ORYX GTL Experience in Flaring Reduction Challenges and
Opportunities
Marlene Janse van Vuuren,& Venkatesan .V
IQPC 3rdAnnual Flare Management & Reduction Summit
26th – 29th Oct 2013
• Qatar National Vision-2030
• Flaring in Qatar
• ORYX GTL – An introduction
• Sources of Flaring at ORYX GTL
• Flaring Calculation Methodology
• Flare Minimization Action Plan
• Flare Reduction Challenges & Actions
• Conclusion
Contents of Presentation Slide 2
Qatar National Vision-2030
• Qatar National Vision 2030 launched end 2008 • Initiatives to support GHG and Flare Reduction entrenched in QNV 2030
Econ
omic
D
evel
opm
ent
Soci
al
Dev
elop
men
t
Hum
an
Dev
elop
men
t
Envi
ronm
enta
l D
evel
opm
ent
”Management of the environment such that there is harmony between economic growth, social development and environmental protection” • Awareness • Water security • Marine environment • Climate change • Waste – Reduction, more recycling and
more efficient use
Slide 3
National Development Strategy
2011 – 2016
• Qatar joined GGFR in 2008 with a commitment to halve gas
flaring to 0.0115 bcm per million tons of energy produced from
the 2008 level of 0.0230 bcm per million tons of energy produced
• since the year 2000, whilst the oil and gas production in Qatar
increased by almost four fold, gas flaring has been halved. Qatar
flared nine cubic meters of gas per barrel of oil equivalent (boe)
produced in 2000, versus 1.1 m3 per boe in 2011.
Slide 4
Qatar Flaring Zones
OFF SHORE
DUKHAN
MESAIEED
RAS LAFFAN
OFF SHORE
Source: Defense Meteorological Satellite Program (DMSP) Archive Nighttime lights
More Qatar Flaring &GHG Reduction initiatives
• Qatar’s commitment and visibility in the international arena – hosting 18th session of the Conference of the Parties (COP 18) December 2012 at the Qatar National Convention Centre in Doha, Qatar.
• Ministry of Environment new Consent to Operate requirements to industries (compulsory) to implement Flare reporting strategy, submit Flare Reduction Time Bound Action Plans - driving behavior
• Qatar Petroleum’s (QP) Director General ‘s leadership, guidance and support, raising awareness • Regional legislator QP Ras Laffan Industrial City require participation in GHG Accounting Reporting (with guidance
since 2008) • Compulsory participation in GHG Accounting Reporting Audits since 2010 • Sustainable Development Reporting from voluntary (2011) to mandatory (2013) with focus on Climate Change / flaring
& GHG Reduction in 2012 SDR
Slide 6
Our Vision is clear
7
• We discuss our Vision
• We promote our Values
• We make HSE the first topic
of every meeting
Slide 7
49% 51%
What is GTL(Gas to Liquids)?
• Broadly, GTL is a process that converts natural gas to an easily transportable liquid product
• In practice, GTL is synonymous with the Fischer-Tropsch process • Proven alternative route to add value to natural gas prior to sale • GTL can be used to produce a wide variety of refined products, including
GTL diesel, GTL naphtha and LPG
Syngas Production
FT Conversion
Refining
Wastewater Treatment
Natural Gas
Oxygen
GTL Fuels
Tailgas
Reaction water
Condensate & Wax
GTL Process Overview Slide 10
500 350 50 15
35
20
10
Sulphur (ppm)
Aro
ma
tics
(%)
0
GTL Diesel
GTL Fuel - Advantages
High Quality
< 5 ppm Sulphur
< 1% Aromatics
> 70 Cetane No.
Average 30%
emission reduction
Diesel HC CO NOx
PM GTL Fuel
Slide 11
Flare Overview
Pilot gas
Fuel gas system
Tailgas
Syn gas unit
FT Unit
Product work-up
Hydrogen Unit
LPG Hydrogenator
Main flare
• Main flare
• Vent gas flare
Slide 12
Routine & Non-routine Flaring
Routine Flaring: • Pilot gas • Vent gas (low pressure gas from all units & tanks) • Excess tailgas from FT unit • CO2 Stripper off- gas from product work-up unit • Off-gas from LPG hydrogenator unit Non-routine Flaring: • Emergency pressure relief flows • Emergency depressurization operations • During maintenance • Episodic regeneration • Start-up / Shutdown operations
Slide 13
How did ORYX GTL do it?
• Established and refined reporting methodology • Improved stability and reliability of facility (new projects) • Implemented procedures, measuring capabilities • Optimized Fired heater to increase Tail Gas firing • Improved energy efficiency via optimization projects • Reduced unplanned shutdowns
Slide 14
Flaring Reduction Challenges • Absence of governance and guidance during design phase (2001-2003)
• GTL – new technology, complex process with complex energy efficiency process
integration
• Some of largest units in world – ASU, ATR & FT
• Highly complex fuel network (5 fuels) and unique fuels – Tail Gas, liquid fuel
• Initial startup and stabilization challenges
• Unavailability of procedures, equipment (flow meters), resources
• Understanding the complexity of Flaring and GHG reporting requirements
Slide 15
Flaring Calculation
• Flaring calculation are performed using Excel based Aspen Info Plus system on
real time basis.
• The calculation uses composition of various flaring streams and valve/control
outputs and other flare flow data (P,T, compositions).
• The core of the calculation system integrated with advanced process control
system and lab information management system to collect, aggregate, and
validate data prior to use in calculations.
• The tool is managed by production on daily basis to track the flaring volumes
• The data is validated and verified by Process engineers on monthly basis to
report regulators.
Slide 16
Flare Minimization Objectives
Objectives:
To support Qatar National Vision 2030
To achieve near- zero flaring
To comply with regulatory requirements
To reduce GHG emissions
To improve energy and carbon efficiency of the process
To improve the operational stability and reliability of facility
Time frame
Short term actions for December 2012
Medium term actions 2012 - 2013
Long term action plan 2012 to 2017
Slide 17
Flare Minimization Action Plan
Short Term Actions (December 2012): • Improve Tail Gas firing in fired heater • Applying advance process control schemes • Cleaning fired heaters to improve thermal efficiency
Medium Term Actions (2012 – 2013): • Re-routing of vent gases to fuel gas system • Installation of flare flow meters and analyzers
Long Term Actions (2012 to 2017): • Install vent gas recovery and compression project • Install fuel gas mix drum to reduce use of Natural gas as fuel
Slide 18
Flare Sources Contribution
Based on 2013 data
10.60%
5.83%
44.36%3.27%
27.03%
4.64%
3.33%
0.89% 0.07%
Syngas Unit
Product work up unit
Tailgas
Pilot Gas
Vent Gas
FT Unit
Hydrogen Production
Fuel System
LPG Unit
Slide 19
Tailgas to Flare Reduction Slide 20
What is Tailgas?
• Tail gas is an internally generated fuel from the FT process.
• It is treated to remove heavy-end hydrocarbons, and routed to the
synthesis gas unit or used as a fuel in process heaters and excess
tailgas is flared.
Objective:
• To optimize fired heaters to make maximum utilization of tailgas
and reduce the flaring Tailgas Composition - mol% Hydrogen 20 - 30 Carbon Monoxide 20 - 30 Carbon Dioxide 20 - 30 Nitrogen 10-20 Methane 5-15 C2 to C6 1-5
21
Tailgas to Flare Reduction
Challenges & Actions:
• Less heating value of tailgas due to high inert levels, which led to flame instability
• To increase heating value both natural gas and tailgas was mixed at the inlet of individual burners
Stack damper and stack hood problems
• At 75% tailgas to fuel ratio, the stack damper was fully open and restricted the further tailgas firing.
• Review of the stack design indicated that rain hood protection in the stack restricted the flue gas flow. The rain hood
removal provided the better draft control in the heaters.
Slide 21
22
Tailgas to Flare Reduction
Ultra Violet flame scanner issues
• UV scanner port was small and obstructed the view angle by refractories.
• Additional hole was made in the center of the flame plate and re-aligned the UV scanner standpipe to remove the
restriction from the view angle.
• Field trials conducted with different natural gas/tailgas ratios to assess the flame conditions and the stability, by
reducing the low alarm setting for the UV scanner from 400 to 80 counts and trip from 100 to 40 counts.
High skin temperature
• Detachment of skin thermocouples from the tubes was observed and indicating the flue gas temperature, which
resulted in the high skin temperature readings.
Slide 22
23
Tailgas to Flare Reduction
High bridgewall temperature
• Based on simulation studies and OEM recommendation, the trip point of the high bridgewall temperature was
increased to 1050 0 C.
Air/fuel imbalance
• The air damper plate which regulates the air flow to the burners was missing on some of the burners, which resulted
the improper flame characteristics.
Advance Process Control logic
• Implemented the fast response to the natural gas cut back system in case of emergencies via advanced process control
logic
Slide 23
Results : Tail gas Facts 2013
90% of generated tail gas was used as fuel in
2013 resulting in a 51.8% reduction in tail gas to
flare compared to 2012
Natural gas fuel consumption reduced by 11%,
when compared to 2012 due to high rate utilization
of tail gas as fuel even with higher production
levels
Flare reduction initiatives contributed to 15% GHG
reduction in 2013.
Slide 24
Results and Achievements
Annual Flaring volumes in Tons
In 2013, 77% flaring reduction achieved compared to 2011
Slide 25
Planned overall GHG Emission Reduction Slide 26
Achievements
1.81
2.22
1.72
1.46
0.00
0.50
1.00
1.50
2.00
2.50
2010 2011 2012 2013
Mill
ion
to
n o
f C
O2
eq
Year
GHG Emission Reduction
In 2013, 34 % GHG Reduction was achieved compared to 2011 results
Slide 27
Contribution of Flare Reduction GHG Reduction
90%
30%
40%
65%
Slide 28
In 2013, 36% flare
reduction achieved due to
tailgas maximization ,
operational stability and
reliability compared
In 2013, NG consumption
as fuel has reduced 11%,
even though the overall
production rate increased
.
Longer term projects to reduce GHG
Flare Gas Recovery Overview:
Long Term Actions: Vent gas flare recovery project
High pressure Flare
Low Pressure flare
Fuel Gas System
Main Flare KODVery Low Pressure flare
Low Pr Vent Gas Seal Drum
Flare
Process Fired Heaters / Boilers
New Fuel Mix Drum
Vent Gas Blower
New Compressor
Other Process UnitsTailgas
Fuel Mix Drum
Simple schematic - Flare system with Flare gas recovery
Slide 29
Overall 90% flaring reduction can be achieved by 2017
Up to 2013, 77% flaring reduction achieved as compare to 2011
Tail gas utilization, operational stability and reliability – main contributor
Flare reduction contributed to 34% of GHG reduction .
Flare gas recovery project – will reduce GHG by 7%
Carbon efficiency of the GTL process can be improved over 2%
40% decrease in natural gas utilization as fuel
56 million $ projects in pipeline to improve the operational stability and
reliability which can either directly or indirectly reduce the flaring
Flare Reduction Summary Slide 30
Recommendation to Industries
• Be aware of world trends and local authority regulations changes
• Be proactive and up to date with new emerging technologies for Flare &GHG reduction
• Include capabilities to measure in design
• Share your knowledge and experience with other industrial partners
Slide 31
Thank You لتعاونكم
Flare Sources Contribution
Based on 2013 data
10.60%
5.83%
44.36%3.27%
27.03%
4.64%
3.33%
0.89% 0.07%
Syngas Unit
Product work up unit
Tailgas
Pilot Gas
Vent Gas
FT Unit
Hydrogen Production
Fuel System
LPG Unit
Slide 33
Flaring Data Comparison
Flare Data (MT) Comparison for 2012 & 2013
Source Description 2012 2013 Variation
Pilot gas 4,356 4,994 14.6%
Vent gas 65,023 41,283 -36.5%
Tail gas 140,448 66,751 -51.8%
Syn gas Unit 3,649 16,185 343%
FT Unit 4,875 7,088 45.4%
Product work-up Unit 9,797 8,900 -9.2%
Hydrogen production 2,150 5,084 136.5%
Fuel system 287 1,356 372.5%
LPG hydrogenator 1790 102 -94.3%
Total Flaring 232,375 152,743 -34.27%
Slide 34
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