English VRU Evolution

7/27/2019 English VRU Evolution

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PresentationofVapourRecoverySystems

ByTiesMulderProcessandImplementationConsultant

June2005


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Presentation VRU - June 20052/64

History of Vapour Recovery & Technologies developed

Worldwide Emission legislation

Closed circuit European recovery system for truck

Implementation of Vapour Recovery systems on terminals

Recovery product, rate, tax refund

Safety aspects, ATEX, SIL


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First systems = thermal destruction (air assisted flare)

FirstSystems

Energy consumption : high

Destruction : 97 % efficiency

Maintenance : low


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First recovery systems installed in the United States

Flare gas recovery using compression and cooling

FirstRecoverySystems

Separator

Cooler

Compressor

Vapour Inlet

Outlet to Flare

Recovered Liquid

Energy consumption : highEmissions : 80 % efficiency

Maintenance : medium


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Early 70s : first activated carbon / vacuum system(Rheem Brothers - USA)

Adsorptionsystems

Energy consumption : lowEmissions : 80 % efficiency

Maintenance : high

Activated Carbon Filters

Re-absorber

Vacuum Pump

Glycol Separator

Gasoline return

Gasoline supply

Top product vented to atmosphere

Vapour Inlet

Clean air outlet


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Deep cooling systems @ -35C (Edwards - USA)

Deepcoolingsystems

Vapour Inlet

De-icingheater

Clean Air Outlet

ChillerCooling

Elements

Pure Product

Energy consumption : highEmissions : < 80 g/m3

Maintenance : very high


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First patent by McGill in 1978 based on Rheem brothers with

recycling of absorber top

EvolutionofAdsorptionsystems...

Vacuum Pump

Activated Carbon Filters

Re-absorber

Glycol Separator

Gasoline return

Gasoline supply

Top product returned to inlet

Vapour Inlet

Clean air outlet

Energy consumption : lowEmissions : 35 g/m3

Maintenance : high

Replacement of deep cooling by

adsorption systems in USA


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Since 1980 s : Activated carbon / Liquid ring vacuum systems

as known today

EvolutionofAdsorptionsystems

Adsorbers

Clean Air Outlet

Vapour Inlet

Purge

Vacuum Pump

Absorber

Absorbents

SeparatorCooler

EG

Energy consumption : highEmissions : < 35 g/m3

Maintenance : high

Suppliers patents in several

European countries


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Fear of patent infringement Development of alternativesolutions in Europe Cold absorption system : Coolsorption / Kappagi

Membrane system : Vaconocore / Preussag

Activated carbon + cold re-absorption : Kaldair

Cogeneration : Petro-Plus (Qlear) / Schwelm Absorption / Adsorption / Absorption : Mc Gill

Introduction by Germany and Switzerland of extremely low

emissions

Development of complex hydride systems Cold adsorption + Steam regenerated carbon : Coolsorption

Membrane + Vacuum regenerated carbon : Vaconocore

LRVP + Roots blowers : J ohn Zink

Thermal balance adsorption : Ties Mulder

Alternativesolutions


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Coldabsorptionsystem

VapourInlet

Clean

AirOutlet

Absorbents Inlet

Absorbents Return

Reabsorber

Splitter

Chiller

HeaterAbsorber

Cooler

Nonane Circuit


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Membranesystem

Evnt. 2 nd Stage

Membrane

Vacuum Pump

Separator

Cooler

Compressor

Vapour Inlet

Clean Air Outlet


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Clean Air Outlet

Vac pump

Separator

Heat exchanger

Absorber

Adsorpt ion

Filters

Vapour

Inlet

Condenser

Absorbents

ThermalBalanceAdsorption


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Latestdevelopments

Latest developments : Dry screw pumps systems by CarboVac

Re-Absorber Absorbants CirculationDry Screw

Vacuum Pump

Inlet

Activated Carbon Beds

Outlet

Energy consumption : low

Emissions : < 10 g/m3

Maintenance : low

Replacement of glycol systems

by dry systems


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Activated carbon = highly favourite solution since 1980

More than 90% of all recovery systems in the world

In the USA, destruction by combustion still represents 40%

But restrictions are coming due to : New CO2 limitation policies (Kyoto protocol)

Adoption by Petroleum Companies (BP, Shell) of internal greenpolicies (engagement to reduce 50% of CO2 emissions)

Replacement of destruction by recovery solutions

Actualsituation


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VOCeffects

VOC emissions impact on the

human health (carcinogenic components)

pollution of the troposphere (ozone creation)

In Europe, 17 million tons /year of VOC released in the atmosphere

in 1990.

Implementation of legislation and several regulationsin particular on emissions in hydrocarbon storage and transfer terminals


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In the 80ies, 1st legislation : Clean Air Act on VOC

Emission limit : 80 g/m3

loaded

In 1982, emission limit reduced to 35 g/m3 loaded (general case)and locally to 10 or 6 g/m3 loaded.

Complex control measurement method to prove compliance.

First with balloons and mass balance

Later by using CIM and CEM

USA1stCleanAirAct


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European Directive EC94/63

35 g / m3 of air emitted (often 10 g / m3 is desired - Oslo protocol)

3 phases :

1998 : a VRU for all new terminals + terminal > 150 000 tons/year of gasoline

2001 : a VRU for terminal > 25 000 tons/year

2004 : a VRU for terminal > 10 000 tons/year

Application for fuels with RVP > 276 mbar

TA-Luft 01 in Germany, LRV in Switzerland

If emission mass flow > 3 kg/h :

150 mg HC/ m3 of air emitted (20. BImSchG)

5 mg / m3 for benzene

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

Europeanlegislation


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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 hrs

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

Continuous measuring system with complex and expensivedevices 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)

Emissioncontrol


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Energyconsumptionversusemissions

0

0,05

0,1

0,15

0,2

0,25

0,3

0510152025303540

Emission l imit (g/m3)

Energyconsumptio

n(kWh/m3treated)

TA-Luft Emissions

EU Emissions

Israeli Emissions

N.B : Data based on LRVP Systems


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Recoverychain

Refinery

Service-station

Terminal

Car f illing

Losses : 0,1 kg/m3Emission reduction measures up to 99%

Losses : 1 kg/m3Emission reduction measures up to 90%

Losses : 1 kg/m3

Emission reduction measures up to 99%

Losses : 1 kg/m3Emission reduction measures up to 99,99 %

Total efficiency of the recovery chain is never better

than the weakest link


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Stage 1 :

Recovery of the vapour from the service-station ground tank tothe truck

and Recovery of the vapours from truck loading on theterminal.

Stage 2 :

Recovery of the vapour from the car fuel tank to the groundtank

Not ratified by some countries in Europe due to lack ofefficiency

ECDirective94/63Stage1and2forfueldistribution...


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To VRU

At the Service Station

At the Terminal

Stage 2

Stage 1

Car

ECDirective94/63Stage1and2forfueldistribution


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Service-station :

Pressure / vacuum relief valve to be installed in the ground tank

vent line

Vapour return connection to be installed on the tank vent line

Truck

Truck modified to bottom loading

Overfill protection

All compartments connected to a central vapour collecting lineequipped with 4" API coupler with check valve.

ImplementationofStage1...


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Terminal :

Modification from top loading to bottom loading

Installation of a Vapour Recovery System

Vapour collecting line to the Vapour Recovery System

Use of a dedicated gasoline tank for recovered product Installation of floating roof in fixed roof type storage tanks or

complete balancing of the vapour space to the VRU

Integration of a new process in the terminal and adaptation of

operating and safety procedures

ImplementationofStage1


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Stage1examplewithfixedrooftanks

PT

Ventilator

Vapour Recovery Unit

Tanks

Detonation Arrestor

Pressure Vacuum

Valve

P

LoadingOperation

Vapours

Emitted

Absorbents


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ImplementationofStage2

Cars : Installation of small canister in gasoline cars (91/441/CEE)

Installation of large canister resisted by automobile industry

Service-station Installation of vapour balance system between car fuel tank and

ground tank

For every litre of gasoline filled into the tank, one litre of vapouris returned to the ground tank

Efficiency not demonstrated Solutions not promoted byOil Companies

T i l iti


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During the loading of gasoline and diesel in trucks, the concentration of the vapours may vary

between 0 to 50 % Vol. depending of :

the nature of the products previously loaded.

the loading station (equipped or not acc. to Stage 1 and 2 of the EC Directive)

Theses hydrocarbons are generally composed of :

C1 0 - 0.2 % Vol.

C2 0 - 0.45

C3 1.5 - 3.8

C4 37 - 50

C5 22 - 43

C6 8 - 12

C7++ 1.7 - 5.4

Benzene 0.26 - 2.6

Toluene 0.36 - 1.8

C4 and C5 represent around 90% of the

hydrocarbons at the inlet vapours

Typicalvapour composition(Truckloading)


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Important data for VRU sizing for truck and rail car loading:

Peak flow rate

= max. 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 diameter

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

Max. throughput per cycle

= max. vapour amount generated in 15 minutes (for truck loading)(i.e number of loading bays x volume loaded per cycle or vessel capacity)For continuous throughputs the cycle time is usually fixed at 12 minutes Determination of the activated carbon volume in the beds

Max. throughput per 4 hour period

= evaluation of the intensity of the activities at the terminal during the busiest period Determination of the required vacuum capacity Determination of the re-absorber and absorbents circulation pumps

Max. daily throughput= evaluation of the loading profile per day Adjustment of the vacuum capacity

HowtosizeaVRU


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Typicalcompartmenttruck

Vapour Collector connected to each compartment

4 API Vapour Coupler

Compartment cover serves as

pressure safety relief valve


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Vapour Line

Pressure Vacuum

Safety Valve

Detonation Arrestor

Level Switch

Drain valve

Vapour arm

Position Switch

VRU

VapourCollectingSystemTruckloadingApplication


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Vapour Collecting System


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Vapour CollectingSystemTruckloadingApplication


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AbsorbentCirculationSystem

RU

P601

P501


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Civilworks


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Civilworks


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Vapour

Recovery

Unit

CablingVapour pipe work

Nitrogen

Water

Gasoline

in

out

Foundation drainage

Modem line

Open/close Emergency VentEmergency vent valve positionPowerInput (start/stop truck loading)Gasoline pump start /stop/running signalSite ESD signalVRU runningVRU alarm

Air Air Compressor(instrument quality)

Control buildingmodem

Operations Room PC &interactive keyboard

Cabling

Electricalworks:communicationsignals

El l k


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Hazardous AreaSafe Area

Control Room

Cables

Electricalworks

El i l bl h i


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Electricalcablesschematics

Electrical Room

VRU

J

PLC

PC

Power feed cable

PC Monitoring

Power cables to Motors

Instrument cables

Customer signals

O ti l ti h ti


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Power Cabinet

Control Cabinet

CONTROL ROOM

VRU SUPPLIER

Instrumentations

Modem

LOCAL

REPRESENTATIVE

Modem

Modem

Operationalconnectionschematic

E-Motors

VRU L ti


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Important parameters :

Pressure drop of the vapour line

- EU Directive : 55 mbar @ truck coupler

- Typical P of a 4" API vapour coupler : 3 mbar

- Typical P of a vapour arm + hose : 12 mbar

- Typical P of an anti-deto FA : 5 mbar

- Typical P of a VRU : 25 mbar

Max available P of vapour l ine : 10 mbar

Pressure drop of the gasoline circulation lines

- Supply pump : usually close to the tank or in the pump station

- Return pump : usually on the VRU foundation

Accessibility for maintenance works

Electrical cable routing

VRULocation


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Quality of the recovered product


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QualityoftherecoveredproductGasolineApplication

Recovered product mostly C4 and C5.

Tendency to increase the absorbent s RVP

Tendency to increase the absorbent s temperature

Selection of a absorbent tank with a reasonable throughput

Typical Recovered Product


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Hypotheses :

Vapour inlet concentration :

Average outlet concentration :Average MW :

40 % Volume

2g / Nm

-3

65 (Gasoline vapours)

Masse of hydrocarbons recovered 1159.5 g / m-3 of inlet vapour

The recovery rate :

The effective recovery rate is 1.49 litre per m3

Vapour recovery rate 99. 9 %.

Inlet vapour

Calculation :

0.4 x 65Mass of hydrocarbons at inlet per m-3 =

22.4 x 10 - 3= 1160,7 g / m-3

Masse of hydrocarbons in the outlet per m-3 inlet = 2 x (1 - 0.4) = 1.2 g / m-3

TypicalRecoveredProduct

Tax refund in Europe


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Tax refund inEurope

Recovered product not easily measured

Recovered product = only a small % of the return absorbent flow

Accuracy of the metering devices not sufficient

Agreement between tax authorities and oil companies to

implement a fixed rate equal to 1.4 to 1.5 litre per m3 of gasoline

entering the terminal

1.4 litre/ m3 of the gasoline throughput exempted from taxes


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VRU Safety


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VRUSafety

VRU are installed in environment containing combustible liquid and

explosive gases

Risks of fire and explosion with toxic emissions

Preventive measures and risk analysis have to be performed :

HAZOP

ATEX explosion protection document (EXDOC)

SIL safety integrity level risk assessment

ATEX Philosophy


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ATEXPhilosophy

Four possible types of equipment :

Assemblies Assemblies with fully specified configuration of parts

Assemblies with various configuration

Installations

Electrical equipment

VRU is an assembly with fully specified configuration of parts

( 3.7.1 of the ATEX guideline)

3.7.1Resume


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e u e

VRU = assembly of two different pieces of equipment :

Equipmentwith CE marking (ATEX) :

Manufacturer may presume conformity of these pieces

Equipmentwithout CE marking :

Manufacturer has to cover those parts with his own conformity

assessment of the whole assembly

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 wholeassembly

Manufacturer provides clear instructions for assembly / installation /operation / maintenance in the operating manual.

VRUSafetyfeatures


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Some of the VRU safety features

The whole system is explosion pressure proof to 9 barg

All valves with open / closed limit switches

Gasoline pumps installed below liquid level

High and low level switches on the re-absorber column Temperature monitoring in the activated carbon beds

Outlet temperature of the vacuum pump < 50C

Detonation arrestor in the inlet Two positive closing valves in each gasoline circulation line

etc...

f y f

VRUExplosionproofdesign


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p p f g

Detonationarrestorininletlineand


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Valveswithlimitswitches

G li t


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Gasolinereturnpump

L l t l d it h


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Levelcontrolandswitches

Temperaturesensorsandindicators

i b b d


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incarbonbed

DryVacuumPump

Temperature Monitoring


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TemperatureMonitoring

Twosafetyvalves

in each gasoline circulation line


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ineachgasolinecirculationline

SafetyIntegrityLevel...EN 61508 5 2001


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Safety integrity level risk assessment of a dry screw VRS :

4 elements to be assessed

Consequence of the risk (C)

Minor Injury

Serious Injury or permanent incapacity

Fatality or catastrophic incapacity

Frequency of exposure (F)

Rare to more often (0 - 10%)

Frequent to permanent (10 - 100%)

EN615085.2001

SafetyIntegrityLevelEN 615085 2001


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Possibility of avoidance of a hazardous event (P)

Possible under certain conditions

Almost impossible

Demand rate (W)

High W3Low W2

Very low W1

Result of SIL risk assessment is Category a

No special safety requirements

EN615085.2001

Result of SIL risk assessment


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Minor Injury 10

C4

>1

C3

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