Post on 03-May-2018
Safe Tank Truck Loading Alternatives
Why are we here today
Oxygen and VOC problems encountered in
today’s truck loading environment
Loading Options
• Free venting and purging
• Vapor balancing
• Vapor burning (combustion)
• Vapor recovery
Free venting and purging
Typically a facility's air permit is
limited to 50 tons or less of VOCs
annually.
The issue: Loading one 200 barrel
truck per day and venting the gases
into the atmosphere consumes 14.8
tons of the 50 ton annual limit or
30%.
The issue: Heath and Safety in the
loading rack area becomes apparent
in terms of vapor clouds that are
explosive and contain carcinogens.
Vapor Balancing
Facilities are typically limited to 10
ppm per ft3 of O2 in the natural gas
sales pipe line.
The issue: Vapor balancing a 200
barrel load to a storage tank (to
reduce emissions) will on average
inject 16 ft3/min of a 124,000 ppm
O2/hour.
Vapor burning (combustion)
Facilities are stressed to add
combustion products to a
production facility
The issue: Re-permitting, finding
available safe real-estate, lost
revenue, and public perception.
.
Vapor recovery
Note higher removal efficiencies can be achieved if requested.
Recovery Calculation 14 gal per
200 barrel truck load
0.00
10.00
20.00
30.00
40.00
50.00
60.00
Va
po
r C
on
ce
ntr
ati
on
Recovery rate per 1000 gal loaded
Recovery Rate per 1000 gallons loaded
A carbon based Vapor recovery unit
eliminates re-permitting, HSE and oxygen
shut in issues while providing an
attractive ROI.
The issue: The initial CAPEX is large
when compared to flaring alternatives.
Advantages
Ele
vate
d F
lare
En
clo
sed
Fla
re
Th
erm
al
Oxid
izer
/ T
ruck
Lo
ad
ing
N
atu
ral
Dra
ft E
ncl
ose
d C
om
bu
sto
r
N
itro
ge
n/C
O2
Pu
rge
Air
Defe
nd
er
(Carb
on
Bed
Vap
or
Re
cov
ery
)
Familiar technology X X X
Minimal foundation requirements X
Low installation cost X X
Low CAPEX X X
Fully automated X X X X X
Minimal maintenance X X X
Removes odor X X X X
Can be combined with a scavenger system to reduce H2S X X X X
Low Noise X X X X
No Visible Flame X X X X
Minimal HAP release X X
+99% DRE X NA NA
No assist or purge gas required X X
Flameless operation X X
Recovers product X
Easily scalable/ modular design X
Can be installed in a Class 1 Div 2 area(panel unclassified and remote mounted)
X
No production of NOX CO or CO2 X X
Can meet +99% VOC reduction to meet EPA Control device not affecting permit
X
Disadvantages
Ele
vate
d F
lare
En
clo
sed
Fla
re
Th
erm
al
Oxid
izer
/ T
ruck
Lo
ad
ing
Natu
ral
Dra
ft E
ncl
ose
d C
om
bu
sto
r
Nit
rog
en
/CO
2 P
urg
e
A
ir D
efe
nd
er
(Carb
on
Bed
Vap
or
Reco
very
)
Possible smoke X X X
Noise X
Visible flame/ Negative public perception X
Requires Nitrogen or Natural Gas purge prior to start up during
operation and shut down X X
98% DRE X X
Potential for flashback explosions X X
Location on site requires safe area X X X
Affects air permitting X X X
Emits CO NOX CO2 X X X
Lost revenue by burning product X X X
Requires significant fuel gas/ High operating cost X X
Higher maintenance X
Larger footprint X
Initial CAPEX X X X
Heat trace required for vacuum pump to storage tank
X
Noted as not desired at Midstream sales point X
Initial cost Power usage Pilot gas usage Assist gas usage liquid recovered product Operational costs per yr
Elevated Flare operating 24 hrs per day $ 36,000.00 12 KW 1440 SCF 9216 SCF N/A $ (11,669.00) .
Enclosed Flare operating 12 hrs per day $ 32,000.00 12 KW 720 SCF 7400 SCF N/A $ (8,891.00)
Enclosed Combustor operating 12 hrs per day $ 125,000.00 60 KW 720 SCF 30000 SCF N/A $ (35,390.00)
Carbon Vapor recovery operating 24 hrs per day $ 215,000.00 192 KW N/A N/A 168 gal $ 89,294.00
Assumptions
1. Loading twelve 200 barrel trucks in a 24 hour period (truck load time 1 hr.)
2. Natural gas costs at $3 per 1000 ft3
3. Power costs at 8 cents per KW hour
4. Crude costs at $65/barrel
`
Typical capital and operations costs