,5 bar abs
2001 CONOCO REEFINERY, PONCA CITY, OKLAHOMA U.S.A.Three liquid ring compressor type AB 1500 handling 1820 m^3/h of flare gas from 1,08 to 6,85 bar abs
2001 R.A.M. RAFFINERIA DI MILAZZO (ME) - ITALYOne liquid ring compressor type AB 2500 (former C250-X/SP) handling 2300 m^3/h of flare gas from
1 to 7,85 bar abs
2001 REPSOL YPF PETRONOR, REF. DE SOMORROSTRO, BILBAO SPAINOne liquid ring compressor type AB 850 handling 900 m^3/h of flare gas from 1 to 8 bar abs
2001 STATOIL, MONGSTAD REFINERY - NORWAYTwo liquid ring compressors type AB 2500 (former C250-X/SP) each handling 2600 m^3/h of flare gas
from 1 to 5 bar abs
2001 BP OIL, CASTELLON - SPAINOne liquid ring compressor type AB 1500 handling 1450 m^3/h of flare gas from 1 to 7, 5 bar abs(from different flare)
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2002 SHELL OIL CO. PORT ARTHUR, TX - U.S.A.Four liquid ring compressors type AB 1500 each handling 1500 m^3/h of flare gas from 1 to 8 bar abs
2002 SHELL OIL CO. NORCO, LA - U.S.A.Three liquid ring compressors type AB 1500 each handling 1500 m^3/h of flare gas from 1 to 8 bar abs
2002 SHELL OIL CO. CONVENT, LA - U.S.A.
Four liquid ring compressors type AB 1500 each handling 1500 m^3/h of flare gas from 1 to 8 bar abs
2002 SHELL OIL CO. DEER PARK, TX - U.S.A.Five liquid ring compressors type AB 1500 each handling 1500 m^3/h of flare gas from 1 to 8 bar abs
2002 CARMEL OLEFINS - ISRAELTwo liquid ring compressorstype AB 600 each handling 570 m^3/h of flare gas from 1,1 to 9 bar abs
2002 AGIP ECUADOR EPSS VILLANOTwo liquid ring compressors type AB 600 each handling 720 m^3/h of flare gas from 1,2 to 6,5 bar abs
2002 RELIANCE INDUSTRIES LIMITES INDIAOne liquid ring compressor type AB 1500 handling 3600 m^3/h of flare gas from 1,1 to 8 bar abs
2003 REPSOL YPF PETROLEO RAFFINERIA DE PUERTOLLANO SPAINTwo compression systems each with four liquid ring compressors type AB 1500 each handling 1650 m^3/h
of flare gas from 0,95 to 7 bar abs
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GAS WASHING
6
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1
2 3 4
5
6
1. Sour gas
2. Regenerated amine
3. Skimmed hydrocarbons4. Semi-rich amine to be sent to a medium pressure absorber or to regenerator
5. Regenerated amine to the final clean up column
6. Sweet gas to fuel gas network
FLARE GAS RECOVERY INTEGRATEDFLARE GAS RECOVERY INTEGRATED SYSTEMSYSTEM
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EQUIPPEDEQUIPPEDWITHWITH LIQUIDLIQUIDRINGRING COMPRESSORCOMPRESSOR
Process water
M edium pressure absorber
Slop
Blow Down
Fuel gas
Am ine washing unit
SW S treatm ent
Cooling water
Am ine regeneration unit
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LIQUID RINGCOMPRESSOR
APPLICATIONS
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Main applicationsMain applications Chlorine (wet and dry)
Vinyl Chloride Monomer
Ethylene Flare and vent gases (any kind)
Carbon monoxide / dioxide
Hydrogen
Hydrogen sulphide
Nitrogen oxides
Hydrochloric acid
Ethylene dichloride
Typical Applications
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A P P LIC A T IO N G A S H A N D LE D S E R V IC E LIQ U ID
V inyl A cetate E thylene (R ecovery) A cetic A cidP V C V C M (R ecovery) W ater
P ulp & P aper W et C hlorine W ater
P ulp & P aper C O 2 (R ecovery) W ater
C hlorine D ry C hlorine S ulphuric A cid
S ugar C O 2 W ater
S ugar C H 4 W ater
H 2O 2 H 2 (R ecovery) S olvent (U hde)
H 2O 2 H 2 (R ecovery) W ater
E D C D ry C hlorine S ulphuric A cid
E D C E D C (R ecovery) E D C
E D C V ent G ases (C O 2) C entrifugal
T iO 2 D ry C hlorine S ulphuric A cid
V C M V ent G ases (C 2H 4) E D C
A dipic A cid N O x N itric A cid & w ater
F ertiliser N O x N itric A cid & w ater
C aprolactam N O x N itric A cid & w ater
E xplosives N O x N itric A cid & w ater
N 2 N O x N itric A cid & w ater
H C l H C l S ulphuric A cid
N uclear P ow er H 2S W ater
O lefins B F 3 (B oron F luoride) X ylols
P olyolefins O lefins W ater
E nergy R ecovery (R e finery) B low D ow n G ases W ater/G asoline
D esalination C O 2 W ater
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REFERENCESGENERAL APPLICATIONS
GENERAL REFERENCE LISTGENERAL REFERENCE LIST
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GENERAL REFERENCE LISTGENERAL REFERENCE LIST
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GENERAL REFERENCE LISTGENERAL REFERENCE LIST
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GENERAL REFERENCE LISTGENERAL REFERENCE LIST
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GENERAL REFERENCE LISTGENERAL REFERENCE LIST
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GENERAL REFERENCE LISTGENERAL REFERENCE LIST
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