Air Emission Management

Air Emission ManagementKNPC Experience
The 2nd Joint Qatar-Japan Environment
Symposium
"Sustainable Environment, Climate Change and
Renewable Energy for Oil and Gas Industry",
February 5-6, 2013, Doha, Qatar
About the Speaker
Abhay Kumar Kashyap
Senior Engineer, Environment Services
Kuwait National Petroleum Company (KNPC)
•Since 2001: Environment Division, KNPC
•1995-2001 : Manager, Environment, Hindustan Petroleum Corporation
Ltd (HPCL), Visakhapatnam , India
•1984-1995 : Operations, HPCL, Mumbai
•1984 : B.Tech., Chemical Engineering, Indian Institute of Technology,
Kanpur India
Index
1.
2.
3.
4.
KNPC
Development of Air emission Management Program
Programs / Projects
Questions.
KNPC Core Business
KNPC is a Government owned refining company of Kuwait
3 Petroleum Refineries with total refining capacity of 936,000 bbls/ Day.
A LPG/Gas Plant with 3 trains.
Local Marketing facilities
MINA ALAHMADI
SHUAIBA
REFINERY
200 M BPD
REFINERY
466 M BPD
MINA
ABDULLAH
REFINERY
270 M BPD
LOCAL
LPG / GAS
PLANT
3 Trains x
560 MMSCFD
MARKETING
39 Filling
Stations
2 Depots
Sabhan
&Ahmadi
LPG
466 MBPD
NAPTHA
MOGAS
KERO / ATK
200 MBPD
DIESEL
MARINE DIESEL
High Sulphur
Fuel Oil
Low Sulphur
Fuel Oil
270 MBPD
BITUMEN
SULPHUR
COKE
Development of Air Emission Management Program
Inputs which have shaped
Management programs:
KNPC’s
Air
•Air Emission Regulations at Kuwait
•Implementation of ISO 14001
•KPC HSE Strategies
•Community concerns and voluntary initiatives
Emission
Appendix 20
“Environmental Requirement and Standards in the State of Kuwait” Kuwait Al Youm
Appendix of issue no 533 year 47 dated October 2, 2001
Source
First : Fixed Source
1.1 All emission sources
Pollutant
Scale
- Particulate
Darkness level should not exceed 20% (max .limit)
- Asbestos
No emissions are allowed
1.2 Stacks of Products
- Particulate
Darkness level should not exceed 20% (max .limit)
1.3 Stacks
- Particulate
115 mg/m3
Darkness level must not exceed 20% (max. limit)
2. Facilities Operated by
- Particulate
Combustion
Fossil fuel fired Boilers and furnaces - SO2
with heat energy input more than 30 MW - Nox
(100 MBTU/hr)
- Nox
- Opacity
43 Nanograms /Joule
512 Nanograms / Joule
86 Nanograms/Joule facilities burning natural gases
130 Nanograms/Joule facilities burning fuel oil
Should not exceed more than 20%
3.3 Petroleum Refineries
3.1 FCC Unit (with incinerator or waste - Particulate
heat boiler)
- SO2
- CO
- Opacity
1.0 Kg/Metric ton of coke burn off
9.8 Kg/Metric ton of coke burn off
500 ppmv
Should not exceed 30% for more than 6 minutes / hr
3.2 Fuel gas used in combustion
- H2S
230 mg per dry standard cubic meter
3.3 Claus unit for Sulfur recovery &
capacity exceeding 20 T/day.
- SO2
250 ppmv in stack with oxidation or reduction and
incineration
Electrostatic Precipitator (ESP) at Fluidized Catalytic Cracking Unit
(FCCU) at Mina Al Ahmadi (MAA) Refinery
KEPA Limits
Particulate Matter, Kg/ton of coke
Low NOx Burners in Heaters and Boilers
• KNPC uses gaseous Fuel
• KEPA limit for Gas combustion is 86 Nano Gram / Joule (Approximately
165 ppmv reported at 3 % O2 in stack)
• 10 Heaters & Boilers were identified as not meeting the limit.
• 1 Heater and 1 Boiler Burners are replaced with 120 ppmv NOx burners.
Burners in two more heaters are under replacement.
• 69 ppmv NOx burners are being installed at 5 boilers in the second phase.
• Option of lower specification is being studied for some additional existing
heaters and new projects.
Low NOx Burners in Heaters and Boilers
Low NOx Burners in Heaters and Boilers
Lowering H2S in Fuel Gas
•
KNPC uses a mix of Refinery generated fuel gas and imported gas (after
extraction of C3, C4 and other useful components)
•
Part treatment of Imported gas.
•
Split streams generated from Ethane Recovery unit which was low in H2S has
resulted in KEPA Fuel gas H2S limit being met at MAA Refinery.
Flare Gas Recovery Units (FGRU) at MAA Refinery and MAB Refinery
• KNPC has initiated two FGRU projects at its MAA & MAB Refineries
• Flare Gas Recovery Unit to minimize flaring through the Refinery
Modernization Project ( RMP) units and Future Up gradation Project (FUP)
units Flare systems at MAA is expected to be commissioned in 2013.
• Study phase is completed for Flare Gas Recovery Unit to minimize flaring
through Flares at MAB Refinery.
• The two projects are expected to reduce Green House Gases
emissions by approximately 140,000 Tons Co2 eq per year.
Emission Monitoring program
Sr.
A.
Source Category
Gas fired combustion Equipment (Boiler &
Process Heaters)
B.
Fuel oil fired / Mixed firing combustion
Equipment (Boiler & Process Heaters)
C.
Sulphur Recovery Unit (SRU)
D.
FCCU
E.
Hydrocarbon flares
F.
Acid gas flares
G.
Combustion equipment (Boilers, Heater,
Compressor engines, FCCU, flares) &
Hydrogen Unit
Parameters
H2S in Fuel Gas Header
NOx in Stack
As in A above
and
Sulfur in fuel oil
SOx,
Frequency
Daily
Once in a month by the contractor
As in A above
Every batch
Continuous
and twice in a week by the contractor.
H2S
As required to confirm incineration.
Continuous in new facilities.
Particulate, SOx, CO
Continuous and once a week by the
Contractor
Quantity flared
Reported monthly
Quantity of SO2 emitted
Reported monthly
CO2
Reported monthly
The monitoring is carried out by a contractor and also continuous monitoring systems have
been provided at some stacks.
Odor Management System (OMS) and Associated Programs
• Public Perception about an industry within community is affected
considerably by odor and flaring.
• KNPC took up an Environmental Objective of developing an “Odor
Management System” (OMS) which went beyond conventional fugitive
emission management programs driven by regulations.
• Odors sources/locations have been detected, identified and quantified
through an odor survey which consisted of review of previous work,
incidents & complaints, walk through in Refinery sites including
maintenance areas and interview with Operators/Supervisors.
• A Complaint Recording and Tracking System was developed to capture
both Internal and External Environmental Complaints in future.
Odor Management System (OMS) and Associated Programs
Some of the key programs arising out of this objectives are
OMS Program
Chemical
Decontamination:
Description
Preparing the unit/vessels for shut down through steaming and water washing is a source of odor.
Use of Chemical Decontamination process reduces this problem and also reduces the downtime.
However, the effluent disposal is closely regulated as it impacts Effluent Treatment Plant.
Bulk Chemical handling:
Handling of chemicals procured in small drums and disposal of empty drums are another source
of odor. KNPC has started procurement in ISO Tanks (Figure 5) or Tote Bins (Figure 6) for
many chemicals.
Relief Gas Management:
To reduce routine loss of hydrocarbon to flare due to passing Pressure Relief Valves, a team
carries out a systematic and regular check of identified bad actors (valves) using an acoustic
meter (Vacpac) and a Thermal IR camera. Review of shutdown and start up procedures have
been done to reduce flaring through sequencing of shut down activities.
Other site specific actions
H2S scavenging for Eocene Desalter drain in MAA, Cover CPI/API, Vapor Recovery System at
Filling stations, Closed Loop Sampling, Welding Flume extractor at Welding shops (Local
Marketing Facilities).
Leak Detection & Repair
Program
KNPC has implemented a smart LDAR program to control fugitive emissions from leaky
components like valves, flanges, pumps drains and vents etc. Hydrocarbon leaks are identified
through infrared camera (Figure 7,8) followed by conventional method of measuring the
concentration of leak and repair. Non hydrocarbon sources are included in the program and
follows the conventional method of listing all components and monitoring it at fixed frequency.
Thank You
Questions???????
ISO Tank
Back
Boiler chemicals being handled in Tote Containers at MAB Refinery
Back
LDAR using IR Camera
Back