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© 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
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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.
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PETROLEUM PRODUCTION, REFINING AND DISTRIBUTION SYSTEMS (Sources of organic evaporative emissions are indicated by vertical arrows.)
3
Crude Storage Tanks
Crude Tanks
Terminal Tanks
Bulk Plant Tanks
Commercial Storage Tanks
Product Tanks
Service Stations
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VAPOUR CONTROL FOR DISTRIBUTION FACILITIES
Applications:
Storage Tank Vents Truck Loading Railcar Loading Ship and Barge Loading
4
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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)
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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
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VAPOR COLLECTION METHODS
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Fill Pipe Vapor Emissions
Vapors
Product
CARGO TANK
SPLASH LOADING METHOD
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Fill Pipe Vapor Emissions
Vapors
Product
Cargo Tank
SUBMERGED FILL PIPE
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Fill Pipe
Vapor Vent to Recovery or Atmosphere
Vapors
Product Cargo Tank
BOTTOM LOADING
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11
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)
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WHAT TECHNOLOGY TO USE ?
12
VAPOUR RECOVERY
VAPOUR COMBUSTION
Recognized Technologies
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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)
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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
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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
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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
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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
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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
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INLET VAPOR
0 °C -70 °C -100 °C
MECHANCIAL REFRIGERATED
PRE-CONDENSER
MECHANICAL CASCADE
REFRIGERATED CONDENSER
LIQUID NITROGEN CONDENSER
DECANTER
WATER
RECOVERED PRODUCT
PUMP
VENT AIR
CONDENSATION TYPE VAPOUR RECOVERY SYSTEM
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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
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INLET VAPOR
VACUUM PUMP
AIR VENT
PUMP
A B
RECYCLE ADSORBER ADSORBER
-20°C MECHANICAL
REFRIGERATED CONDENSER
RECEIVER
RECOVERED PRODUCT
CARBON ADSORPTION-CONDENSATION (ADCON™) VAPOUR RECOVERY SYSTEM
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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
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INLET VAPOR
AIR VENT
COMPRESSOR
ABSORBER
PUMP
LEAN GASOLINE ABSORBENT
RICH GASOLINE
ABSORBENT
A
B
MEMBRANE Modules
PUMP VACUUM PUMP
MEMBRANE VAPOR RECOVERY SYSTEM
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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)
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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
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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
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ACTIVATED CARBON
Important Features:
High mechanical strength
Low pressure drop
High adsorption capacities
Low rententivity (easy to regenerate)
Low reactivity
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CARBON ADSORPTION/ABSORPTION (ADABTM)
Two Types of Systems:
Dry Vacuum Pump Regeneration
Liquid Ring Vacuum Pump Regeneration
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ADAB™ Adsorption / Absorption Liquid Ring Vacuum Pump
Major Components: Carbon Beds MOVs Vacuum Pump Separator Absorber Circulation Pumps Seal Fluid Pump Seal Fluid Cooler
29
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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
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Liquid Ring Vacuum Pump
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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
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DRY SYSTEM ADVANTAGES
Reduced power consumption
Ethylene glycol seal fluid and associated components are eliminated (biofuels)
Greater flexibility to handle variety of products
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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
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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
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Vapour Combustion Systems
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TYPES OF VAPOUR COMBUSTION DEVICES
Open flame combustors
Enclosed flame combustors
Flares
Thermal Oxidizer systems
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ENCLOSED VAPOUR COMBUSTOR
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STANDARDS FOR SAFETY Flashback Protection:
Certified detonation arrestors
Anti-flashback burners
Reliable, stable, energy efficient pilots
Multiple burner stages for high turndowns
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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
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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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VRU/VCU – PROCESS DESIGN PARAMETERS 2/3
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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VRU/VCU – PROCESS DESIGN PARAMETERS 3/3
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
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VRU – THREE DRY VACUUM PUMPS
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Gasoline/Diesel Truck Loading – France 1400 m3/hr
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VRU – SIX DRY VACUUM PUMPS / 4 BEDS
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Gasoline/Ethanol Ship Loading – Belgium 4000 m3/hr
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MARINE VRU, UK
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Crude Oil Ship Loading – UK 16,000 m3/hr
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MARINE VRU – LRVP + Booster Blowers
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Naphta Ship Loading – UAE 10,000 m3/hr
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MARINE VRU
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Crude Oil Ship Loading – Sweden 6,000 m3/hr
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MARINE VRU, UK
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Marine VCU Installed in Crude Oil Loading - 19,080 m3/hr Turkey
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THANK YOU
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