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

Presentation Outline

• Oxidation Overview, Industry Applicability & Operating Cost Comparison

• Technology Review & Design

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• Technology Review & Design Considerations

• Case Studies

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

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.

Oxidizer Technology Overview:ANGUIL

Catalytic Recuperative OxidizersThermal Recuperative Oxidizers

Concentrators

Regenerative Thermal Oxidizers (RTO) Direct-Fired Thermal Oxidizers

ANGUIL Green Completions in Natural Gas Development

www.epa.gov/airquality/oilandgas/pdfs/20120417summarywellsites.pdf

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

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

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

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)

RTO Mode of OperationANGUIL

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

Poppet Valve OperationANGUIL

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

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.

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.

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!

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

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

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

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

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

-15,000 SCFM

-Sour gas system w/ H2S present

-Fresh air is heated to 340oF with slip

ANGUIL Amine Tail Gas RTO

stream from hot side bypass

-316L SS media support and poppet valves

-Vinyl Ester Coating

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