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Vapour Control
on Crude Oil
Loading
Challenges & Technological Developments
Marco Puglisi
Manager Process and
Product Development
©2013 John Zink Company, LLC 2 CONFIDENTIAL AND PROPRIETARY
Notice
► The information contained in these materials is for informational purposes only and is provided “AS IS”, without warranties of any kind. Your use of the information contained herein is at your sole risk. We expressly disclaim any express or implied representations, warranties or guaranties, including without limitation, the implied warranties of merchantability and fitness for a particular purpose. We will have absolutely no liability (whether direct, indirect or consequential) in connection with these materials (and/or the information contained therein) including without limitation, any liability for damage to person or property. We also reserve the right the make subsequent changes to the materials without prior notice. For purposes of this notification, “We” includes John Zink Company, LLC and its affiliates and their respective employees, partners, principles, agents and representatives, and any third-party providers or sources of information or data.
► JOHN ZINK HAMWORTHY COMBUSTION is a trade name of John Zink Company, LLC. JOHN ZINK and JZ are registered trademarks of John Zink Company, LLC in the United States and various other countries. HAMWORTHY COMBUSTION is a registered trademark of Hamworthy Combustion Engineering, Inc. in the U.K. and various other countries. ADCON, ADAB, and ACE are trademarks of John Zink Company, LLC.
©2013 John Zink Company, LLC 3 CONFIDENTIAL AND PROPRIETARY
Petroleum Production, Refining and
Distribution Systems
Crude Storage Tanks
Crude Tanks
Terminal Tanks
Bulk Plant Tanks
Commercial Storage Tanks
Product Tanks
Service Stations
► Sources of organic eVaporative emissions are indicated by vertical arrows.
©2013 John Zink Company, LLC 4 CONFIDENTIAL AND PROPRIETARY
Distribution Facilities
Vapour Control Applications
►Applications:
►Storage Tank Vents
►Truck Loading
►Railcar Loading
►Ship and Barge
Loading
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©2013 John Zink Company, LLC 5 CONFIDENTIAL AND PROPRIETARY
Crude Oil Transportation
Oil Transportation and Major Chokepoints ► From storage and loading operations roughly 3.2 billion cubic
meters of air/hydrocarbon Vapours (VOC) are generated per
year, equivalent to 5.2 million cubic meters of liquid crude
oil if recovered.
► In 2005 2.4 billion tons of crude oil was moved by ship,
which is roughly 62% of all crude oil produced
©2013 John Zink Company, LLC 6 CONFIDENTIAL AND PROPRIETARY
Example: Stabilised crude from Middle East
Composition Of Crude Oil Vapour
VOL% WT%
AIR/INERT 68.0 51.7
METHANE 0.3 0.1
ETHANE 0.3 0.2
PROPANE 7.9 8.7
I-BUTANE 2.2 3.2
n-BUTANE 10.2 14.9
I-PENTANE 2.9 5.3
n-PENTANE 4.5 8.2
HEXANE+ 3.7 7.7
100.0 100.0
1 m3 of such Vapours do contain 1.2 liters of liquid VOC !
©2013 John Zink Company, LLC 7 CONFIDENTIAL AND PROPRIETARY
Economic Opportunity
Environmental Concerns
What are VOCs?
► Volatile Organic Compounds (VOCs) are organic compounds that are involved in atmospheric photochemical reaction.
Why Vapour Control?
► VOCs form Ozone which is primary constituent in smog
► Ozone has adverse effects on human health and vegetation. ► Crude oil price at 120 $/bbl
► Recovery is also an attractive economic opportunity
► For every 1,000 m3 of crude oil loaded into a ship there is the potential to recover the equivalent of $700
©2013 John Zink Company, LLC 8 CONFIDENTIAL AND PROPRIETARY
What Technology To Use?
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Vapour RECOVERY
Vapour COMBUSTION
Recognized Technologies
©2013 John Zink Company, LLC 9 CONFIDENTIAL AND PROPRIETARY
Types of Vapour Recovery
►Compression Absorption
►Lean Oil Absorption
►Refrigeration (Condensation)
►Membrane
►Carbon Adsorption/Absorption (ADAB™/ ADCON™)
►BDT : Best Demonstrated Technology
►ACE™ (Adsorption + Conversion + Energy)
► New technological development, Patent Pending
©2013 John Zink Company, LLC 10 CONFIDENTIAL AND PROPRIETARY
INLET
Vapour
VACUUM
PUMP
ABSORBER
LEAN GASOLINE
ABSORBENT
RICH
GASOLINE
ABSORBENT
AIR VENT
PUMP
A B
RECYCLE
ADSORBER ADSORBER
PUMP
Vapour Recovery System
Carbon Adsorption-Absorption (ADAB™)
©2013 John Zink Company, LLC 11 CONFIDENTIAL AND PROPRIETARY
Vapour Recovery System
Carbon Adsorption-Absorption (ADAB™)
Advantages:
► Worldwide acceptance as the standard for gasoline Vapour recovery
► Many years of proven and favorable experience
► Highest emission control efficiency, meets almost all known emission standards
► Lowest Vapour recovery capital and operating costs
► Relatively simple to operate and maintain; no special expertise required
► Near ambient pressure and temperature operation, no Vapour holder, no refrigeration
► Electricity is only utility
Disadvantages:
► Measurement of recovered product requires special equipment
► Does not recover the light ends (methane, ethane)
©2013 John Zink Company, LLC 12 CONFIDENTIAL AND PROPRIETARY
Crude Oil Ship Loading – UK 16,000 m3/hr
Marine VRU, UK
©2013 John Zink Company, LLC 13 CONFIDENTIAL AND PROPRIETARY
Marine VRU, UK
©2013 John Zink Company, LLC 14 CONFIDENTIAL AND PROPRIETARY
Crude Oil Ship Loading – Sweden 6,000 m3/hr
Marine VRU, Sweden
©2013 John Zink Company, LLC 15 CONFIDENTIAL AND PROPRIETARY
Marine VRU, Sweden
©2013 John Zink Company, LLC 16 CONFIDENTIAL AND PROPRIETARY
INLET
Vapour
VACUUM
PUMP
AIR VENT
PUMP
A B
RECYCLE ADSORBER ADSORBER
COMPRESSOR
RECEIVER
RECOVERED
PRODUCT
Vapour Recovery System
Carbon Adsorption-Condensation
(ADCON™)
©2013 John Zink Company, LLC 17 CONFIDENTIAL AND PROPRIETARY
Vapour Recovery System
Carbon Adsorption-Condensation
(ADCON™)
Advantages:
► Like ADAB™, can be designed to meet almost all known emission standards
► No Vapour holder required
► Only electricity required to operate
► Direct measurement of recovered product
Disadvantages (relative to ADAB™):
► Higher capital and operating costs
► More complex design requiring higher maintenance cost
► Does not recover the light ends (methane, ethane)
©2013 John Zink Company, LLC 18 CONFIDENTIAL AND PROPRIETARY
Vapour Recovery System
ACE™ (Adsorption + Conversion + Energy)
ELECTRIC
POWER
INLET
Vapour
VACUUM
PUMP
AIR VENT
PUMP
A B
RECYCLE ADSORBER ADSORBER
COMPRESSOR
RECEIVER
RECOVERED
PRODUCT
STEAM
BOILER GENERATOR
(Patent Pending)
©2013 John Zink Company, LLC 19 CONFIDENTIAL AND PROPRIETARY
Adsorption + Conversion + Energy (Patent Pending)
ACE™
The idea of this new technological development in Vapour Control is
born combining the synergies and experiences of John Zink and
Hamworthy Combustion
Over 30 years’ experience in
Vapour Control
► More than 1600 systems supplied
worldwide
Over 40 years’ experience in
Marine Combustion Equipment
► Nearly 60 installations in
FPSO/FSO since 1991
©2013 John Zink Company, LLC 20 CONFIDENTIAL AND PROPRIETARY
Process Sketch Summary
ACE™
LIQUID VOC
STORAGE TANK
WEAK GAS
(INERT GAS,
METHANE
AND SOME
ETHANE)
VENT GAS FROM OIL STORAGE TANKS
(INERT GAS AND VOC VAPOURS)
STEAM TURBINE
DRIVEN
ELECTRICAL
GENERATOR
VOC
SEPARATION
EVAPORATOR
SEA
WATER IN
FRESH
WATER OUT
VOC
LIQUIFACTION
CONCENTRATED
VOC VAPOUR LIQUID VOC
BOILER
BRINE DISPOSAL
©2013 John Zink Company, LLC 21 CONFIDENTIAL AND PROPRIETARY
Utility Generation System When Loading
ACE™
BOILER, STEAM
TURBINE GENERATOR,
EVAPORATOR
CUSTODY TRANSFER
SYSTEM
SINGLE POINT MOORING
BUOY (SPM 1)
FUELLING AND VAPOUR
RETURN HOSES
SUBSEA HOSESOFFSHORE PIPELINES
VAPOUR FROM SPM 1
OIL TO SPM 2
OIL TO SPM 3
VAPOUR FROM SPM 2
VAPOUR FROM SPM 3
OIL TO SPM 1
MAIN OIL TERMINAL
SEAWATER SUPPLY
SEAWATER RETURN
FRESHWATER
OUTPUT
ELECTRICITY OUTPUT
OFFSHORE LOADING
RICH
GAS IN
WEAK GAS OUT
TO BOILER CARBON
ADSORPTION
SYSTEMGAS
BLOWER
LIQUID VOC
STORAGE
TANK
LIQUID VOC TO
BOILER
BRINE DISPOSAL
©2013 John Zink Company, LLC 22 CONFIDENTIAL AND PROPRIETARY
Utility Generation System When Not Loading
ACE™
BOILER, STEAM
TURBINE GENERATOR,
EVAPORATOR
CUSTODY TRANSFER
SYSTEM
SINGLE POINT MOORING
BUOY (SPM 1)
FUELLING AND VAPOUR
RETURN HOSES
SUBSEA HOSESOFFSHORE PIPELINES
MAIN OIL TERMINAL
SEAWATER SUPPLY
SEAWATER RETURN
FRESHWATER
OUTPUTELECTRICITY
EXPORTED
CLOSED
VALVE
CARBON
ADSORPTION
SYSTEMGAS
BLOWER
LIQUID VOC
STORAGE
TANK
LIQUID VOC TO
BOILER
BOILER, STEAM
TURBINE GENERATOR,
EVAPORATOR
CUSTODY TRANSFER
SYSTEM
SINGLE POINT MOORING
BUOY (SPM 1)
FUELLING AND VAPOUR
RETURN HOSES
SUBSEA HOSESOFFSHORE PIPELINES
MAIN OIL TERMINAL
SEAWATER SUPPLY
SEAWATER RETURN
FRESHWATER
OUTPUTELECTRICITY
EXPORTED
CLOSED
VALVE
CARBON
ADSORPTION
SYSTEMGAS
BLOWER
LIQUID VOC
STORAGE
TANK
LIQUID VOC TO
BOILER
BRINE DISPOSAL
©2013 John Zink Company, LLC 23 CONFIDENTIAL AND PROPRIETARY
Marine version, FPSO/FSO
ACE™
WEAK GAS
(INERT GAS, METHANE
AND SOME ETHANE)
VOC
SEPARATION
VOC
LIQUIFACTION
CONCENTRATED
VOC VAPOUR LIQUID VOC
LIQUID VOC
STORAGE TANK
ZERO VENTING
VENT HEADER
VENT RISER -
CLOSED
OIL LOADING
BOILER
FUEL GAS
(IF AVAILABLE)
FUEL
OIL
VENT
GAS
LIQUID VOC
RETURN TO
STORAGE TANK
©2013 John Zink Company, LLC 24 CONFIDENTIAL AND PROPRIETARY
Vapour Recovery System
Adsorption + Conversion + Energy
(ACE™)
It addresses new market requirements in Vapour control for large crude oil land based export facilities and marine production facilities
(FPSO and FSO)
Advantages and WHO shall be interested:
► It effectively addresses light ends VOC emission (methane, ethane): Terminals where strict environmental regulations apply on VOC emission
► It transforms a «waste» into high value outputs (steam, electric power, sweet water): Terminals/facilities not owning the crude stored and loaded; FPSO/FSO where steam and electric power is highly valuable
©2013 John Zink Company, LLC 25 CONFIDENTIAL AND PROPRIETARY
Cost/Revenues Analysis
The application: Land base facility, crude oil ship loading; 20,000 m3/h 50 million tons of crude per year
Summary of the ACE VRU cost:
► Estimated Installed power: 5500 kW
► Estimated Consumed power: 4200 kW
TOTAL EQUIPMENT COST (Ex-works): 25-30 M$
Summary of the Revenues:
► E-power production: 30 MW
► Revenues from net e-power export: ► 25,000 kW x 8,300 oper. h/year x 0,06 $/kWh = 12 M$
► 25,000 kW x 8,300 oper. h/year x 0,10 $/kWh = 20 M$
TOTAL Estimated Revenues: 12-20 M$/year
©2013 John Zink Company, LLC 26 CONFIDENTIAL AND PROPRIETARY
Vapour Combustion Systems
©2013 John Zink Company, LLC 27 CONFIDENTIAL AND PROPRIETARY
Types of Vapour Combustion Devices
► Open flame combustors
► Enclosed flame
combustors
► Flares
► Thermal Oxidizer systems
©2013 John Zink Company, LLC 28 CONFIDENTIAL AND PROPRIETARY
Marine VCU
How does Vapour Combustor work?
VOC Vapours pass through shutdown valves and detonation arrestors into combustion chamber with assist gas burners for flame temperature and assist air for mixing and proper combustion.
©2013 John Zink Company, LLC 29 CONFIDENTIAL AND PROPRIETARY
Standards for Safety
Flashback Protection:
► Certified detonation arrestors
► Anti-flashback burners
► Reliable, stable, energy efficient pilots
► Multiple burner stages for high turndowns
©2013 John Zink Company, LLC 30 CONFIDENTIAL AND PROPRIETARY
Advantages
Vapour Combustion Systems
►99%+ removal efficiency
►Can handle multiple products
simultaneously
►Effectively controls methane and ethane
►Lower capital cost than VRU
►Low electricity consumption
►Easy to install, operate, and maintain
©2013 John Zink Company, LLC 31 CONFIDENTIAL AND PROPRIETARY
Marine VCU Installed in Crude Oil Loading - 19,080 m3/hr Turkey
Marine VCU
©2013 John Zink Company, LLC 33 CONFIDENTIAL AND PROPRIETARY
Questions?
©2012 John Zink Company, LLC 34
Thank You