Safe Tank Truck Loading Alternatives€¦ · · 2017-11-08Safe Tank Truck Loading Alternatives ....
Transcript of Safe Tank Truck Loading Alternatives€¦ · · 2017-11-08Safe Tank Truck Loading Alternatives ....
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Safe Tank Truck Loading Alternatives
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Why are we here today
Oxygen and VOC problems encountered in
today’s truck loading environment
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Loading Options
• Free venting and purging
• Vapor balancing
• Vapor burning (combustion)
• Vapor recovery
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Free venting and purging
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Typically a facility's air permit is
limited to 50 tons or less of VOCs
annually.
The issue: Loading one 200 barrel
truck per day and venting the gases
into the atmosphere consumes 14.8
tons of the 50 ton annual limit or
30%.
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The issue: Heath and Safety in the
loading rack area becomes apparent
in terms of vapor clouds that are
explosive and contain carcinogens.
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Vapor Balancing
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Facilities are typically limited to 10
ppm per ft3 of O2 in the natural gas
sales pipe line.
The issue: Vapor balancing a 200
barrel load to a storage tank (to
reduce emissions) will on average
inject 16 ft3/min of a 124,000 ppm
O2/hour.
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Vapor burning (combustion)
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Facilities are stressed to add
combustion products to a
production facility
The issue: Re-permitting, finding
available safe real-estate, lost
revenue, and public perception.
.
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Vapor recovery
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Note higher removal efficiencies can be achieved if requested.
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Recovery Calculation 14 gal per
200 barrel truck load
0.00
10.00
20.00
30.00
40.00
50.00
60.00
Va
po
r C
on
ce
ntr
ati
on
Recovery rate per 1000 gal loaded
Recovery Rate per 1000 gallons loaded
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A carbon based Vapor recovery unit
eliminates re-permitting, HSE and oxygen
shut in issues while providing an
attractive ROI.
The issue: The initial CAPEX is large
when compared to flaring alternatives.
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Advantages
Ele
vate
d F
lare
En
clo
sed
Fla
re
Th
erm
al
Oxid
izer
/ T
ruck
Lo
ad
ing
N
atu
ral
Dra
ft E
ncl
ose
d C
om
bu
sto
r
N
itro
ge
n/C
O2
Pu
rge
Air
Defe
nd
er
(Carb
on
Bed
Vap
or
Re
cov
ery
)
Familiar technology X X X
Minimal foundation requirements X
Low installation cost X X
Low CAPEX X X
Fully automated X X X X X
Minimal maintenance X X X
Removes odor X X X X
Can be combined with a scavenger system to reduce H2S X X X X
Low Noise X X X X
No Visible Flame X X X X
Minimal HAP release X X
+99% DRE X NA NA
No assist or purge gas required X X
Flameless operation X X
Recovers product X
Easily scalable/ modular design X
Can be installed in a Class 1 Div 2 area(panel unclassified and remote mounted)
X
No production of NOX CO or CO2 X X
Can meet +99% VOC reduction to meet EPA Control device not affecting permit
X
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Disadvantages
Ele
vate
d F
lare
En
clo
sed
Fla
re
Th
erm
al
Oxid
izer
/ T
ruck
Lo
ad
ing
Natu
ral
Dra
ft E
ncl
ose
d C
om
bu
sto
r
Nit
rog
en
/CO
2 P
urg
e
A
ir D
efe
nd
er
(Carb
on
Bed
Vap
or
Reco
very
)
Possible smoke X X X
Noise X
Visible flame/ Negative public perception X
Requires Nitrogen or Natural Gas purge prior to start up during
operation and shut down X X
98% DRE X X
Potential for flashback explosions X X
Location on site requires safe area X X X
Affects air permitting X X X
Emits CO NOX CO2 X X X
Lost revenue by burning product X X X
Requires significant fuel gas/ High operating cost X X
Higher maintenance X
Larger footprint X
Initial CAPEX X X X
Heat trace required for vacuum pump to storage tank
X
Noted as not desired at Midstream sales point X
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Initial cost Power usage Pilot gas usage Assist gas usage liquid recovered product Operational costs per yr
Elevated Flare operating 24 hrs per day $ 36,000.00 12 KW 1440 SCF 9216 SCF N/A $ (11,669.00) .
Enclosed Flare operating 12 hrs per day $ 32,000.00 12 KW 720 SCF 7400 SCF N/A $ (8,891.00)
Enclosed Combustor operating 12 hrs per day $ 125,000.00 60 KW 720 SCF 30000 SCF N/A $ (35,390.00)
Carbon Vapor recovery operating 24 hrs per day $ 215,000.00 192 KW N/A N/A 168 gal $ 89,294.00
Assumptions
1. Loading twelve 200 barrel trucks in a 24 hour period (truck load time 1 hr.)
2. Natural gas costs at $3 per 1000 ft3
3. Power costs at 8 cents per KW hour
4. Crude costs at $65/barrel
`
Typical capital and operations costs
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