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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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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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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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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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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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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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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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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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VapourCollectingSystemTruckloadingApplication
Vapour Collecting System
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Vapour CollectingSystemTruckloadingApplication
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VapourCollectingSystemTruckloadingApplication
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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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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
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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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
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