anguil environmental systems, inc. · supplier association (gpsa) deb,gene and chris anguil ... co...
TRANSCRIPT
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Introduction
ANGUIL ENVIRONMENTAL SYSTEMS, INC.Innovative Air Pollution Control Solutions
Air Pollution Abatement Technologies for theOil and Natural Gas Processing Industries.
Jeff Kudronowicz / Application Engineering Manager / Anguil
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Presentation Outline
• Oxidation Overview, Industry Applicability & Operating Cost Comparison
• Technology Review & Design
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• Technology Review & Design Considerations
• Case Studies
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BackgroundFounded in 1978Family owned and operatedHeadquartered in Milwaukee, WI
with additional offices across the world
Committed to quality and application-driven engineering
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application-driven engineering
• Largest Supplier of Thermal Oxidizers to the Gas Industry
• Members of the Gas Processors Supplier Association (GPSA) Deb,Gene and Chris
Anguil
www.anguil.com/industries-served/petroleum-natural-gas.aspx
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What is Oxidation? Definition: CnH2m + (n + m/2) O2 ⇒ n CO2 + mH2O + heat
Temperature:Based on the VOCs that need to be destroyed there is a temperature at which the compounds can be oxidized.
Time:Relates to how long a compound needs to be at a certain temperature in order for it to be oxidized.
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order for it to be oxidized.
Turbulence:A fixed condition built into the equipment design that ensures a proper mixture of VOCs and oxygen for combustion.
Specific compounds and desired destruction rate efficiency determine temperature and residence time.
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Oxidizer Technology Overview:ANGUIL
Catalytic Recuperative OxidizersThermal Recuperative Oxidizers
Concentrators
Regenerative Thermal Oxidizers (RTO) Direct-Fired Thermal Oxidizers
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ANGUIL Green Completions in Natural Gas Development
www.epa.gov/airquality/oilandgas/pdfs/20120417summarywellsites.pdf
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Suitable Technologies for Gas Producers:
• Regenerative Thermal Oxidizer (RTO)
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Industry Standard for Gas Plants
• Catalytic Recuperative Oxidizers
• Direct-Fired Thermal Oxidizers / Flares
Emerging, Energy-Efficient Alternative
• Catalytic Recuperative Oxidizers
• Thermal Recuperative Oxidizer
• Concentrators: Zeolite and Carbon
Not Recommended for Gas Plants
Not Recommended for Gas Plants
Unsuitable for Gas Plants
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Pollutants Addressed by the Oil and Natural Gas Sector NSPS and NESHAP
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ANGUIL Why Technology Changes Are Coming… Operating Cost Comparison
20
30
40
50
60
RTODFTO / Flare
Operating Cost ($/hr.)
Assumptions:
1. 5,000 SCFM Process Exhaust Flows
2. 21,000 btu/lb. VOC heat of combustion
3. Auxiliary Fuel Cost of $4/mmbtu
4. 90% Thermal Energy Recovery on RTO
5. No Thermal Energy Recovery on DFTO/Flare
VOC Loading (BTU/ft3)
0
10
20
0 6 15
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ANGUIL Why Technology Changes Are Coming…
CO2 Emission from from Different Control Equipment
1200
1400
1600
1800
Em
issi
on
(lb
s/h
r)
0
200
400
600
800
1000
Direct Fired ThermalOxidizer (Flare)
Thermal RecuperativeOxidizer
Catalytic RecuperativeOxidizer
Regenerative ThermalOxidizer
Emission Control Technology
CO
2 E
mis
sio
n (l
bs/
hr)
CO2-Natural Gas Emission
CO2-Solvent Combustion
Process Assumptions:-5,000 SCFM -6 BTU/ft3 in Process Gas-Primarily Methane Emissions
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Regenerative Thermal OxidizerTypical Applications: Oil and Gas, Chemical, Composites, Metal Decorating, Expanded Polystyrene, Painting, Pharmaceutical, Wood Finishing, Coating, Printing
• Air Flow Range:
2,500-70,000scfm / Single Unit
70,000-500,000scfm / Multiple Units
• Concentration Range: 0%-25% LEL
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• Concentration Range: 0%-25% LEL
• True 95%+ Thermal Energy Recovery
• 99% plus Rate Efficiency (DRE)
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RTO Mode of OperationANGUIL
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ValvesTypes of Valves:
Poppet Valves (Horizontal and Vertical)
Butterfly Valves
Rotating (Single) Valves
Modes of Operation
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Modes of Operation
Pneumatic
Hydraulic
Why Vertical Poppet Valves?
Maintenance
Design
Cost
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Poppet Valve OperationANGUIL
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Types of RTO Heat Recovery Media
Random Packing· Typically 1” or 1½”
· ½” – 3” Available
Extruded Honeycomb Monolith
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Extruded Honeycomb Monolith· Variety of cell sizes and wall widths
· Typical block size: 150 x 150 x 300
Multi-Layered Media· Style and Size Options
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Sour Streams & the Presence of Sulfur
H2S + O2 ⇒ SO2 / SO3
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H2S + O2 ⇒ SO2 / SO3
SO2 + H2O ⇒ H2SO3
SO3 + H2O ⇒ H2SO4
Condensation of H2SO4 (sulfuric acid) should raise corrosion concerns.
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Acid Dew Point Considerations
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• If the acid dewpoint is reached in the oxidizer the acid will condense and possibly cause corrosion.
• Will the addition of fresh, dilution air cause condensing? Fresh air may need to be heated.condensing? Fresh air may need to be heated.
• High RTO thermal efficiency leads to low outlet temperatures. Check acid dewpoint temperatures and select appropriate materials of construction.
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Corrosion Protection Strategy
• Pre-heat the inlet air stream above the acid dewpoint
• Upgrade materials of critical items to protect against potential corrosion from acids
• Corrosion resistant outer reactor shell to protect
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• Corrosion resistant outer reactor shell to protect against dew point corrosion – Vinyl Ester coating
Certain amine processes require metals be upgraded
to specialty alloys!
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Media: Proper Design
RTO Thermal Efficiency RTO Fuel Usage
Operating Scenario:• 8,100 SCFM
• 2.2 BTU/ft3
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A difference of 1,440,000 BTU/Hr
95% Thermal Efficiency 40,000 BTU/Hr93% Thermal Efficiency 310,300 BTU/Hr91% Thermal Efficiency 702,000 BTU/Hr89% Thermal Efficiency 1,100,000 BTU/Hr87% Thermal Efficiency 1,480,000 BTU/Hr
24/7 operation and $4/MMBTU = $50,000 per year
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Hot Side Bypass
● Allows unit to handle high VOC loads
● Damper position controlled by PLC and driven with pneumatic actuator with positioner
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positioner
● Internally lined bypass duct to plenum of grade
● Duct and plenum are internally insulated
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Dilution Air
• Preheating fresh air prevents condensation and subsequent
Will the addition of fresh, dilution air cause condensing?
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and subsequent corrosion
• Steam coil, electric heater or burner are typically used
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Coating Application Process:• Surface and insulation pins should be sandblasted to
near white and inspected by a third party inspector• First coat is applied to surface and insulation pins• First coating application should be inspected by a third
party inspector• Final coat is applied
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• Final coat is applied • Final coating application
should be inspected by a third party inspector
• To make sure there are no hot spots present on the shell infrared images should be taken during start-up
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ANGUIL Amine Tail Gas RTO
-5,000 SCFM
-Sour gas system w/ H2S present
-Fresh air is heated to 340oF with slip stream from hot side bypass
-316L SS media support and poppet valves
-Vinyl Ester Coating
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-15,000 SCFM
-Sour gas system w/ H2S present
-Fresh air is heated to 340oF with slip
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stream from hot side bypass
-316L SS media support and poppet valves
-Vinyl Ester Coating
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Thank You!
ANGUIL ENVIRONMENTAL SYSTEMS, INC.
8855 N. 55th Street · Milwaukee, Wisconsin 53223
Phone : 414-365-6400 · Fax : 414-365-6410
www.anguil.com
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www.anguil.com
More Information on Gas & Oil Abatement Technologies:
www.anguil.com/industries-served/petroleum-natural-gas.aspx