Vapour Recovery SolutionsMethane is excluded (difficult to recover, only destruction possible by combustion with secondary emissions) ... •Determination of the pressure drop of the

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Vapour Recovery Solutions

for petroleum industry

CARBOVAC © Copyright – All rights reserved

- October 2015 -

www.carbovac.comCARBOVAC © Copyright – All rights reserved

1. Introduction

2. Why installing a VRU?

3. Carbovac « dry technology » VRU

4. VRU implementation

5. Some references

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ALMA and CARBOVAC, as part of the holding group S.A. LE GARREC & Cie,

have been working together for 10 years now, developing their respective, but

complementary, business areas.

Transport Metering

Solutions

Terminal

Metering Solutions

Vapour Recovery

Solutions

Global Maintenance

Services + Expertise

1. IntroductionPresentation


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Supporting clients worldwide | Servicing downstream activities

Oil companies

BP, Shell, Total,

ExxonMobil,

Lukoil, IOCL,

Saudi Aramco…Storage &

Trading

companies

Vopak, Oiltanking,

Eurotank, VTTI,

Rubis…

Engineering

companies

Technip, Samsung,

Petrofac, Jacobs,

DPL…

1. IntroductionOur clients


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CARBOVAC has three representations: France (HQ), Russia and Middle-East

And has managed more than 80 projects …

… in more than 25 countries, since 2005.

1. IntroductionCarbovac Worldwide


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1. IntroductionReference letters & certificates



1. Introduction




5. Some references

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To reduce VOC impact on environment.

To protect human health (drivers, operators… neighborhood).

To reduce the pollution of the troposphere: ozone creation at ground level.

To increase the safety on the terminal.

To recover a valuable product.

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2. Why installing a VRU?Reasons


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2. Why installing a VRU?Legislation

1980: 1st legislation in USA “Clean air Act”

Emission limit: 80 g/m3 loaded----------

Improvement in the technology has led to more stringent legislation

Emission limit: 35 g/m3 loaded (general case) and 10 to 6 g/m3 loaded (loacally)

EPA: 35 g/m3 of gasoline loaded (many states ask lower emissions)----------

1994: European Directive EC94/63

Application for fuels with RVP > 276 mbar 35 g/m3 of air emitted to atmosphere----------

1999: Gothenburg Protocol

Emission limit: 10 g/m3 of air emitted to atmosphere----------

TA-Luft 01 (Germany) / LRV (Switzerland) / NER (Netherlands)

If emissions mass flow is > 3 kg/m3 50 mg/m3 for HC and 1 mg/m3 for benzene

Methane is excluded (difficult to recover, only destruction possible by combustion with secondary emissions)


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• Energy consumption increases with lower emission requirements !

• Basis 1200 g/m3 HC in the inlet to the VRU

• Energy consumption difference between 1 g/m3 and 0.15 g/m3 is more than x 2

• Extra 0,5 gram recovered costs 0.1 kWh or 200 kWh per kg

• To make this energy we need to burn 75 x the equivalent as fuel

Emissions limit

(g/m3)

35

(EU)20

10

(France)

1

(Optimum)

0.15

(Germany/Holland)

Energy required

(kWh/m3)0.08 0.09 0.09 0.1 0.2

Recovery

(g/m3)1179 1188 1194 1194.4 1199.916

Recovery delta

(g)9 6 5.4 0.5

2. Why installing a VRU?Recuperation vs. energy consumption


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2. Why installing a VRU?Emission measurement

In USA: emissions measured as a function of loaded gasoline

Complex system required for EPA compliance test

Measurement of the entire volume during 6 hours

Measurement of the average hydrocarbon concentration

Measurement of the total volume of gasoline loaded during 6 hours

Calculation of the mass emitted/litre loaded averaged over 6 hours

Continuous measuring system with complex and expensive devices:

CIM : Control Inlet Monitoring

CEM : Continuous Emissions Monitoring

In Europe: emissions measured as real emission concentration

Simple emissions monitor in the outlet line (infra-red detector) or analyzer with

separation of methane and non methane components.


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It is very difficult to have an accurate measurement of the recovered product:

the recuperation is only a small percentage of the absorbent circulation used to reabsorb the vapours

The existing meters accuracy is not sufficient (flow, level…)

Agreement between tax authorities and oil companies are reached to implement a fixed rate of recovery:

this rate is around 1.4 and 1.5 liter per m3 of gasoline entering the terminal

1.5 liter/m3 of gasoline loaded is exempted from taxes

(in most European countries)

2. Why installing a VRU?Recovery measurement


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• Hypotheses:

Vapour inlet concentration: 40% HC when vapours return from service station

Average outlet concentration: 2 g / Nm3

Average MW: 65 Gasoline vapours

• Calculation:

Mass of HC at inlet per m3:

Mass of HC recovered: 1158.7 g/m3 of inlet vapour

• The recovery rate:

The effective recovery rate is: 1.49 L/m3 of inlet vapour

Vapour recovery rate: 99.9%

2. Why installing a VRU?Recovery calculation

0.4 x 65= 1160.7 g/m3

22.4 x 10-3



1. Introduction




5. Some references

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Step 1 Adsorption of the hydrocarbons on activated carbon

Step 2 Regeneration of the carbon by means of vacuum = desorption

Step 3 Re-absorption of the hydrocarbons in a liquid product

3. Carbovac dry technology VRUAdsorption / Desorption / (re)Absorption


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Activated carbon most used adsorbent in the World

Obtained through carbonization and activation of natural products

The adsorption capacity depends on:

Specific internal surface, up to 1800 m2/g

Pore size and distribution

Base material properties / hardness

3. Carbovac dry technology VRUActivated carbon


http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=iwEQb3UQc_mchM&tbnid=cJCxBtuMg32YZM:&ved=0CAgQjRwwAA&url=http://www.docstoc.com/docs/51439041/The-Activated-Carbon-Book&ei=KgWJUbWLLcTD0QX-yYH4CQ&psig=AFQjCNE7KU-8dgYKJm3DRcg3e32Y9mHDfA&ust=1368020650779842

http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=iwEQb3UQc_mchM&tbnid=cJCxBtuMg32YZM:&ved=0CAgQjRwwAA&url=http://www.docstoc.com/docs/51439041/The-Activated-Carbon-Book&ei=KgWJUbWLLcTD0QX-yYH4CQ&psig=AFQjCNE7KU-8dgYKJm3DRcg3e32Y9mHDfA&ust=1368020650779842

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HC molecules

Air

To atmosphere

with emission

monitoring

Purge

Inlet vapours

HC molecules Air

3. Carbovac dry technology VRUActivated carbon filter


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• The emission level of the system depends on:

Carbon type / Vacuum Level / Amount of purge air

30 mbar for 50 to 100 mg/m3

100 mbar for 1 to 5 g/m3

• The saturation rate of the “outlet” layer of carbon

must always stay low

• The transition zone of the carbon bed provides a

buffer for variations in flow rate and concentration

• The mass transfer zone removes the bulk of the

hydrocarbons

3. Carbovac dry technology VRUActivated carbon


Mass transfer zone

Purge air during

vacuum regeneration

Vapour mixture inlet

Transition zone

Emission zone

Clean air outlet

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Gas inlet Gas Outlet

Cooling liquid

Gear oil

3. Carbovac dry technology VRUDry screw technology pumps


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DRY SCREW VACUUM PUMP

The dry screw technology permits to reduce the system to the essential components

required for optimistically functioning.

The vacuum pumps used in the Carbovac technology are totally dry and cause no pollution of the recovered products,

eliminating all corrosion and abrasion problems related to “wet” systems.

The absence of glycol or any other seal fluids (compatibility problem) and a

deep vacuum level offers the possibility to treat a vast range of products:

3. Carbovac dry technology VRUDry screw technology pumps

Methanol

EthanolETBE MTBE Benzene Crude oil Gasoline Naphtha …


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1510

Typical pump speed curve

Cycle time (in minutes)

Pressure in the adsorber

(in mbar)

500

1000

100Air Purge

3. Carbovac dry technology VRUDesorption curve


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3. Carbovac dry technology VRURe-absorption column


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Same unit before and after we changed the vacuum system …

Liquid ring vacuum system Dry screw vacuum system

3. Carbovac dry technology VRULiquid ring pumps vs. Dry screw pumps


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3. Carbovac dry technology VRUMajor advantages of Carbovac VRUs

OPTIMIZED / HIGHER LIFETIME OF VACUUM PUMPS

• Robust design

• No internal touching parts, no internal wear

• Overhaul of the pumps only after more than 40,000 operating hours

HIGHER LIFETIME OF ACTIVATED CARBON

• Reverse flow (no dusting)

• Pressure controlled desorption process

• Optimized pore size distribution

• Low pressure drop

LOWER ENERGY CONSUMPTION < 0.12 kwh/m3 of vapours treated

• Regeneration energy proportional to the mass of hydrocarbons absorbed

• Pumps equipped with VFDs to adapt the energy consumption to the mass of HC to be treated

LOWER MAINTENANCE COSTS

• No corrosion and abrasion (absence of glycol)

• Very simple process: system optimized and limited to its mere elements

• Selection of high quality equipment



1. Introduction




5. Some references

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Important data for VRU sizing (trucks and railcars loading):

Q(i)

PEAK FLOW RATE Maximum flow rate generated by the loading facility

(i.e.: max number of loading points connected simultaneously x flow rate per point)

• Determination of the pressure drop of the VRU and the vapour collecting system

• Determination of the lines size, carbon bed diameters

• All vapours have to pass through the VRU. Influence on price is small.

Q(c)

MAX. THROUGHPUT PER CYCLE Max. vapour amount generated in 15 min (for truck loading)

(i.e.: number of loading bays x volume loaded per cycle or vessel capacity)

• Determination of the activated carbon volume in the beds

• For continuous throughputs the cycle time is usually fixed at 12 minutes

Q(4)

MAX. THROUGHPUT IN 4 HOURS Evaluation of the intensity of the activity during a “peak” period

• Determination of the required vacuum capacity

• Determination of the re-absorber and absorbents circulation pumps

Q(d)MAX. DAILY THROUGHPUT Evaluation of the loading profile per day

• Adjustment of the vacuum capacity

4. VRU implementationVRU base design data


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Vapour treatment, at the terminal:

The truck vapour return arm is connected to the VRU directly.

Balancing System: vapours are balanced with the tank and vapours from the tank (filling and breathing) go to the VRU.

4. VRU implementationTruck / Railcar loading facilities


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BOTTOM LOADING FOR TRUCKS



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TOP LOADING FOR TRUCKS



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3 m

Storage tank piquage on one

side, must see 3 meters between

the two pipes.

Also, it is recommended to have

an alternative absorbent product

storage tank line (in order to

operate maintenance operations

on the storage tanks without

puting the VRU off.

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4. VRU implementationMarine loading operations


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Marine loading arm with vapour connection


Hoses for vapour connection on ship


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Berth connection:

Vapour line with shut down valve and

detonation arrestor.



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• Hydrocarbon vapours are heavier than air and form a layer on top of the product.

• This layer prevents further evaporation.

Product

loading arm

Vapour return

line Product and vapour

headers on board

Vapours from

Previous Cargo

Layer of new

Vapours



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Product

loading arm

Vapour return

lineProduct and vapour

headers on board

Layer of new

Vapours

• After 80% of the loading time, the new vapours start leaving the vessel.

• At the end of the loading operation, the relative saturation will reach approx. 80%.



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Product

unloading arm

Inert gas

Inert gas generator or

exhaust gasesProduct and vapour

headers on board

Vapour mixture from

previous cargo and

inert gas

• During unloading of the tanker, inert gas or exhaust vapour is injected into the tanker.

• The oxygen content is less than 5% by volume.

• Overall vapour concentration after unloading is relatively low.



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25%

5%

Loading Time in %

0% 80% 100%Vap

our

Con

cent

ratio

n in

% b

y

Vol

ume

Typical concentration profile for gasoline loading versus time



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Absorbent circulation:

Recovered Product Solutions:

• Return to loading Line

• Re-absorption in an other available light Product

• Liquefaction of the desorbed Vapour by Compression and Cooling



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4. VRU implementationVRU interface with the terminal


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4. VRU implementationPLC and MCC connections


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4. VRU implementationImplementation


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4. VRU implementationSafety

VRU are installed in environments containing liquid combustible and explosive gases

Risks of fire and explosions with toxic emissions

Preventive measures must be taken and risk analysis must be performed:

> HAZOP

> Explosion Protection Document

> SIL (Safety Integrity Level) risk assessment

EC declaration of conformity for the whole unit (§ 3.7.1.1)

Manufacturer assumes responsibility for compliance with the directive

Manufacturer should provide a conformity assessment of the whole assembly

Manufacturer provides clear instructions for assembly / installation / operation /

maintenance… in the operating manual.


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4. VRU implementationSafety

Some of the VRU safety features

The whole system is explosion

proof to 9 barg

All valves with limit switch

Gasoline pumps installed

below liquid level

High-high and low-low level

switches on the re-absorber

Temperature monitoring in the

activated carbon beds

Outlet temperature of the

vacuum pumps < 50°C

Detonation arrestor at the inlet

of the VRU

Two positive closing valves in

each gasoline circulation line



1. Introduction




5. Some references

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Client: IOCL

Location: Jasidih

Type: Trucks loading operations

Products: Motor Spirit

Capacity: 480 m3 / h

Emissions: 10 g / m3

5. Some references


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Client: IOCL

Location: Chitoor





5. Some references


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Client: HPCL

Location: Vishakhaptnam





5. Some references


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Thank you for your attention.

We are at your disposal for any further information.


Your CARBOVAC contacts

[email protected]

[email protected]

4 A boulevard de la Gare, Porte 1

94470 BOISSY SAINT LEGER

France

Your MP ENGINEERING contacts:

[email protected]

[email protected]

1003/1004, Lodha Supremus III

I Think Techno Campus, Off JVLR

Kanjurmarg (E), MUMBAI – 400 042

INDIA

Documents

Vapour Recovery SolutionsMethane is excluded (difficult to recover, only destruction possible by combustion with secondary emissions) ... •Determination of the pressure drop of the