DCP MIDSTREAM LP-MOBILE BAY GAS TREATING AND …

DCP MIDSTREAM, LP-MOBILE BAY GAS TREATING AND PROCESSING FACILITY

5300B Highway 188

Coden, Mobile County, AL

Facility No.: 503-8085

1 | P A G E

STATEMENT OF BASIS

On February 12, 2020, DCP Midstream, LP, submitted a permit application to modify its existing Major

Source Operating Permit (MSOP) No.: 503-8085 for the Mobile Bay Gas Treating and Processing Facility

(Mobile Bay Plant). The permit was issued on September 14, 2017 with an expiration date of September

13, 2022. On July 29, 2020, DCP Midstream, LP, notified the Department of changes to their original

proposal submitted to the Department. Revisions to the application were submitted to the Department

on February 21, 2020, July 30, 2020, and October 26, 2020.

NOTABLE CHANGES

In this modification, DCP is requesting to make modifications to its current operating scenario for the

thermal oxidizer and acid gas flare and to include requirements for its existing reconstructed emergency

fire water pump engine A (P-903A) under 40 CFR 60 Subpart IIII [NSPS IIII].

The engine was permitted in Air Permit No.: 503-8085-X008 issued in May 2020. The permit limits for the

modified fire water pump engine will be rolled into the MSOP during this modification (see Engineering

Analysis dated May 18, 2020 for engine requirements and emission limits).

The gas plant is currently designed to process 300 million standard cubic feet per day (MMscf) of natural

gas. When the plant was originally designed, the thermal oxidizer and emergency acid gas flare were

designed with the intent of having two trains and processing a total of 600 MMscf/day; however, only one

train was constructed, and the thermal oxidizer and acid gas flare were not redesigned to handle the

reduced capacity. The current operating scenario for the plant allows the use of the emergency acid gas

flare for only 60 hours per calendar quarter for gas with a high sulfur content, and the thermal oxidizer is

the primary control device for the plant. The operational limit was established in order to avoid a

Prevention of Significant Deterioration (PSD) Review. Due to a reduction in current production rates for

the plant, DCP is requesting to modify the current plant operating scenario.

Current production rates for the plant are between 70 and 80 MMscf/day which is significantly below the

plant’s original design capacity. The decrease in natural gas liquid (NGL) production has resulted in a

decrease in the amine system recirculation rate to its minimum operational rate, and it has resulted in a

low amine vent gas volume. The lower vent gas volume reduces the speed of gas routed to the thermal

oxidizer and causes ignition to occur prior to the combustion zone. As a result, metal fatigue and cracking

occurred over time from hot spots within the thermal oxidizer’s manifold.

DCP’s long-term solution to resolve the issue with low production and low flow to the thermal oxidizer

was to use the existing emergency acid gas flare as a process flare when production volumes are less than

100 MMscf/day resulting in less than 120 thousand standard cubic feet per day (Mscf/day) of amine vent

gas. The acid gas flare will serve as the primary control device during this operating scenario. This would

remove the restriction which currently only allows the operation of the acid gas flare for no more than 60

hours per calendar quarter. The acid gas flare has a lower destruction removal efficiency than the thermal

oxidizer (98% vs 99%); however, a decrease in emission is expected for all pollutants with the exception

of volatile organic compound (VOCs). The thermal oxidizer will remain in standby mode in case production

volumes


FACILITY NO.: 503-8085

STATEMENT OF BASIS

2 | P A G E

increase to 100 MMscf/day or greater. Once the volume increase occurs above the allowable, amine vent

gases will be routed to the thermal oxidizer.

After researching further, DCP notified the Department in July 2020 that their long-term solution should

be based on the volume of waste acid gas from the amine treating vent rather than the volume of NGLs

processed at the plant. The reason for this change was because the volume of waste gas sent to the

thermal oxidizer has an impact on whether there is enough gas to be properly combusted. Lower amounts

of sulfur in the waste gas stream will result in lower volumes of acid gas being routed to the thermal

oxidizer. This has created problems for the facility if the stream is not properly burned in the thermal

oxidizer’s combustion zone because of a low flowrate. Rather than sending low volumes of acid gas to

the thermal oxidizer, they will be routed to the acid gas flare instead.

DCP has proposed that if the waste gas stream volume from the amine treating unit exceeds 120 thousand

standard cubic feet per day (Mscf/day) or greater, the stream will be routed to the thermal oxidizer for

combustion. However, if the waste gas stream volume from the amine treating unit is less than 120

Mscf/day, the stream will be routed to the acid gas flare for combustion. An existing overhead flow meter

or an equivalent device will be used to measure the volume of the waste gas from the amine treating unit.

EMISSIONS

In the table below, the proposed alternative operating scenario (Scenario 2) shows the reduction of

emissions for each pollutant, except VOCs. The current operating scenario (Scenario 1) shows vent gas

vapors from the amine treating unit being routed to the thermal oxidizer during normal operation.

OPERATING

SCENARIO

AMINE VENT

GAS VOLUMES

PRIMARY

CONTROL

OPERATING

UNIT

EMISSIONS

TPY

PM 2.5/10 NOX CO VOC SO2 H2S

SCENARIO 1:

CURRENT/NORMAL >120 SCF/DAY

THERMAL

OXIDIZER (TO)

AGFL-1 0.01 0.08 0.37 0.062 0.001 0.00

TO 0.77 10.12 8.50 0.95 122.11 0.66

TOTAL EMISSIONS 0.78 10.20 8.87 1.01 122.12 0.66

SCENARIO 2:

ALTERNATIVE <120 MSCF/DAY

ACID GAS FLARE

(AGFL-1)

AGFL-1 0.17 1.57 7.14 4.95 24.25 0.26

TO 0.00 0.005 0.004 0.00 0.00 0.00

TOTAL EMISSIONS 0.17 1.58 7.51 4.95 24.25 0.26

REGULATIONS

The acid gas flare’s applicability to the state and federal regulations will be discussed in the following sections.

STATE REGULATIONS

Applicability:

ADEM Admin. Code R. 335-3-4-.01(1)(a) and (b), “Visible Emissions” for Control of Particulate Emissions

These regulations would not be applicable to the acid gas flare because it is subject to the more stringent opacity

standards found in §60.18 and §63.11.



STATEMENT OF BASIS

3 | P A G E

Applicability:

ADEM Admin. Code R. 335-3-5-.03 (1), (2), and (3) “Petroleum Production”

The Mobile Bay Plant handles sour gas that contains 0.10 grains of hydrogen sulfide per standard cubic feet

(H2S/scf) of gas or more. The facility flare, acid gas flare and thermal oxidizer are used to comply with these

regulations. These requirements will remain applicable in the permit.

EMISSIONS STANDARDS

The flares are required to burn sour gas in order to maintain the ground level concentrations of hydrogen sulfide

(H2S) at less than twenty parts per billion beyond the plant property limits, average over a thirty (30) minute

period. Venting to atmosphere shall not exceed 15 continuous minutes while vessels or equipment are being

depressurized and/or emptied and the reduced pressure will not allow flow of the process gas to the

combustion device.

According to ADEM Admin. Code R. 335-3-5-.03(3), provided that the available sulfur being processed at the

plant is less than five (5) long tons per day (LTD), there is no limit on SO2 emissions. The Mobile Bay Plant has

a sulfur production of less than 2 LTD. However, the facility has elected to be a minor source with respect to

PSD regulations; therefore, SO2 emissions from the facility shall not exceed 245 TPY as discuss in the applicability

section of PSD requirements.

COMPLIANCE AND PERFORMANCE TEST METHODS AND PROCEDURES

Each process gas stream that can be routed to a flare shall be tested for its Btu content (Btu/Scf) utilizing one

of the following methods and procedures: the chromatographic analysis procedures in 40 CFR Part 60, Appendix

A, Method 18, Method 25A, or equivalent methods and procedures to determine the heat content of the gas

stream. It should also be tested for its H2S content (mol%) utilizing one for the following methods and

procedures: Tutwiler procedures found in 40 CFR §60.648, the chromatographic analysis procedures found in

ASTM E-260 or the stain tube procedures found in GPA 2377-86, or those provided by the stain tube

manufacture.

EMISSIONS MONITORING

Compliance is met by burning or recycling to the process all process gas that can be vented to atmosphere.

Periodic monitoring to ensure that the offsite H2S concentration from the acid gas flare does not exceed 20

parts per billion volume (ppbv), is in the form of maintaining an acid gas to assist gas volume ratio at equal to

or greater than 1.0 to 0.5 and maintaining a spark or flame at the flare tip.

The requirements to minimize the flaring of high sulfur gas to less than 60 hours per calendar quarter and to

maintain an acid gas to assist gas ratio were established because of an anticipated increase in the facility’s

sweetening capacity due to the proposed treatment of sour natural gas from Exxon’s Mary Ann/823 Gas Plant

after its shutdown (see September 13, 2010 Engineering Analysis). Prior to the shutdown of the Mary Ann/823

Gas Plant, the DCP plant rarely treated sulfur-laden gases.

RECORDKEEPING AND REPORTING REQUIREMENTS

A record of events when process gas streams were burned in the acid gas flare instead of the thermal oxidizer,

records when venting from the acid gas flare occurs for greater than 15 minutes, records of the acid gas to assist

gas volume and ratio, and records of the presence or absence of a spark or flame at the flare tip shall be

maintained. All recordkeeping and reporting requirements, with the exception of limiting the hours to 60 hours

per calendar quarter, will remain in the permit during this modification.



STATEMENT OF BASIS

4 | P A G E

Applicability:

ADEM Admin. Code R. 335-3-14-.04 “Prevention of Significant Deterioration (PSD) Permitting”

The AGFL-1 flare has emission limits in place to maintain VOC emissions from the amine vent gas below 2.70

lbs/hr and 0.242 tons per 12 consecutive months. These limits were established in order to avoid a PSD review

under this subpart and they will remain unchanged in the modified permit. In the current MSOP, acid gas flaring

hours from the AGFL-1 is limited to 60 hours per calendar quarter to minimize sulfur dioxide (SO2) emissions;

however, the removal of this requirement from the permit during this modification should not circumvent the

facility-wide SO2 requirement to maintain emissions from the entire plant below the PSD threshold of 250 tons

per year (TPY) for all emissions sources since the plant is not major for PSD. Since the hours of operation and

thus emissions from the thermal oxidizer will be reduced during the proposed alternative operating scenario,

and since the Anti-PSD SO2 limit of 27.90 lbs/hr for the thermal oxidizer will remain in the permit, the facility’s

status of a minor source with respect to this subpart will remain unchanged.


The acid gas flare VOC content shall be sampled annually using chromatographic analysis procedures in 40 CFR

Part 60, Appendix A, Method 18, Method 25A, or equivalent methods and procedures.


The flared gas volume shall be monitored with a system capable of measuring and recording the flowrate and/or

parameters utilized for flow rate calculations.


Records of the date, time, and duration of each acid gas flaring event, records of annual sampling of the fuel

gas for its VOC content, and records of the thermal oxidizer’s and each flare’s SO2 emissions shall be maintained.

Deviations shall be included in the semi-annual Periodic Monitoring Report (PMR) which is due to the

Department within 30 days of the end of the reporting period.

Applicability:

ADEM Admin. Code R. 335-3-16-.03, “Major Source Operating Permits”

The acid gas flare is subject to the requirements of this subpart since it is located at a site that is a major

source of criteria pollutants and a major source of hazardous air pollutants (HAPs). Records of deviations from

the permit requirements and emissions from the flare shall be maintained to comply with this regulation.

FEDERAL REGULATIONS

NEW SOURCE PERFORMANCE STANDARDS (NSPS)

Applicability:

40 CFR 60 Subpart A, “General Provisions”

Provided that affected sources located at the plant are subject to one of the applicable subparts found under

this part, the facility shall comply with this regulation as specified in that subpart.



STATEMENT OF BASIS

5 | P A G E

Applicability:

40 CFR 60 Subpart KKK, “Standards of Performance for Equipment Leaks of VOC from Onshore Natural Gas

Processing Plants” [NSPS KKK]

The Mobile Bay Plant is subject to the requirements of this subpart for affected sources that were constructed,

reconstructed, and/or modified after January 20, 1984 and on or before August 23, 2011. Except as specified

in §60.633, the emissions standards specified in §60.632 of this subpart shall be met. Compliance with this

subpart is demonstrated through the review of records and reports as specified in §60.635, review of

performance test results, and inspections using the methods and procedures specified in §60.485. Semi-annual

leak detection and repair (LDAR) reports as required by §60.636 are submitted to the Department to

demonstrate that the monitoring requirements under this subpart are being met.

Flares used to demonstrate compliance with this subpart are required to comply with §60.18. The acid gas flare

is used to control VOC emissions from the amine vent gases; therefore, it is subject. The requirements under

§60.18 will be discuss later in this document.

Applicability:

40 CFR 63 Subpart A, “General Provisions”

The acid gas flare is used to comply with NESHAP HH and must comply with the requirements under this subpart

as specified in Table 2 of that subpart [§63.764(a)].

NATIONAL EMISSION STANDARDS FOR HAZARDOUS AIR POLLUTANTS (NESHAP)

Applicability:

40 CFR 63, Subpart HH, “National Emission Standards for Hazardous Air Pollutants from Oil and Natural Gas

Production Facilities”

The Mobile Bay Plant is a major source of HAPs with respect to this subpart. Affected facilities under this

subpart include each glycol dehydration unit, each storage vessel with the potential for flash emissions, and the

group of all ancillary equipment and compressors intended to operate in volatile hazardous air pollutant (VHAP)

service. Only the requirements applicable to equipment leak standards under this subpart will apply.

The acid gas flare may be used as a control device to control emissions from affected sources subject to this

subpart. The acid gas flare is already subject to the requirements of this subpart, and it must comply with the

requirements of §63.11(b) for flares (as defined in §63.761) and as specified in the following sections:

§63.764(c)(3) for general standards, §63.769(c)(8) for equipment leak standards, §63.771(d)(1)(iii) for control

equipment requirements, §63.772 (e)(2) for compliance demonstrations, §63.773(d) for inspection and

monitoring requirements and §63.775(d) for reporting requirements. The existing requirements under this

subpart will remain unchanged during this modification.

Applicability:

40 CFR §60.18 & 40 CFR §63.11(b)

The acid gas flare is subject to the requirements of these subparts because this flare is used to control HAP

emissions from sources subject to 40 CFR 63 Subpart HH and/or to control VOC equipment leak emissions from

affected sources subject to 40 CFR 60 Subpart KKK.



STATEMENT OF BASIS

6 | P A G E

EMISSION STANDARDS

The acid gas flare will still be required to comply with the following emission standards:

• Must be operated with no visible emissions, except for periods not to exceed a total of 5 minutes

during any 2 consecutive hours

• Must be operated with a flame present at all times

• Must adhere to the heat content specifications found in §60.18 (c)(3)(ii) and §63.11(b)(6)(ii) AND the

maximum tip velocity specifications in in §60.18 (c)(4) or (c)(5) and §63.11(b)(7) or (b)(8) OR they must

adhere to the requirements specified in §60.18 (c)(3)(i) and §63.11(b)(6)(i)

• Must be monitored to ensure that they are operated and maintained in conformance with their

designs

• Must be operated at all times when emissions may be vented to them


Opacity monitoring shall utilize EPA Test Method 22.


Compliance with the visible emission standards for the flares shall be met by conducting a daily visual inspection

on each flare and by conducting visible emission observations when necessary for each flare as specified in the

opacity monitoring section of the existing permit.


The following records are required to be maintained for each flare at the facility.

• Records of all periods of operation during which the flare pilot flame is absent

• Records of the flare design

• All visible emission readings, heat content determinations, flowrate measurements, and exit velocity

determinations

• Dates of startup and shutdowns of the closed vent system and control device

Semi-annual reports of all periods in which the pilot flame was absent shall be submitted to the Department

within 30 days of the end of the reporting period.

Applicability:

40 CFR 64, “Compliance Assurance Monitoring” (CAM)

The requirement to burn off gases is considered to be a work practice standard and not an emission limitation.

As defined in the CAM regulation, an emission limitation may be expressed in the form of a work practice,

process parameter, or other form of specific design. Thus, CAM is applicable and shall be utilized to ensure

compliance with the requirement to burn off gases. The acid gas flare is utilized as a control device to burn gas

containing greater than 0.10 grains of H2S/Scf. The presence of a spark or flame at the flare tip shall be

maintained at all times when a process gas stream can be routed to the flare. CAM requirements will remain

applicable to the acid gas flare during the modification of the MSOP.



STATEMENT OF BASIS

7 | P A G E

RECOMMENDATIONS

After evaluating the alternative operating scenario proposed by DCP for its Mobile Bay Gas Plant, it appears

that all state and federal regulation can still be met for the proposed modifications. DCP will be allowed to

utilize the existing emergency acid gas flare when the waste gas volume from the amine treating unit is less

than 120 Scf/day. The acid gas flare may serve as the primary control device during this operating scenario.

When production volumes exceed 120 MScf/day or greater, the thermal oxidizer may be utilized. DCP will be

required to maintain records demonstrating the daily volume of waste gas generated from the amine treating

unit and to maintain records calculating emissions from both operating scenarios.

The acid gas flare will no longer be referred to as an emergency flare, and the requirement to maintain less

than 60 hours high sulfur gas flaring from the acid gas flare will be removed during this modification. After a

public comment period and the EPA review has been completed, I recommend issuing a modification allowing

use of the alternative operation scenario in the facility’s existing MSOP No: 503-8085. Also, the requirements

for the modified P-903A firewater pump engine, which was permitted under Air Permit X008, will be rolled into

the MSOP during this modification.

The following pages of the MSOP have been revised to reflect the modification changes (see draft pages in

Attachment A):

• Cover page

• Provisos for Emergency Diesel Engines: Pages 29, 31-35

• Provisos of the NGL Treating Unit: Pages 51-55

• Provisos for the Facility Flares: Pages 71 and 73, 74, 76-79

_________________________________ October 27, 2020

Harlotte Bolden-Wright Draft Date

Environmental Engineering Specialist, Sr.

Air Division

Energy Branch

Industrial Minerals Section



STATEMENT OF BASIS

8 | P A G E

ATTACHMENT A: DRAFT PROVISOS

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EMISSION

POINT DESCRIPTION POLLUTANT

EMISSION LIMIT

REGULATIONS

(FL-1) Continuous Process Flare VOC Less than or equal to 11.82 Lbs/hr

335-3-14-.04 [Anti-PSD Limit]

(AGFL-1) Emergency Acid Gas Flare

VOC

Sulfur

Less than or equal to 2.70 Lbs/hr

AND

0.242 Tons/12 consecutive months

Less than or equal to 60 hours of high sulfur gas flared during a calendar quarter

335-3-14-.04 [Anti-PSD Limit] 335-3-14-.04 [Anti-PSD Limit]

335-3-14-.04 [Anti-PSD Limit]

Each Facility Flare H2S

Burn gas with 0.10 grains or more of H2S/Scf of gas

AND

<20 ppbv offsite concentration

Rule 335-3-5-.03(1)

Rule 335-3-5-.03(2)

Opacity No visible emissions, except for 5 minutes in a 2 consecutive hour

period

�60.18(c)(1),§60.633(g) [NSPS KKK] §63.11(b)(4), §63.769(c)(8) [NESHAP HH]

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