English VRU Evolution

PresentationofVapourRecoverySystems
ByTiesMulder ProcessandImplementationConsultant June2005
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
Presentation VRU - June 2005
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FirstSystems
First systems = thermal destruction (air assisted flare)
Energy consumption : high Destruction : 97 % efficiency Maintenance : low
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FirstRecoverySystems
First recovery systems installed in the United States Flare gas recovery using compression and cooling
Outlet to Flare
Vapour Inlet
Cooler Separator
Energy consumption : high Emissions : 80 % efficiency Maintenance : medium
Compressor
Recovered Liquid
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Adsorptionsystems
Early 70s : first activated carbon / vacuum system (Rheem Brothers - USA)
Clean air outlet
Top product vented to atmosphere
Gasoline supply Glycol Separator
Energy consumption : low Emissions : 80 % efficiency Maintenance : high
Vapour Inlet Activated Carbon Filters
Re-absorber
Vacuum Pump
Gasoline return
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Deepcoolingsystems
Deep cooling systems @ -35C (Edwards - USA)
Clean Air Outlet De-icing heater Cooling Elements
Energy consumption : high Emissions : < 80 g/m3 Maintenance : very high

Chiller
Vapour Inlet
Pure Product
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EvolutionofAdsorptionsystems...
First patent by McGill in 1978 based on Rheem brothers with recycling of absorber top
Clean air outlet
Top product returned to inlet
Energy consumption : low Emissions : 35 g/m3 Maintenance : high

Gasoline supply
Glycol Separator
Vapour Inlet Activated Carbon Filters
Re-absorber
Replacement of deep cooling by adsorption systems in USA
Vacuum Pump
Gasoline return
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EvolutionofAdsorptionsystems
Since 1980 s : Activated carbon / Liquid ring vacuum systems as known today
Clean Air Outlet
Purge
Adsorbers
Energy consumption : high Emissions : < 35 g/m3 Maintenance : high Suppliers patents in several European countries
Vapour Inlet
Absorber
Absorbents Cooler
EG Separator
Vacuum Pump
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Alternativesolutions
Fear of patent infringement Development of alternative solutions in Europe

Cold absorption system : Membrane system : Activated carbon + cold re-absorption : Cogeneration : Absorption / Adsorption / Absorption :
Coolsorption / Kappagi Vaconocore / Preussag Kaldair Petro-Plus (Qlear) / Schwelm 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 : John Zink Thermal balance adsorption : Ties Mulder
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Coldabsorptionsystem
Clean Air Outlet Absorbents Inlet Vapour Inlet
Cooler
Reabsorber Absorber Heater Absorbents Return Nonane Circuit Chiller Splitter
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Membranesystem
Clean Air Outlet
Evnt. 2 nd Stage
Separator Vapour Inlet Cooler
Membrane
Vacuum Pump Compressor
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ThermalBalanceAdsorption
Clean Air Outlet
Adsorption Filters
Absorber
Vapour Inlet
Condenser
Separator Vac pump
Absorbents
Heat exchanger
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Latestdevelopments
Latest developments : Dry screw pumps systems by CarboVac

Outlet
Energy consumption : low

Emissions : < 10 g/m3 Maintenance : low Replacement of glycol systems by dry systems
Inlet Dry Screw Vacuum Pump P
Activated Carbon Beds
Re-Absorber
Absorbants Circulation
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Actualsituation
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 green policies (engagement to reduce 50% of CO2 emissions) Replacement of destruction by recovery solutions
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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 regulations
in particular on emissions in hydrocarbon storage and transfer terminals
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USA1stCleanAirAct
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
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Europeanlegislation
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 by combustion with secondary emissions)
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Emissioncontrol
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 expensive devices

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)
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Energyconsumptionversusemissions
0,3
Energy consumption (kWh/m3 treated)
TA-Luft Emissions
0,25
0,2
0,15
Israeli Emissions
0,1
EU Emissions
0,05
0 40 35 30 25 20 15 10 5 0
Emission limit (g/m3)

N.B : Data based on LRVP Systems
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Recoverychain
Refinery
Losses : 0,1 kg/m3 Emission reduction measures up to 99%
Total efficiency of the recovery chain is never better than the weakest link
Terminal Service-station Car filling
Losses : 1 kg/m3 Emission reduction measures up to 90%
Losses : 1 kg/m3 Emission reduction measures up to 99,99 %
Losses : 1 kg/m3 Emission reduction measures up to 99%
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ECDirective94/63Stage1and2 forfueldistribution...
Stage 1 : Recovery of the vapour from the service-station ground tank to the truck and Recovery of the vapours from truck loading on the terminal. Stage 2 : Recovery of the vapour from the car fuel tank to the ground tank Not ratified by some countries in Europe due to lack of efficiency
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ECDirective94/63Stage1and2 forfueldistribution
At the Service Station
Stage 2
Car
At the Terminal
Stage 1 To VRU
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ImplementationofStage1...
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 line equipped with 4" API coupler with check valve.
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ImplementationofStage1
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
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Stage1examplewithfixedrooftanks
Pressure Vacuum Valve Vapours Emitted
Detonation Arrestor
Ventilator
P PT
Tanks Loading Operation

Absorbents
Vapour Recovery Unit
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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 vapour
is returned to the ground tank
Efficiency not demonstrated Solutions not promoted by Oil Companies

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Typicalvapour composition
(Truckloading)
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 C2 C3 C4 C5 C6 C7++ Benzene Toluene 0 0 1.5 37 22 8 1.7 0.26 0.36 0.2 0.45 3.8 50 43 12 5.4 2.6 1.8 % Vol.
C4 and C5 represent around 90% of the hydrocarbons at the inlet vapours
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HowtosizeaVRU
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
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Typicalcompartmenttruck
Compartment cover serves as pressure safety relief valve Vapour Collector connected to each compartment
4 API Vapour Coupler
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VapourCollectingSystem
TruckloadingApplication
Pressure Vacuum Safety Valve
Vapour Line
Detonation Arrestor
Vapour arm
Level Switch Position Switch Drain valve
VRU
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Vapour CollectingSystem
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AbsorbentCirculationSystem
VRU
P501
P601
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Civilworks
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Civilworks
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Electricalworks:communicationsignals
Gasoline out in
Operations Room PC & interactive keyboard Cabling Control building modem Modem line Open/close Emergency Vent Emergency vent valve position Power Input (start/stop truck loading) Gasoline pump start /stop/running signal Site ESD signal VRU running VRU alarm
Vapour pipe work Nitrogen Water
Vapour Recovery Unit Cabling

Air
Air Compressor (instrument quality)
Foundation drainage
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Electricalworks
Safe Area
Hazardous Area
Control Room
Cables
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Electricalcablesschematics
Electrical Room VRU I Power feed cable J Instrument cables Power cables to Motors
PC
PLC
PC Monitoring Customer signals
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Operationalconnectionschematic
Control Cabinet
CONTROL ROOM Power Cabinet
Modem
VRU SUPPLIER
Instrumentations E-Motors
Modem LOCAL REPRESENTATIVE
Modem
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VRULocation
Important parameters :
Pressure drop of the vapour line

- EU Directive : - Typical P of a 4" API vapour coupler : - Typical P of a vapour arm + hose : - Typical P of an anti-deto FA : - Typical P of a VRU : 55 mbar @ truck coupler 3 mbar 12 mbar 5 mbar 25 mbar
Max available P of vapour line : 10 mbar
Pressure drop of the gasoline circulation lines

- Supply pump : - Return pump : usually close to the tank or in the pump station usually on the VRU foundation
Accessibility for maintenance works Electrical cable routing

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Qualityoftherecoveredproduct
GasolineApplication
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
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TypicalRecoveredProduct
Hypotheses : Vapour inlet concentration : Average outlet concentration : Average MW : Calculation : Mass of hydrocarbons at inlet per m-3 = 0.4 x 65 22.4 x 10 - 3 = 1160,7 g / m-3 40 % Volume 2g / Nm-3 65 (Gasoline vapours)
Masse of hydrocarbons in the outlet per m-3 inlet = 2 x (1 - 0.4) = 1.2 g / m-3 Masse of hydrocarbons recovered 1159.5 g / m-3 of inlet vapour The recovery rate :

The effective recovery rate is Vapour recovery rate
1.49 litre per m3 99. 9 %.
Inlet vapour
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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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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
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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)
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3.7.1Resume
VRU = assembly of two different pieces of equipment :
Equipment with CE marking (ATEX) :

Manufacturer may presume conformity of these pieces
Equipment without 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 whole assembly Manufacturer provides clear instructions for assembly / installation / operation / maintenance in the operating manual.
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VRUSafetyfeatures
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...
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VRUExplosionproofdesign
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Detonationarrestorininletlineand Valveswithlimitswitches
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Gasolinereturnpump
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Levelcontrolandswitches
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Temperaturesensorsandindicators incarbonbed
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DryVacuumPump TemperatureMonitoring
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Twosafetyvalves ineachgasolinecirculationline
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SafetyIntegrityLevel...
EN615085.2001
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%)
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SafetyIntegrityLevel
EN615085.2001
Possibility of avoidance of a hazardous event (P)

Possible under certain conditions Almost impossible
Demand rate (W)

High W3 Low W2 Very low W1
Result of SIL risk assessment is Category a

No special safety requirements
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ResultofSILriskassessment
Consequence of Risk (C) Minor Injury Toxonomy Serious Injury or permanent incapacity Fatality or catastrophic incapacity C1 Frequency of Exposure (F) Toxonomy Rare to more often ( 0 - 10% ) Frequent to permanent ( 10 - 100% ) F1 F2 F1 F2 F1 F2 <1 <=1 1 C2 >1 C3 >10 C4
Possibility of avoidance of a hazardous event (P) Toxonomy Possible under certain conditions Almost impossible P1 P2 P1 P2 P1 P2 P1 P2 P1 P2 P1 P2
Demand Rate (W) High W3 Toxonomy Low W2 Very Low W1 a 1 a 2 1 a 3 2 1 2 1 a 3 2 1 4 3 2 3 2 1 4 3 2 b 4 3
Result of the Risk Reduction Estimation = a, no special safety requirements
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PresentationofVapourRecoverySystems

ByTiesMulder ProcessandImplementationConsultant June2005

First systems = thermal destruction (air assisted flare)

Energy consumption : high Destruction : 97 % efficiency Maintenance : low

Presentation VRU - June 2005

Energy consumption : high Emissions : 80 % efficiency Maintenance : medium

Presentation VRU - June 2005

Top product vented to atmosphere

Gasoline supply Glycol Separator

Energy consumption : low Emissions : 80 % efficiency Maintenance : high

Vapour Inlet Activated Carbon Filters

Presentation VRU - June 2005

Deep cooling systems @ -35C (Edwards - USA)

Clean Air Outlet De-icing heater Cooling Elements

Energy consumption : high Emissions : < 80 g/m3 Maintenance : very high

Presentation VRU - June 2005

Top product returned to inlet

Energy consumption : low Emissions : 35 g/m3 Maintenance : high

Vapour Inlet Activated Carbon Filters

Replacement of deep cooling by adsorption systems in USA

Presentation VRU - June 2005

Presentation VRU - June 2005

Fear of patent infringement Development of alternative solutions in Europe

Coolsorption / Kappagi Vaconocore / Preussag Kaldair Petro-Plus (Qlear) / Schwelm Mc Gill

Clean Air Outlet Absorbents Inlet Vapour Inlet

Reabsorber Absorber Heater Absorbents Return Nonane Circuit Chiller Splitter

Presentation VRU - June 2005

Clean Air Outlet

Separator Vapour Inlet Cooler

Vacuum Pump Compressor

Presentation VRU - June 2005

Clean Air Outlet

Separator Vac pump

Presentation VRU - June 2005

Latest developments : Dry screw pumps systems by CarboVac

Energy consumption : low

Inlet Dry Screw Vacuum Pump P

Activated Carbon Beds

Presentation VRU - June 2005

Presentation VRU - June 2005

Presentation VRU - June 2005

Presentation VRU - June 2005

European Directive EC94/63

35 g / m3 of air emitted (often 10 g / m3 is desired - Oslo protocol) 3 phases :

Application for fuels with RVP > 276 mbar

TA-Luft 01 in Germany, LRV in Switzerland

In USA : emissions measured as a function of loaded gasoline

Continuous measuring system with complex and expensive devices

CIM : Control Inlet Monitoring CEM : Continuous Emissions Monitoring

In Europe : emissions measured as real emission concentration

Presentation VRU - June 2005

Energy consumption (kWh/m3 treated)

Emission limit (g/m3)

Presentation VRU - June 2005

Losses : 0,1 kg/m3 Emission reduction measures up to 99%

Losses : 1 kg/m3 Emission reduction measures up to 99,99 %

Losses : 1 kg/m3 Emission reduction measures up to 99%

Presentation VRU - June 2005

Presentation VRU - June 2005

At the Service Station