Engineered Concepts

TECHNICAL BULLETIN :

EFD Emission Free Dehydrator

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Although BTEX is a major concern as a gas dehydration hazardous waste, there are other hazardous wastes, methane gas, and hydrocarbon components produced by the dehydration process. Most methane emissions produced by gas dehydration are by Kimray® glycol pumps, gas stripping of the rich glycol, and flashing as the rich glycol is released from high pressure to atmospheric pressure. Conventional dehydrator still columns, without equipment to recover or destroy the overhead hydrocarbon emissions,

emit the overhead hydrocarbon emissions directly to the atmosphere.

• CH4(Methane)is21timesmoredestructiveasagreenhousegasthanCO2(CarbonDioxide)

• DehydrationisthethirdlargestCH4(Methane)emissionsourceinthenaturalgasproductionindustry.

• Glycoldehydratorventingproducesover80%oftheoilandgasindustry’sannualHAPandVOC

emissions.

To address a range of field conditions, Engineered Concepts has 3 varieties of Emission Free Dehydrators (EFD) and Emission Free Systems (EFS) that, regardless of size, all produce the same results of a 99.74%+/- HAP (hazardous air pollutants) and VOC (volatile organic compounds) destruction or recovery efficiency. All of the systems can be operated with or without electricity and generate profit to the operator

throughout the life of the dehydrator.

I.StandardEFD(mayberetrofittedtoadehydratoralreadyinserviceorbuiltintoanewdehydrator)Retrofittingadehydratoralreadyinthefieldrequiresonlyminorchangestothedehydrator

a.Withelectricity – This system uses an emissions free electric glycol pump, an effluent condenser, eductor, and low-pressure (approximately 4 ounces) liquids removal separator. The electric glycol pump is used to circulate the process glycol. The condenser receives the effluent from the reboiler still column vent. The hydrocarbons and water vapor from the still column are routed through the condenser to the liquids removal separator operating at ounces. Liquids condensed from the still column effluent are sent to storage or disposal. The non-

condensable hydrocarbon vapors are sent to the eductor system. The eductor system captures and compresses the non-condensable vapors before sending them back to the dehydrator fuel system. The vapors to the reboiler are compressed to primary fuel gas delivery pressure. By capturing the non-condensable vapors and sending them back to the fuel gas system, the EFD supplies an estimated 80% of the dehydrators’ total fuel gas requirements and, because the emissions are pressurized, they burn efficiently and safely. By supplementing the fuel required to fire the reboiler burner, this system significantly reduces the cost of operating a dehydrator.

The3systemsareasfollows:

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EMISSION

S FREE TECHNOLOGIES (EFD) DEHYDRATOR FLOW

DIAGRAM

DESIGNED FOR USE W

ITH ELECTRIC POWER

BOTH NEW

OR RETROFITTED DEHYDRATOR

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b.Withoutelectricity–This system uses a Kimray glycol pump instead of an electric glycol pump to circulate the process glycol. All the other components of the system are the same, and operate the same, as the unit powered by electricity. An internal combustion engine equipped with a catalytic converter and air fuel ratio controller is used to power the non-electric unit. In this system the internal combustion engine powers two pumps; one pump provides energy to run an eductor, and the second is a hydraulic pump to power the Kimray glycol pump. The Kimray pump is a major source of methane emissions. The amount of gas normally required to power a Kimray glycol pump is more gas than is required to fire the dehydrator reboiler burner. Powering

the Kimray glycol pump hydraulically eliminates all of the gas required to power the pump, thus eliminating the emissions vented by the Kimray pump. By capturing the non-condensable vapors and sending them back to the fuel gas system, the system will provide for an estimated 80% of the dehydrators’ total fuel gas requirements and, because the emissions are pressurized, they burn efficiently and safely. Capturing the still column emissions and eliminating the gas emissions from the Kimray glycol pump greatly reduce the total dehydrator gas usage and thus the cost of the dehydrator and the environmental impact of the hydrocarbon (Methane, BTEX etc.) emissions as well as eliminating any requirements for a thermal oxidizer on the location.

Engineered Concepts’ EFD systems can be operated with or without electricity and generate a profit to the operator throughout the life of the dehydrator.

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Engineered Concepts’ EFD (Emissions Free Dehydration) is an odorless, totally closed loop process that is unaffected by variable (cold) weather conditions.

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EMISSION

S FREE TECHNOLOGIES (EFD) DEHYDRATOR FLOW

DIAGRAM

DESIGNED FOR USE W

ITHOUT ELECTRIC POWER

BOTH NEW

OR RETROFITTED DEHYDRATOR

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II.EFDwithavaporrecoveryunit(VRU)mayberetrofittedtoanydehydratorinserviceorincorporatedintoanewdehydrator.

a.Withelectricity–This system uses an emissions free electric glycol pump, effluent condenser, and low-pressure (approximately 4 ounces) liquids removal separator. The system further utilizes a VRU compressor that collects and compresses the hydrocarbon vapors that are released when liquid hydrocarbons are dumped first to the vapor recovery tower (VRT) and then to the storage tanks. The condenser receives the effluent from the reboiler still column vent. The natural gas product and water vapor are routed

through the condenser to the liquids removal separator operating at 4 to 6 ounces. Liquids condensed from the still column effluent are sent to storage or disposal. The non-condensable vapors from the dehydrator still column vent are routed to the VRU compressor and are mixed with the hydrocarbon vapors that are flashed when liquid hydrocarbons are dumped to the VRT. The mixture of hydrocarbon vapors is compressed by the VRU compressor to a pressure high enough for the vapors to be captured and sent to sales. The additional volume and higher BTU content of the natural gas product sent to market through the VRU increases profits throughout the working life of an EFD equipped dehydrator and eliminates the capital and operational expense of a thermal oxidizer.

In retrofit EFD applications, the large amounts of emissions produced by the Kimray pumps are eliminated.

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EMISSION

S FREE TECHNOLOGIES (EFD) DEHYDRATOR FLOW

DIAGRAM

DESIGNED FOR USE W

ITH ELECTRIC POWER AN

D AUXILIARY COMPRESSOR (VRU)

BOTH NEW

OR RETROFITTED DEHYDRATOR

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In some applications a VRU is employed to send the the combined tank and dehydrator emissions to sales.

b.Withoutelectricity–This system uses a Kimray glycol pump instead of an electric glycol pump to circulate the process glycol. All other components are the same, and operate the same, as the unit powered by electricity. The gas required to power the Kimray glycol pump (mostly methane) is entrained in the rich glycol stream and is released into the gas to glycol separator. The gas flows from the glycol flash separator through a back-pressure regulator into the liquid removal separator. The rich glycol is dumped from the glycol flash separator into the reboiler. The emissions (hydrocarbons and water vapor) exit the reboiler still column vent and flow through the effluent condenser into the low-

pressure liquids removal separator. The reboiler emissions mix with the gas from the glycol flash separator and flow to the VRU compressor where, as previously described, the vapors are mixed with the flash vapors from the VRT and are compressed into the sales line. This system provides for a direct increase in profits by eliminating the capital and operational expense of a thermal oxidizer. Additional volume and higher BTU content of the emissions that are captured and sent to market increase profits and eliminate the operating losses associated with venting of the methane required to

power the Kimray glycol pump.

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III.EFDwithcompressoremissionrecovery(CER)mayberetrofittedtoadehydratorinserviceorincorporatedintoanewdehydrator.This system requires low line pressure such that a small auxiliary compressor operating at a suction pressure of 4 to 6 ounces can compress the collected emissions directly into the sales line or into the suction scrubber of the sales line compressor.

a.Withelectricity–This system uses an emissions free electric glycol pump, effluent condenser, and a low-pressure (approximately 4 ounces) liquids removal separator. In addition, a small auxiliary compressor operating at ounces of

suction pressure is used. The condenser receives the effluent from the reboiler still column vent. The hydrocarbon vapors and water vapor in the still column effluent are routed through the condenser to the liquids removal separator operating at 4 to 6 ounces. Liquids condensed from the still column effluent are sent to storage or disposal. The non-condensable vapors from the dehydrator still column vent are routed to a small auxiliary compressor that compresses the emissions into the sales line or the suction scrubber of a sales line compressor. This system eliminates the capital and operating expense of a thermal oxidizer while providing a measurable increase in product and profits generated by the additional volume of higher BTU content natural gas sent to market.

The use of an Engineered Concepts EFD provides for a direct increase in profits by eliminating the capital and operational expense of a thermal oxidizer.

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EMISSIONS FREE TECHNOLOGIES (EFD) DEHYDRATOR FLOW

DIAGRAM

DESIGNED FOR USE WITHOUT ELECTRIC POW

ER, POSITIVE DISPLACEMENT PUM

P, AND AUXILIARY COMPRESSOR (CER)

BOTH NEW OR RETROFITTED DEHYDRATOR

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EMISSIONS FREE TECHNOLOGIES (EFD) DEHYDRATOR FLOW

DIAGRAM

DESIGNED FOR USE WITHOUT ELECTRIC POW

ER, KIMRAY PUM

P, AND AUXILIARY COMPRESSOR (CER)

BOTH NEW OR RETROFITTED DEHYDRATOR

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1. Recoveryofallstillcolumnoverheadvapors.The EFD systems can recover all the hydrocarbon emissions created by the dehydration of natural gas including stripping gas. Under normal operation, no emissions, from the dehydration process, are vented or routed to the stack, flare, or thermal oxidizer. 100% of the hydrocarbons are utilized.

Hydrocarbon recovery depends on the composition of the inlet gas stream. For most applications the recovery ranges from 1000 to 2100 BTUs of fuel gas plus 0.005 to 0.012 gallons of condensate per gallon of glycol circulated. Therefore, for a dehydrator circulating 1 gpm of glycol, the recovery would be valued in the range of $6,000 to $17,500 per year depending upon the current natural gas prices.

There are three main sources of cost savings using Engineered Concepts advanced dehydration

technologies that can increase revenues up to $55,000 (or more) per year for every gpm of glycol

circulation rate.

1 Unless otherwise noted, savings are calculated on the basis of $3.00 per MM BTU for gas and $80 per barrel for condensate.

b.Withoutelectricity–This system uses a catalytic converter and air fuel ratio equipped internal combustion engine and uses a Kimray glycol pump instead of an electric glycol pump to circulate the process glycol. All the other components are the same, and operate the same, as the unit with electricity. As previously described on the unit utilizing the VRU, the gas required to power the Kimray glycol pump (mostly methane) is entrained in the rich glycol stream and is released into the glycol flash separator along with the rich glycol. The gas flows from the gas to glycol flash separator through a back-pressure regulator into the liquid removal separator. The rich glycol is dumped from the gas to glycol flash separator into the reboiler. The hydrocarbon emissions and water vapor exiting the reboiler still column are routed through the condenser to the liquids removal separator operating at 4 to 6 ounces. Liquids condensed from the still column effluent are

sent to storage or disposal. The non-condensable vapors from the dehydrator still column vent are routed to the compressor. After compression, the captured emissions are routed into the sales line or the suction scrubber of the sales line compressor. This system provides for a direct increase in profits generated by the additional volume and higher BTU content of the natural gas product sent to market by eliminating the operating costs of venting the methane emissions from the Kimray glycol pump.By recovering the still column emissions and using them as fuel gas or sending them to sales and eliminating the venting of methane by the Kimray glycol pump, each of these systems eradicates the energy waste and pollution caused by traditional glycol dehydration. From a profit standpoint, fuel cost reductions, elimination of the capital and operating expense of a thermal oxidizer and increased product sales give the operator a profit generating solution to the emission problems associated with glycol dehydration.

EmissionsFreeDehydratororRetrofitReturnonInvestment

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2.EliminationofthegaswastedbytheKimraypump.Use of Engineered Concepts exclusive direct drive pump process or recovery by VRU method provides an alternate power source for the Kimray pump, thus eliminating the gas wasted by the pump. The gas used by the Kimray pump far exceeds the fuel requirements for the glycol reboiler, and the

excess gas is wasted via the vent, flare, or thermal oxidizer. Depending on the operating pressure of the dehydrator, the gas wasted ranges from 2.0 to 8.0 scf per gallon of glycol circulated. The value of the gas saved by conversion of the Kimray pump to the Direct Drive system ranges from approximately $5000 to $22,000 per year per gpm circulated. Alternately, an electric pump can be used in lieu of the Kimray pump if electricity is available.

3.ReductionofThermalOxidizerfuelrequirements.Many sites now use a thermal oxidizer to incinerate the excess vapors from the dehydration process. Most of the excess vapors come from the uncondensed portion of the still column overheads and from the excess gas wasted by the Kimray pump. For each gallon of glycol circulated, a thermal oxidizer requires about 3 to 6 scf of fuel to incinerate the wasted vapors. Therefore, the fuel required for the thermal oxidizer is valued at $8000 to $16,000 per year per gpm of glycol circulated.

The Direct Drive Pump Process is covered by U.S. Patent. Based on $5 per MM BTU gas. $3000 to $13,000 range at $3 per MM BTU gas. Gas is assumed to have heating value of 1000 BTU per scf.

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The EFD system has integrated levels of protection designed for maximum operational run time in order to prevent uncontrolled dehydrator emissions from occurring. Some run time issues outside the control of the EFD process will occur, such as an electrical power failure. Other run time issues may be mechanical such as worn compressor valves or engine component failures. Acknowledging there will be times when the EFD process is not operational, the effects of a system shut-down are described below.

1. Electricpowereddehydratorglycolpump,allEFDsystemspoweredbyelectricity

a. Global loss of electrical power will stop the dehydrator glycol pump and the EFD process. Both the dehydrator and the EFD system will be non-operational. Valves and controls inherent to the EFD system will route any residual emissions from the dehydrator still column vent to the flare system until electrical power is restored.

b. In the case of a singular electrical or mechanical failure affecting the EFD alone, valves and controls inherent to the EFD system will route any emissions from the dehydrator still column vent to the flare system until the failure is corrected. The dehydrator will remain operational.

2.Kimraygaspoweredglycolpumps,allEFDVRUandCERsystemspoweredbyaninternalcombustionengine

a. Loss of engine power or a mechanical failure in the EFD system will not stop the dehydrator glycol pumps, but the EFD process will become non-operational. Valves and controls inherent to the EFD system will route any emissions from the dehydrator still column vent and the Kimray pump to a standard flare system until engine power is restored or the mechanical fault is corrected. The dehydrator will remain operational.

EFDOperationInterruptions:

The value of the gas saved by the conversion of the Kimray pump to the direct drive system ranges between $5,000 and $20,000 per year per gpm circulated.

3.Kimrayhydraulicpoweredglycolpumps,EFDsystempoweredbyaninternalcombustionengine

a.Loss of engine power will stop the dehydrator glycol pump and the EFD process. Both the dehydrator and the EFD system will be non-operational. Valves and controls inherent to the EFD system will route any residual emissions from the dehydrator still column vent to a flare system until engine power is restored.

b.In the case of a singular engine system or mechanical failure affecting the EFD alone, valves and controls inherent to the EFD system will route any emissions from the dehydrator still column vent to the flare system until the failure is corrected. The dehydrator will remain non-operational until the EFD fault is corrected.

ConclusionEngineered Concepts EFD technology is a fully integrated, completely closed and flexible natural gas dehydration emissions recovery system with a HAP and VOC destruction efficiency of 99.74%. The potential to emit uncontrolled emissions will be well below 1.0 ton per year of VOC’s and in all actuality the EFD will be virtually emissions free.

Kimray is a registered trademark of Kimray Inc.

The Engineered Concepts EFD is the only emission free dehydration

process to be field tested and proven.

EFDOperationInterruptions:

THE ENVIRONMENTAL TECHNOLOGY VERIFICATION PROGRAM

ETV Joint Verification Statement

The U.S. Environmental Protection Agency (EPA) has created the Environmental Technology Verification (ETV) program to facilitate the deployment of innovative or improved environmental technologies through performance verification and information dissemination. The ETV program goal is to further environmental protection by accelerating the acceptance and use of improved and cost-effective technologies. ETV seeks to achieve this by providing high-quality, peer-reviewed performance data to those involved in the purchase, design, distribution, financing, permitting, and use of environmental technologies. ETV works in partnership with recognized standards and testing organizations, stakeholder groups composed of buyers, vendor organizations, and permitters, and with the full participation of individual technology developers. The program evaluates technology performance by developing test plans that are responsive to stakeholders’ needs, conducting field or laboratory tests, collecting and analyzing data, and preparing peer-reviewed reports. All evaluations are conducted in accordance with rigorous quality assurance protocols. This ensures that the resulting data are of known quality and that the results are defensible. Southern Research Institute operates the Greenhouse Gas Technology Center (GHG Center), one of six ETV Centers, in cooperation with EPA’s National Risk Management Research Laboratory. The GHG Center has recently evaluated the performance of the Quantum Leap Dehydrator (QLD), manufactured by

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U.S. Environmental Protection Agency

TECHNOLOGY TYPE: Emissions Control of Criteria Pollutants, Hazardous Pollutants, and Greenhouse Gases APPLICATION: Natural Gas Dehydration TECHNOLOGY NAME: Quantum Leap Dehydrator COMPANY: Engineered Concepts, LLC ADDRESS: 1909 E. 20th St., Farmington, NM 87401 E-MAIL: gasstripper@netscape.net

SOUTHERN RESEARCHI N S T I T U T E

N/A

Texas Commission on Environmental QualityInvestigation Report

CN601319361

PRODUCTION FACILITY

RN106146012Investigation # 1043320 Incident #

Investigator: SAMUEL CORTEZ Site Classification

MINOR SOURCE

Conducted: 02/15/2013 -- 03/15/2013 SIC Code: 1311

Program(s): AIR NEW SOURCE PERMITS

Location : FROM THE INTERSECTION OF BEAUMONT HWY & BELTWAY 8, TRAVEL NORTH ON BELTWAY 8 APPROX 6.3 MI TO W LAKE HOUSTON PKWY. TRAVEL NORTHEAST ON W LAKE HOUSTON PKWY APPROX 1.2 MI TO SUMMERWOOD LAKE DR. TRAVEL SOUTHEAST ON SUMMERWOOD LAKES DR APPROX 0.6 MI TO SITE

Investigation Type : Compliance Investigation

Additional ID(s) : 4820101970

Address: ; , Activity Type : REGION 12 - HOUSTON

GFIR - AIR GFIR - GAS FIND INFARED CAMERA

FIAIRNGP - AIR FIAIRNGP - FOC INV FOR NATGASPETRO FACILITY

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