CEMS Engineering Design for Refinery Processes - Tim Kuiken

Continuous Emissions Monitoring Systems Engineering Design For Refinery Processes a technical solution to meet ever every y need…

CEMT CEMTEK EK Envir onm ental Inc. 3041 S. Oran ran e Ave. Ave. Santa Ana, CA 92707 800-400-0200 www.cemteks.com © 2009 2009 Cemtek Environmental, Inc.

Refinery Process Diagram

© 2009 2009 Cemtek Environmental, Inc.

Fractional Distillation Fractional distillation is us eful f or s eparating parating a mixture of s ubstances with narrow di fferences fferences in boiling points , and is th e most i mportant .

Crude Heater © 2009 2009 Cemtek Environmental, Inc.

Atmospheric Distillate Tower Tower

Vacuum Distillate Tower Descriptions courtesy of www.howstuffworks.com

Chemical Processing You ca c an change ch ange one fraction into int o another by o ne of thr ee methods : breaking brea king large hydrocarbons into smalle smallerr pie p ieces ces (cracking (cracking))  

rearr rearra anging ngi ng variou s pieces to make make desired hydr ocarbons ocarbo ns (alteration) (alteration)

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(sometimes high pressures as well) until they break apart. steam - high temperature temperature steam steam (1500°F (1500°F / 816°C) is is used to break ethane, butane and naptha into ethylene and benzene, which are used to manufacture chemicals. visbreaking - residual from from the distillati distillation on tower is heated heated (900°F/ 482°C), cooled with gas oil and rapidly burned . viscosity of heavy weight oils and produces tar. coking - residual from from the distillation distillation tower tower is heated to temperatures above 900°F/ 482°C until it cracks into eavy o , gaso ne an nap t a. en t e process s done, a heavy, almost pure carbon residue is left (coke (coke); ); the coke is cleaned from the cokers and sold. © 2009 2009 Cemtek Environmental, Inc.

Coker Descriptions courtesy of www.howstuffworks.com

Chemical Processing You ca c an change ch ange one fraction into int o another by o ne of thr ee methods : breaking brea king large hydrocarbons into smalle smallerr pie p ieces ces (cracking (cracking))  


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. Catalysts include zeolite, aluminum hydrosilicate, bauxite and silica-alumina. fluid catalytic catalytic cracking - a hot, fluid catalyst catalyst (1000°F/ 538°C) cracks heavy gas oil into diesel oils and gasoline. hydrocracking - similar to to fluid catalytic catalytic cracking, cracking, but uses a different catalyst, lower temperatures, higher , . it into gasoline and kerosene (jet fuel).

Fluid Catalytic Cracker

Hydrocracker © 2009 2009 Cemtek Environmental, Inc.

Descriptions courtesy of www.howstuffworks.com

Chemical Processing You ca c an change ch ange one fraction into int o another by o ne of thr ee methods : breaking breaking large hydrocarbons into smaller smaller pie p ieces ces (cracking (cracking )  


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Sometimes, you need to combine smaller hydrocarbons to make larger larger ones -- this process process is called unification. unification . The major unification process is called catalytic catalytic reforming and uses a catalyst (platinum, platinum-rhenium mix) to combine low weight naphtha into aromatics, which are used in making chemicals and in blending b lending gasoline. A significant by-product by-produc t of this reaction is hydrogen gas, which is then either used for hydrocracking or sold.

Catalytic Reformer © 2009 2009 Cemtek Environmental, Inc.

© BP p.l.c.


Chemical Processing You ca c an change ch ange one fraction into int o another by o ne of thr ee methods : breaking breaking large hydrocarbons into smaller smaller pie p ieces ces (cracking (cracking )  

rearr rea rra angi nging ng various variou s pieces to make make desired hydr ocarbo ocarbons ns (alteration) (alteration)

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Sometimes, the structures of molecules in one fraction are rearranged to produce produc e another. Commonly, Commonly, this is done using a process called alkylation. alkylation . In alkylation, low molecular weight compounds, such as propylene and butylene, are mixed in the presence of a catalyst such as hydrofluoric acid or sulfuric acid (a by-product from removing impurities from many oil products). The products of alkylation are high octane hydrocarbons, which are used in gasoline blends to reduce knocking.

Alkylation Unit © 2009 2009 Cemtek Environmental, Inc.


Fractional Distillation and Most un its u tilized tilized in f ractional distillation and chemical chemical proc essing utilize uti lize hea heaters burn b urning ing refinery and/or n atural gas and requir e CE CEMS. MS. 

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NOX control.

Area classification of shelter/cabinet placement

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If shelter/cabinet is placed in a classified area Can a positive pressure purge system be used to declassify shelter/cabinet interior to general purpose area? Site requirements for conduit, receptacle, misc. equipment whether in a classified or general purpose . 

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Space limitations including access for HVAC maintenance and I/O connections. 

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e ter am ent gas mon tors or wor er sa ety. Class 1, Div 2 HVAC w/ Purge


Fractional Distillation and CEMS CEMS Design Design Considerations Continu ed If SCR is utilized for NO X control Dual range NOX analyzer for post-SCR measurement including associated cal gas equipment. How will NH3 slip be measured? Tunable Diode Laser (TDL)

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Converted NH3 measured as NOX

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Calibration gas supply for startup and certification.

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e spec c o erp a e spec ca ons requ re

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Data Acquisition How will CEMS data be handled and stored? Data Acquisition System (DAS) for data handling and storage. DCS to handle CEMS data Co-mingling of data issues Most refinery processes subject to 40CFR Part 60 . subject to 40CFR Part 75, requiring data substitution routines.

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NOX & O2 CEMS on refinery heater with stack mounted NH 3 measurement using TDL (tunable diode laser)

Auxiliary Refinery Processes Ad A d d i t i o n al s u p p o r t p r o c ess es s es are ar e req r equ u i r ed f o r r efi ef i n ery er y o p erat er atii o n t o aid ai d in refining o f the crude oil and handling handling of the process waste: waste: hydrogen hydr ogen produc tion for hydro treating treating proc esses (Hydrog (Hydrog en Plant) Plant) sulfu r recovery recovery for processing waste acid acid gases gases (Sulfur (Sulfur Recovery Unit)   

Cogeneration Plants are used to produce power and steam for use in the refinery processes. Steam specifically can be used for process heat and is integral in the operation of the hydrogen plant and sour water steam stripper.

Cogeneration Plant © 2009 2009 Cemtek Environmental, Inc.

Cogeneration Plant CEMS Most Cogeneration ogeneration Plants Plants utilize combined cy cle turbin es burnin g natur al gas and requir r equir e CEM CEMS. S. 

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NOX control.

Area classification of shelter/cabinet placement is typically general purpose as the CoGen plant is remotely located from the refinery. 

If SCR is utilized for NO X control Dual range NOX analyzer for post-SCR measurement including associated cal gas equipment.

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Tunable Diode Laser (TDL) Differential NOX calculation Converted NH3 measured as NOX

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a

rat on gas supp y or startup an cert cat on. Cogeneration Plant


Cogeneration Plant CEMS CEMS CEMS Design Design Considerations Continu ed Site specific boilerplate specifications required to be met.

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Data Acquisition Stand alone data acquisition system (DAS) typically utilized for data manipulation and storage.

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Part 75, depending on the amount of power sold to the grid.

NEMS (NOX Emissions Monitoring System)


Auxiliary Refinery Processes Ad A d d i t i o n al s u p p o r t p r o c ess es s es are ar e req r equ u i r ed f o r r efi ef i n ery er y o p erat er atii o n t o aid ai d in refining o f the crude oil and handling handling of the process waste: waste: hydrogen hydr ogen produc tion for hydro trea treating ting proc proce esses (Hydrog (Hydroge en Plant) Plant) sulfu r recovery recovery for processing waste acid acid gases gases (Sulfur (Sulfur Recovery Unit)   

Hydrogen plants are used to produce hydrogen gas used in the hydro treating refinery processes, particularly the hydrocracker and hydrotreater units. Natural gas is converted to hydrogen through the steam reforming process.

Hydrogen Plant © 2009 2009 Cemtek Environmental, Inc.

Hydrogen Plant CEMS Most Hydr Hydrogen ogen Plants Plants uti lize steam reformer reform er burners bur ning natural gas and requir requ ire e CEM CEMS. S. 

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X

control.


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If SCR is utilized for NO X control Dual range NOX analyzer for post-SCR measurement including associated cal gas equipment. ow w easure re 3 s p e measu Tunable Diode Laser (TDL) Differential NOX calculation Converted NH3 measured as NOX

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Hydrogen Plant

Hydrogen Plant CEMS CEMS CEMS Design Design Considerations Continu ed Calibration gas supply for startup and certification.

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Site specific boilerplate specifications required to be met.

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Data Acquisition

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Data Acquisition System (DAS) for data handling and storage. DCS to handle CEMS data Co-mingling of data issues os re nery processes su ec o ar compliance. Some processes may be large enough to be subject to 40CFR Part 75, requiring data substitution routines. 

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CEMS measuring NOX, CO, wet and dry O2, ammonia and stack flow on Hydrogen Plant.


Auxiliary Refinery Processes Ad A d d i t i o n al s u p p o r t p r o c ess es s es are ar e req r equ u i r ed f o r r efi ef i n ery er y o p erat er atii o n t o aid ai d in refining o f the crude oil and handling handling of the process waste: waste: hydrogen hydr ogen produc tion for hydro treating treating proc esses (Hydrog (Hydrog en Plant) Plant) sulfurr recove sulfu recovery ry for processing waste acid acid gase gases s (Sulfur (Sulfur Recovery Unit)   

Sulfur Recovery Units remove the sulfur compounds (H2S, SO2) from the waste stream gases and convert them to elemental sulfur using a process developed by Carl Claus. The unit uses both thermal and catalytic reductions for removal of the sulfur compounds. Post recovery gases may be passed to a Tail Gas Incinerator or Causti Causti c Scrub Scrub ber for further cleanup.

Straight-Through 3-Bed Claus Plant © 2009 2009 Cemtek Environmental, Inc.

Sulfur Recovery Unit

Sulfur Recovery Unit CEMS Most Sulfu r Recov Recovery ery Units (SR (SRU) exhaust exhaust waste acid acid gas thr ough oug h a Tail Gas Gas Inci nerator or Caus Causti tic c Scru bber bb er and and r equir e CEM CEMS. S. 

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refinery CEM CEMS applica applic ations tio ns d ue to variable fuel compos com positi itions ons and wide range of expected emis emissio sions. ns.


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Space limitations including access for HVAC maintenance and I/O connections. 

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e ter am ent gas mon tors or wor er sa ety. Sulfur Recovery Unit


Sulfur Recovery Unit CEMS CEMS CEMS Design Design Considerations Continu ed Calibration gas supply for startup and certification.

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Site specific boilerplate specifications required to be met.

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Data Acquisition

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Data Acquisition System (DAS) for data handling and storage. DCS to handle CEMS data Co-mingling of data issues os re nery processes su ec o ar compliance. Some processes may be large enough to be subject to 40CFR Part 75, requiring data substitution routines. 

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Tail Gas Incinerator


Sulfur Recovery Unit CEMS CEMS CEMS Design Design Considerations Continu ed Tail Gas Inc inerator iner ator CEMS CEMS Wide range of SO 2 emissions, ~10ppm during normal operation and % level during plant upsets. Separate SO2 analyzers may be required to cover both controlled and uncontrolled plant operation. . 

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Stack flow measurement typically required do to variable heat input capacity of waste gas. (Mass emissions reporting) 

au s c c r u er Measurement of SO 2 in the presence of NH 3 Formation of ammonia salts Knockout of NH3 at probe location to avoid loss of SO 2 sample. sample. Critical Critical for low low level level SO SO measure measuremen ments. ts.

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Stack Flow measurement typically required.

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Caustic Srubber

Gas Chromatography Gas Gas Chromatographs are used used at di fferent fferent points throu ghout the refinery refinery proc ess for bot h process contro l and and regulatory regulatory reportin g: , 2 , 2, refinery gas sul fur and heat content us ed by h eaters eaters (H2S, SO2, TRS, BTU) produc pro ductt compos com positi ition on (Ethane, (Ethane, Prop Propa ane, Butane, Butane, Penta Pentane, ne, C4+, C6+)   

Class 1, Div 2, GC Shelter Exterior © 2009 2009 Cemtek Environmental, Inc.

Class 1, Div 2, GC Shelter Interior

CEMTEK Environmental

SCAQM SCAQMD D Refin Refinery ery Service Servi ce Contract Cont ract Since 2005, Cemtek Environmental has been responsible for the service of all 26 CEMS at a local SCAQ SCAQMD MD Refi Refine nerr . Cemt Cemtek ek is also also erfo erform rmin in the the routine maintenance and calibration on the ambient air monitoring systems sy stems and fuel flow transmitters. To To provide 7 day a week service, Cemtek has 8 full .

Cemtek Environmental Bronze Safety Award Recipient 2007 & 2008. © 2009 2009 Cemtek Environmental, Inc.

CEMTEK Environmental BAAQM BAA QMD D Refinery Refinery SRU SRU Inc Incin ine erator Monitor Monit orin ing g System Syst em

CEMTEK supplied a new CEMS for monitoring sulfur recovery unit tail gas . , Div 2 CEMS shelter measuring NO X, SO2, CO, wet & dry O 2, and stack flow. Also provided was a custom built, 18 foot multi-point heated heated probe for measurement of a stratified stack. © 2009 2009 Cemtek Environmental, Inc.

CEMTEK Environmental SCAQMD SCAQMD Refi Refiner nery y RECLAIM RECLA IM CEMS CEMS Ap A p p l i c ati at i o n

Supplied CEMS in a NEMA 4X Class I, Div II Stainless Steel shelter to measure X, 2, 2.


CEMTEK Environmental SCAQMD SCAQMD Refi Refiner nery y RECLAIM RECLA IM CEMS CEMS Ap A p p l i c ati at i o n f o r Hydro yd rogen gen Plant Plant

Supplied CEMS in a NEMA 4X Class measure NOX, CO, wet and dry O 2, ammonia and stack flow. flow. Included field installation supervision services, s ar -up, ra r a n ng an cer ca on services. Certified 2005 © 2009 2009 Cemtek Environmental, Inc.


SCAQMD SCAQMD Refi Refiner nery y RECLAIM RECLAIM CEMS A l i c at i o n

Cemtek provided a new SCAQMD na ca net for measuring NO X, O2, & ammonia. © 2009 2009 Cemtek Environmental, Inc.


Local Lo cal Refinery Refinery Process Mo n i t o r i n S s t em

Cemtek provided four new NEMS (NO X Emissions Monitoring Systems) in a NEMA 3R cabinet for measurin inlet NOX. These replaced 20 year old KVB process systems. © 2009 2009 Cemtek Environmental, Inc.


Northwest ort hwest Refin Refine ery Application App lication

Cemtek provided a new CEMS in a Class I, Div II shelter for measuring inlet NO and stack NO & O utilizin ABB analyzers and M&C Products probes for classified areas. © 2009 2009 Cemtek Environmental, Inc.


Northwest Refinery Wet Gas Scrubbe crubber r Ap A p p l i c ati at i o n

Cemtek provided a new CEMS in a s e er or o r measur ng 2 2 n a wet gas scrubber application. © 2009 2009 Cemtek Environmental, Inc.


Tim Ku iken Refinery Appli cations Enginee ngi neer r Ph: 714 714 904904-62 6276 76 [email protected] Most Cemtek Cemtek Enviro nmental staff m embers .

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Cemtek Cemtek Envi Environ ronmental mental is an acti active ve parti particip cipant ant in the OSC OSCA/ASAP A/ASAP Drug Drug Solutio olu tions ns testing program. pro gram. 


CEMS Engineering Design for Refinery Processes - Tim Kuiken

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