3/7/16 Page 1Authorization Process for Pressure Assisted MultiPoint Ground Flares

Authorization Process for Pressure Assisted MultiPoint Ground Flares

Anne Inman, P.E.Technical SpecialistOperational Support SectionAir Permits DivisionTexas Commission on Environmental Quality

3/7/16 Page 2Authorization Process for Pressure Assisted MultiPoint Ground Flares

Overview of Regulatory Authorization Process for MPGF• Federal Regulation Applicability

• AMEL Introduction and Streamline Framework

• Project Scope and Background

• Performance Demonstration

• Monitoring and Operating Conditions

• Public Notice Proposal and Final Decision by EPA

• State/Regional Parallel Authorizations

3/7/16 Page 3Authorization Process for Pressure Assisted MultiPoint Ground Flares

Federal Regulatory Applicability• 40 CFR 60, Standards of Performance for New Stationary Sources

(NSPS) – 88 Subparts A-OOOO

• 40 CFR 61, National Emission Standards for Hazardous Air Pollutants (NESHAPs) - 22 Subparts A-FF

• 40 CFR 63, National Emission Standards for Hazardous Air Pollutants Source Categories (a.k.a. Maximum Achievable Control Technology) (MACT) – 134 Subparts A - HHHHHHH

3/7/16 Page 4Authorization Process for Pressure Assisted MultiPoint Ground Flares

Federal Regulatory Applicability• NSPS, NESHAPs, MACT regulate sources and mandate emission

limitations

• Flares are a common control with design & operating specifications • 40 CFR §60.18 and 40 CFR §63.11

• Continuous Pilot

• Net Heating Value

• Flare Tip Velocity

• Smokeless

3/7/16 Page 5Authorization Process for Pressure Assisted MultiPoint Ground Flares

Pressure Assisted Multi-Point Ground Flares (MPGF)Flare systems:

• Characterized by one or more flare headers and groupings

• Operate at high pressures

• Varying stream characteristics and flows

• 99%+ Destruction Rate Effectiveness (DRE) for VOCs and HAPs

• Cannot meet flare tip velocity requirements in federal regulations §60.18(c) or §63.11(c)

3/7/16 Page 6Authorization Process for Pressure Assisted MultiPoint Ground Flares

Alternate Means of Emission LimitationsAMEL IntroductionFCAA §111(h)(3)

• Alternative Means of Emission Limitation (AMEL)

• Satisfy Administrator (EPA – not delegated)

• Achieve equivalent emission reduction

• Each regulated air pollutant and subpart

• Notice and opportunity for public hearing

• EPA Authorization

3/7/16 Page 7Authorization Process for Pressure Assisted MultiPoint Ground Flares

MPGF AMELs by EPADocket EPA-HQ-OAR-2014-0738• Proposal Dow and Exxon – 2/13/2015 FR pgs 8023-30

• Approval Dow and Exxon, Proposal OCC – 8/31/2015 FR pgs 52426-35

• Streamline Framework Proposal – 8/31/2015 FR pgs 52435-36

• Pending Actions at EPA: OCC (1), CPCHEM (2), R&H (2)

3/7/16 Page 8Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMELs Streamline Framework• Submit AMEL request to EPA

• Copy corresponding state/tribal/local permitting programs and agencies

• Each request stands-alone (documentation)

• Must have all needed information to satisfy EPA Administrator

3/7/16 Page 9Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL Project Scope and Background• Identify site, company, permits, reference IDs

• Describe processes and operational conditions which generate emissions

• Details of typical and worst-case waste gas compositions, flows, profiles

• Anticipated start of construction and operation

3/7/16 Page 10Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL Project Scope and Background• MPGF utilization (routine operations, planned MSS, upsets, etc.)

• Applicable NSPS, NESHAPs, MACT standards

• Authority to request AMEL (FCAA plus subparts)

3/7/16 Page 11Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF• Identify burner manufacturer, design, specifications (type,

geometry, size)

• Describe operational scenarios (low pressure, high pressure)

• Details on capacity, rows/stages, burners, pilots per stage, staging curve

• Include any unique design or operational details

3/7/16 Page 12Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance • Must achieve equivalent control (DRE)

• Most stringent applicable standard• VOC

• HAPs

• Individual constituents

• Demonstration options• Test

• Engineering assessment

3/7/16 Page 13Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance Demonstration Testing• Test

• PFTIR and Extractive

• Specific manufacturer and design

• Representative fuel/waste gas OR Worst-case substitute

• Minimum 3 runs

• Report

3/7/16 Page 14Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance DemonstrationTest Report Contents• Test description

• Protocols and methodologies

• Quality assurance/quality control

• Raw field and laboratory data

• Summary report sheets

• Calibration standards and curves

• Date, time, duration

3/7/16 Page 15Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance DemonstrationTest Report Contents• Fuel/waste gas composition and justification

• Highest operating pressure/sonic velocity conditions

• Visible emissions observation forms

• Calculate average DRE and combustion efficiency

• Flowrates and velocity of gas

• Calculate NHVcz and/or LFLcz of gas

3/7/16 Page 16Authorization Process for Pressure Assisted MultiPoint Ground Flares

Gas Net Heating Value in Combustion Zone (NHVcz)

𝑁𝐻𝑉%& = (𝑥*𝑁𝐻𝑉*

+

*,-

• Based on compositional analysis data

• NHVcz = Net heating value of flare vent gas (Btu/scf).

• i = Individual component in flare vent gas & n = Number of components in vent gas

• xi = Concentration of component i in flare vent gas, volume percent.

• NHVi = Net heating value of component i

3/7/16 Page 17Authorization Process for Pressure Assisted MultiPoint Ground Flares

Gas Lower Flammability Limitin Combustion Zone (LFLcz)

𝐿𝐹𝐿01 =1

∑ 𝜒*𝐿𝐹𝐿*

+*,-

• Based on compositional analysis data

• LFLcz = Lower flammability limit of flare vent gas, volume fraction

• i = Individual component in flare vent gas & n = Number of components in vent gas

• xi = Concentration of component i in flare vent gas, volume percent.

• LFLi = Lower flammability limit of component i

3/7/16 Page 18Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance DemonstrationTest Report Contents• MPGF burner tip pressure

• Waste gas temperature

• Meteorological conditions

• Observed flameouts

• Results analysis and summary

3/7/16 Page 19Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance DemonstrationEngineering Assessment• Demonstrate effectiveness by prior testing

• Similar equivalent burner

• Representative fuel/waste gas OR worst-case substitute

• Address all other factors

• Include supporting documentation/prior tests

• Persuasive conclusions

3/7/16 Page 20Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance DemonstrationEngineering Assessment

Equivalent burner destruction/combustion effectiveness • Design principles of burner type

• Burner size

• Burner geometry

• Air-fuel mixing

• Combustion principles to assure smokeless operation

• Spectrum and variety of operating conditions

3/7/16 Page 21Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance DemonstrationStability Testing

Key Importance – Lit, Stable Flame and Smokeless

Conduct long-term stability test• Spectrum and range of operating conditions

• Representative or worst-case waste gas stream

• Smokeless operation

• Stable flame to flameout point

3/7/16 Page 22Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance DemonstrationStability Testing• Design and complete test

• Purpose to determine point of flame instability and flameout

• Stable minimum 5 minutes• Highest operating pressure/sonic flow conditions

• Most challenging composition

• Document all relevant conditions and parameters

3/7/16 Page 23Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance DemonstrationStability Testing• Replicate results

• Minimum and maximum operating conditions• At least 15 minutes at each condition

• At least 3 test runs

• At or above NHVcz or below LFLcz• Highest operating pressure/sonic flow conditions

• Most challenging composition

• Document and report all relevant conditions and parameters

3/7/16 Page 24Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance DemonstrationCross Lighting• Design and complete test

• Purpose to show all stages will light under range of conditions• Vary operating pressure / velocity

• Appropriate design and installation spacing and pilot locations

• Boundaries• At least 3 test runs at each condition

• NHVcz or LFLcz

• Minimum of 3 burners must light in each stage

3/7/16 Page 25Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance DemonstrationCross Lighting• Report Contents

• Description of the testing

• Protocol of test methodology

• Test method QA/QC parameters

• Time, length, and duration of the test

3/7/16 Page 26Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance DemonstrationCross Lighting• Report continued…..

• Waste gas composition

• Waste gas temperature

• NHVcz and/or LFLcz of the gas tested

• Velocity (or Mach speed ratio) of the waste gas tested

3/7/16 Page 27Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance DemonstrationCross Lighting• Report continued…..

• Burner tip pressure

• Whether successful cross-light was observed over all of the burners

• Length of time it took for the burners to cross-light

• Maintaining a stable flame after a successful cross-light

• Duration of stable flame observed

3/7/16 Page 28Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Performance DemonstrationOther Reduction Considerations• Alternatives to flaring or flare reduction measures

• Evaluate flare gas recovery

• Justify MPGF utilization

3/7/16 Page 29Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Operating Conditions• Each stage equipped with at least two (2) pilots

• No visible emissions when operating

• NHVcz ≥ 800 Btu/scf

• LFLcz ≤ 6.5 vol %

3/7/16 Page 30Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Monitoring• Install, operate, calibrate, maintain, record data, record

downtime & out of compliance periods

• At all times:• Pilot flames on each stage present (thermocouple)

3/7/16 Page 31Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Monitoring• Receiving material

• Downtime for maintenance, instrument adjustments, calibrations (max 5%)

• Component concentrations in vent gas (LFLcz) or measure, calculate and record heating value of vent gas (NHVcz)

• Monitor vent gas flow rate

• Pilot flame / opacity video camera

• Pressure monitors on main header, each staging valve

3/7/16 Page 32Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL MPGF Review• EPA staff will review details of request

• Provide all documentation

• Request for Information – respond promptly to avoid delays

• Draft site-specific AMEL approval or disapproval

3/7/16 Page 33Authorization Process for Pressure Assisted MultiPoint Ground Flares

AMEL Notice and Action• Publish proposal in Federal Register

• 30-day comment and hearing request period

• EPA evaluates all comments

• Publish final AMEL in Federal Register• Approval or Disapproval

• Revisions to AMEL conditions as proposed

• Respond to comments

3/7/16 Page 34Authorization Process for Pressure Assisted MultiPoint Ground Flares

State/Tribal/Regional Authorizations

• Each state/region/tribe/local government has different requirements

• Actions possible• Amend or Revise New Source Review Permits

• Administrative Revision to Federal Operating Permits

• Alternate Method of Compliance or Control (AMOC) Requests

• Public notice and comment/hearing opportunities

• Plans may parallel or be different than EPA AMEL

• May process simultaneously or consecutively

3/7/16 Page 35Authorization Process for Pressure Assisted MultiPoint Ground Flares

Anne Inman, P.E.Air Permits Division, TCEQ

Mail Code 163P.O. Box 13087

Austin, TX 78711

512-239-1276Anne.Inman@tceq.texas.gov