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Karl WalbySenior Key Account ManagerDürr Systems, Inc.
January 29, 2015
RTO start – up duration RTO shut down duration
= Heat Storage Shutdown (Bottle Up Mode)= Idle Modes
Bake-Out = Multiple options for zero opacity bake-out = Multiple options for maintaining dRe during bake-out
Valves, Burners, Controls -Adjustments/Repairs= spare parts= preparation= redundancy = programming modes= UPS systems
Minimizing downtime= Auto relight w/o purge= Flame relay bypass= Continuous pilot systems= Heat storage shutdown= UPS Systems= Resource identification – emergency services
Historically, oil refineries and producers have used flares or vapor combustors for emission controls and tail gas treatment.
Various combustion and oxidizer technologies for effective, efficient destruction of the air toxins from petroleum refineries can be deployed targeting the areas of:
Drum Filling, Stock Tank Vents, Reactor Tank Vents
Amine Tailgas Treatment
Nitrogen Rejection Stages and Other Evaporation Processes
Compressor Stations
Flare Efficiency Improvements and Replacements
Well Completions
Application Focus Areas
Hybrid Equipment Design Considerations
Gas stream constituents beyond conventional VOC/HAP compounds. For example – H2S, dioxins, other halogenated compounds
Specialized metallurgy and acid resistant coating features for corrosion resistance/longevity
Dew-point controls such as inlet preheating, outlet temperature targeting, or external insulation and cladding (hot wall) designs may be required
Staged combustion for selective treatment of select compounds
Integrated systems combining thermal oxidation, acid scrubbing, and SCR polishing beds
Combined VOC-CPS systems
Secondary heat recovery for process energy optimization
ACID GAS REMAVAL
• Amine treating• Benfield process• PSA unit• Others
CONDENSATE AND WATER
REMOVAL SULFUR UNIT• Claus process
TAIL GAS TREATING• Scot process• Clauspol process• Others
Raw
gas
Condensate to an oil refinery
Gas wells
Tail
Gas
Off gas to
incinerator
Wastewater
Elemental Sulfur
Mercury Removal • Mol sieves• Activated carbon
SWEETENING UNITS• Merox process• Sulfrex process• Mol sieves
DEHYDRATION• Glycol unit• PSA unit
NITROGEN REJECTION
• Cryogenic process• Absorption processes
Nitrogen rich gas
LNG RECOVERY
• Turbo-expander and demethanizer
• Absorption (in older plant)
To sales gas pipeline
LNG
FRACTIONATION TRAIN• Deethanizer• Depropanizer• Debutanizer
EthanePropaneButanesPentanes +
Emission Control
Technologies
RTO
DFTO
CPS
Tank
s
Load
ing
Emission Controls for Process Areas
Micro Gas Turbine (MGT) - Compact Power System (CPS)
CPS (Micro Gas Turbine) provides reliable power using unprocessed wellhead gas to generate continuous power.
Upstream
At upstream sites where gas is being flared, CPS power is a great fit. For off grid sites, it’s the answer that can pay for itself the minute you start it up using flare gas or unprocessed site gas.
The CPS delivers flexible, reliable, high-availability, redundant modular power when and where you need it.
Storage/Transmission
CPS will support the continuous long term losses of natural gas storage and transmission systems.
MGT – CPS , a broad range of fuels possible
gaseous
liquidsolid
Wood gas
Sewage gas
Lean gas
Biogas
Natural gas
Landfill gas
Diesel
Ethanol
Butane
Hydrogen
Biomass
Micro Gas Turbine (MGT) - Compact Power System (CPS)
High concentration methane laden air to be used as fuel
Lower concentration methane Mixed with fuel in combustion chamber
MGT-CPS System Design Example
System design Compact Power System
Intake air filter
RecuperatorTurbineGenerator
Compressor
Auxiliary systems
Gas fuel booster
Combustion chamber
MGT-CPS Technical Specifications
Electrical output (net): 100 kW
Thermal output: 716,000 – 1,774,240 Btu/hr
Outlet temperature: 520 - 1200 °F
Generated heat completely in clean gas
Minimum space requirements
Simple and easy installation
MGT-CPS Turbomachinery Specifications
Simple system design
One rotating element
No oscillating elements
Minimal sound emissions: ~ 65dB in 1m distance
Long maintenance intervals: ~ 6,000 – 8,000 hrs
Minimal maintenance costs: ~ $0.75 - $2.25/hr
3000 ppmv H2S with recuperator, 5% by volume H2S without recuperator
100 mg/ncm per hour siloxane without recuperator
MGT-CPS Emission Specifications
Broad range of fuels possible
Operation across a wide calorific value range possible
Minimum harmful emissions
NOx < 15 ppm
CO < 15 ppm
18 Vol.-% residual oxygen at full load
No exhaust gas purificationnecessary
CPS – VOC to Power
Compression of VOC-loaded process air
Higher efficiency through internal preheating with recuperator
VOC purification within combustion chamber of gas turbine
Decompression of combustion gas through turbine
Turbine drives generator for production of electricity
