From: "Wilkins, James R. (MPC)" <jrwilkins@marathonpetroleum.com> 

To: Brenda Shine/RTP/USEPA/US@EPA 

Sent: 11/07/2011 08:54 AM 

Subject: Requested Information 

Brenda 

As requested, enclosed please find documentation and basis regarding installation of steam 

eductor de-pressuring system on the cokers at our refinery in Garyville, LA. We (Marathon 

Petroleum Company) installed the steam eductor on the new (Unit 205) coker in 2010 at a total 

capital cost of less than $1 million. The system has worked so well that we (MPC) are in the 

process of installing similar system on the old (Unit 05) coker in lieu of continuing to operate the 

existing liquid ring compressor(s) to de-pressure its drums. 

We (MPC) have accepted enforceable conditions on Garyville’s Unit 5 and 205 Coking units (each 

45,000 BPD )as follows: 

 Open the coke drum vents at a pressure equal to or less than two (2) psig before venting to 

atmosphere 

 Inject at least 270,000 gallons of quench water into the system per drum unless the high level 

alarm is reached 

 Recycle coker blow down water shall not be used as quench water during venting 

 Inject H2S scavenger at a rate of one-half gallon per minute starting at least thirty minutes prior 

to and after opening the Coker Drum Vents (i.e. one hour in duration) 

Please note that the addition of the H2S scavenger was done in conjunction with agreement with 

LDEQ /EPA (Region VI) to mitigate hydrogen sulfide emissions from the coker vents in conjunction 

with permitting activities associated with a major expansion project at the refinery. 

In addition, MPC has accepted enforceable emission limits for each the Unit 5 and 205 Cokers as 

follows: 

 VOC – 24.2 tons per year 

 H2S – 2.8 tons per year 

 PM – 1.26 tons per year 

 PM2.5 – 0.42 tons per year 

Please let me know if you have any questions. 

James Wilkins 

ES&S Manager, Refining Division 

Marathon Petroleum Company LP 

Phone: (419) 421-3287 

Cell: (419) 348-6471 

<< Garyville - Steam Eductors.pdf >> 
Marathon Petroleum Company LLC 

REFINING 

INITIAL CAPITAL BUDGET 

($000's) 

Year: 2010 Initial Budget Organization: Louisiana Refining Division 

G-955 Coker Drum Depressuring Project 

Project Summary Sheet 

A. Project Title: G-955 Coker Drum Depressuring Project 

B. Objective: 

C. Capital Amount: 

Estimate Quality: A 

Environmental 

Prior to 2010 

2010 

2011 

2012 

2013 

2014 

Total: 

Capital Authorization Amount 

Expense Amount: N/A 

D. Project Description/Source of Benefits: 

$ 

$ 

$ 

$ 

$ 

$ 

$ 

$ 

20101N 2009 MY 

Budget Budget 

250 $ 250 

750 $ 4,000 

- $ - - $ . 

- $ - - $ - 1,000 $ 4,250 

1,000 $ 250 

Change 

$ 

$ (3.250) 

$ 

$ 

$ 

$ 

$ (3.250) 

$ 750 

The current operation of tile Unit 05 Coker includes venting the coke drums directly to the atmosphere after water quenching to 

the blowdown tower. S[nce the Slowdown System operates at 15 psig, further depressuring of the coke drums is accomplished by 

venting the drums to atmosphere before un-heading. This practice is not in compliance with Subpart Ja, which requires the coke 

drums to be depressured below 5 psig before they can be vented to the atmosphere. Although the existing Coker (Unit 05) is not 

presently subject to Subpart Ja. subsequent modifications to the unit in the near future could require the unit to meet this 

regulation. 

In order to allow the Unit 5 Coker Unit to meet the Subpart Ja requirement that coke drums vent below 5 psig, the Marathon 

Project Team first decided to install a Slowdown Vent Gas Compressor to lower the pressure of the blowdown system and hence 

the coke drums. A Decision Support Package for implementing this concept was approved at the end of 2008, and the total 

estimated cost of the project was about $4MM. 

The Project Team later decided to explore a more cost effective option and contracted ConocoPhillips to design a steam ejector 

system in place of a Slowdown Vent Gas Compressor. The ejector system designed by ConocoPhillips and Bechtel is capable of 

lowering the pressure of the blowdown system and the coke drums to below 3 psig in less than 45 minutes, and it discharges the 

recovered vapor at 22 psig into the inlet of the Fractionator Overhead Fin Fans. The system includes two ejectors that are sized to 

handle 50% of the nominal design flow. This was done to cover the potentially wide variation and uncertainty in the coke drum 

vapor flow rate. As a result, only one ejector may be required during operation. The ejector system capacity is 1 060scfm 

(40251b/hr) of water-saturated non condensable gas. and the motive fluid requirements are 150 pslg steam at 8700 lbs/hr. After 

exploration of this option, the Project Team recommends installing the steam ejector system desgined by ConocoPhillips in the 

Unit 05 Coker for depressuring the coke drums down to about 3 psi after the quench step. The system includes two steam ejectors 

and the associated piping, instrumentation, and steel. The total estimated cost to complete the project is $1MM. 

E. Financial Benefits: N/A 

F. Economics: N/A 

G. Attachments: 

1. Design and Cost Estimate 

Last Revision Date: 08/18/2009 

R/1/R 
Year: 2010 Initial Budget 

G-955 Coker Drum Depressuring Project 

Approved Date: 0712912009 

Marathon Petroleum Company LLC 

REFINING 

INITIAL CAPITAL BUDGET 

($000's) 

Organization: Louisiana Refining Division 

R/2/R 
D & E - Decision Support Package Approval Form 

fM...Menrthon 

~.Oil Company 

Pro ect Title/ Oescrl tlon: 

Page I of I 

Louisiana Refining Division 

Date: 

Oeslgr• of Ejector System for the Cok~r · Hire Conoco-Phlllips to < 11 2/11/2008 

Unit Name: 

lo5 -D~ ay~ d C~ker'- Do'!' 7 

Conceptual: r 

Approval R:ole 

Accounting Representative 

Area Environmental 

Area s.tety Representative 

Procea Area Coordinator 

Proc::esa Engineer 

Project Area Coordinator 

Project Engineer 

Project Sponsor 

TA Planning Supervi sor 

Team Leader 

ERTS Number: Work Ore 

I 

DECISION SUPPORT PACKAGE 

Feasibility: P" Definition: r 

---- ··· --·------· --... 

-·-----·· Approval Date Approved Review~ __ .__ __ ........... _... 

12/12/2008 Yes BETH DURON 

12/15/2008 Yes N G (NICOLE) BRIEN -- - 12/12/2008 Yes MARK BAILEY - 12/12/2008 Yes MlotAEL ODELL 

12/11/2008 Yes ANDREW SMITH 

12/12/2008 Yes PETER TALAVERA 

12/11/2008 Yes WENDAL VINCENT -- --- 12/11/2008 Yes RICHARD HERNANDEZ JR - -----~--

12/12/2008 Yes MICHAEL HENSCHEN JR ·--· 12/15/ 2008 Yes K N (KfVIN N.) BASHAM - -

Project Cost Summary_($000's) ,_ ___ _ ....;:....:..:o::.~jL..:: ct-=-=-=:::.:..:. no:::.:..:.:..:.ic..:::=----·--

TotaJ Costs ($000's) 

~ CaP-ital ~xpense 

~ 0 Q ROI ( 0

,-b) ~9: 

~ Q H NVP @ 15o/o .Q 

1JUQ 0 0 Simple Payout ( yrs).Q 

B.tmAinlnt Q Q 

Total 0 ZQ 

Ell Im ct 

Date Approved: 

P-[11 [o8 

Divioion 'lJI'•o~ ";.~H) BEDELL 

I 
Distribution 

OFFICE: LA Refining Division 

SUBJECT: DESIGN & COST ESTIMATE 

Project#: 

Marathon Petroleum Company, LLC 

Louisiana Refining Division 

Design & Cost Estimate 

DATE: 12/16/2008 

FROM: A. Smith I W . Vincent 

Project Till;., D.:: s ign of Ejector m for the Coker 

SCOPE 

The purpose of this project is to evaluate using a steam ejector system in place of the proposed liquid ring 

rnpressor <;ys1Am for reducing pressure at which the coke drum::; now vent to thn ;;tmnsrhF-re. 

RECOMMENDATION 

It is recommended to contract Conoco-Phillips to design a steam ejector system for our existing Coker to 

reduce the venting pressure of the coke drums from the current 16-18 psi to a 3 psi. The cost of this work 

will be $70,000 to be spent in the first and second quarters of 2009. This price includes design man hours 

as well as travel expenses. 

FINANCIAL BENEFITS 

The project to install liquid ring compressor systems on both Cokers is estimated to be $7.6 MM. By using 

ejectors in place of the compressors, there will be an estimated savings of over $4.0 MM in capital 

expenditures. The steam ejectors although consuming 18,000 lbs per day of 150 lb steam will result in net 

nergy savings of $131M. There will also be savings in maintenance costs since the ejector system will 

require mucl1 less rnaintenance than the compressor system. 

DISCUSSION 

The Team decided to explore the possibility of using ejectors instead of liquid ring compressors after 

learning that the standard design for Foster Wheeler Coker Units is now to use steam ejectors to 

reduce the coke drum pressure prior to venting. Steam ejectors were not considered for GME as the 

Conoco Phillip's standard design is to use liquid ring vent gas compressors. Since then Conoco Phillips 

has designed an ejector system for Sun cor in Canada however this system has not yet been installed. 

Based on the new NSPS Subpart Ja requirements other refineries are also designing steam ejectors to 

reduce drum venting pressure such as Hovensa, U.S Virgin Islands and C ITGO, Lake Charles. 

The proposed steam ejector design will educt the coke drum gas and discharge into the Blow down 

system. A conservative estimate by Graham Corp. is that the steam ejector will require 11 mpph of 150 

psig motive steam for an approximate vent gas suction load of 21 mpph at 16-18 psig. The coke drum 

pressure will be reduced to 3 psig therefore the ejector suction pressure will be <1psig to account for 

any line losses and the discharge at 18-20 psig so that vent gas stream can get into the blow down 

system. Based on these preliminary numbers the additional steam requirement and sour water 

generation will not be significant. 

Conoco Phillips was contacted and they proposed a design package that will contain the following 

deliverables: 

1. Design Basis Description 

• Elapsed time. start and end pressures 

....~ ... .... '\ ......... ... - • 
Distribution 

DESIGN & COST ESTIMATE 

December 12, 2008 

~ge 2 

• Basis for generated steam and vapors 

" Description of intended operation 

2. Hand marked P&IDs 

3 Ejector Data Sheet 

4 Control System data for sizing 

• Motive steam flow rate controller, if applicable 

.. Spill back flow rate controller, if applicable 

5. Line Designa tion table 

• Pipe class, metallurgy, size 

• Insulation requirements 

• Piping design temperature, pressure 

6. interlock Description 

PROJECT EXECUTtON 

Tbe project cao be compl eted on the run and should not rcqnire a lHJit shutdown . 

. CCOUNTING ANALYSIS 

,·'he costs associated with tr1e Design of the Ejector System for the Coker (- $70,000} should be expensed 

since its conceptual process study work to determine a viable design solution. 

Solomon Exclusion Information: Excludable; 1 00% Environmental 

Cost Information: Funds associated with this project will be accounted for from within the Tech Services 

outside engineering department budget. 

ENERGY ANALYSIS 

There will be a net savings of $131M annually if the steam ejectors are installed instead of the 400hp 

compressor motor. The Garyville Ell will also be reduced by 0. 002. The steam ejectors will require 18MPPD 

of 150# steam costing $46M while the 400HP compressor motor will cost $177M annually. This assumes an 

electricity cost of $0.0679/kwh and $7/Mibs for 150# steam. 

ENVIRONMENTAL ANALYSIS 

Reduction of the coker drum venting pressure in order to reduce atmospheric emissions is required for 

Subpart Ja compliance and should be implemented as soon as possible. Prior LDEQ approval is not 

required for the design phase but will be required prior to installation of any equipment. 

DISTRIBUTION 

R. D. Bedell, S. H. Baker, W. E. Dows, R. J. Dussold, D. L. Ehrhart, R. A Hernandez, R. G. 
·Distribution 

DESIGN & COST ESTIMATE 

'~ec mber 12, 2008 

Je 3 

Kasubinski, W . M . Kepner, B. J. Levi. D. Roland, N. G. Orien, M. W. Odell, P. G. Talavera 

Team Leaders