p.1 

OAR Box 1784 

Prepped by Ollie Stewart 

Document Number: 

48) II-B-7 

Docket Number: 

A-84-44 

Printed 10/31/2008 8:05:40 AM Sheet 48 of 143 
I P.2 

UNITED STATES ENVIRONMENTAL PROTECTIONAGINCY 

M 1985 

MEMORANDUM 

SUBJECT: Meeting Notes - Refinery Fuel Gas NSPS Review (83/03) 

FROM: Nancy D. McLaughlin, Environmental Engineer 

Industrial Studies Branch, ESED (MD-13) 

TO: Kenneth R. Durkee, Chief 

Standards Documentation Section, ISB (MD-13) 

I. Purpose: 

The purpose of the meeting was to discuss the model plants and 

the approach toward selecting a lower-size cutoff . 

I I. Time and Place: 

Thursday, May 9, 1985 

12:30 - 2:00 p.m. 

7th Floor Conference Room 

III. Attendees: 

ISB - Nancy McLaughlin 

Ken Durkee 

Stan Cuffe 

SDR - Gail Lacy 

Gil Wood 

EAB - Bill Va'tavuk 

IV. Discussion: 

A few days prior to the meeting, all attendees were given background 

• materials (copy attached). These background materials included an outline 

of the design of the model plants and an issue paper discussing problems 

and recommendations. The main issues presented were: 

(1) Determining an approach toward selecting a lower size cutoff 

and designing appropriate model plants for this approach. 

<! l-L^ CONCURRENCES 

SYMBOL i 

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EPA Form 1320-1 (12-70) OFFICIAL FILE COPY 
P.3 

-i ' 

(2) Identifying the various options for compliance that are 

available to a large refinery which has a new, small NSPS source. 

(3) Designing the parameters and control technology for the 

hypothetical case of a small source in a very small refinery. 

At the beginning of the meeting I discussed the background materials, 

filling in some additional technical information. The main points that I 

made were: 

(1) There is no such thing as a "typical refinery" for this NSPS 

because there are numerous configurations of amine treaters, sulfur recovery 

units, and fuel gas systems as well as various types of crudes and final 

products. This standard is particularly awkward because the affected 

facility is each individual combustion device. There may be 15 to 200 

combustion devices in a refinery depending on the size of the refinery. 

However, the number of NSPS sources, and thus the amount of sulfur to be 

controlled, cannot be correlated to the refinery size. 

(2) Designing a model plant for a small source 1n a small refinery 

is mostly a hypothetical exercise. .Small refineries, because of technical 

limitations, usually cannot process non-sweet, crudes; thus, the generated 

fuel gas is low in H^S and usually does not require additional control. 

If additional control is needed, conventional control approaches (amine 

treaters) are not appropriate. So far in the review, only a couple cases 

have been identified that fell into this category and required some 

control. One refinery received an exemption, the other (Quaker State) 

has not yet taken any action. We plan to use caustic scrubbing in model 

plant design because it has been presented in the literature; however, it 

has not been applied to an actual refinery situation. We also discussed 

that the trend is away from small refineries and toward large refineries. 

No serious disagreements arose concerning the proposed model plants 

and reconnendeo approaches. The important issues/approaches that were 

concurred on are: 

(1 ) In calculating a cost/effectiveness for a control system, we 

can include the entire emission reduction due to that control system, not 

just the reductions from NSPS affected facilities. 

(2) Some larger refineries with a new small source are able to comply 

•with the NSPS by rerouting gases. The background paper describes these 

"delaying tactics" in more detail. Essentially these are temporary compliance 

actions which have a minor, nominal cost but do not reduce emissions as the 

original standard had intended. However, as a refinery continues to expand 

or replace old units, it will eventually install a large control system 

and probably control existing as well as new sources. We agreed to accept 

this trade-off and not scrutinize this "delaying tactic" issue further; thus, 

we do not intend to alter the current NSPS to prevent this. 
P.4 

(3) We will design only one model plant to model the situation when 

a refinery with a new source expands an existing control system. Preliminary 

information Indicates that this is cost/effective, but because of the 

variety of possible configurations and size ranges we did not want to model 

all possibilities. Instead, a worst-case (highest C/E) situation was 

selected — a small new source and a relatively small existing control device. 

Two changes to the recommended model plants were suggested. These 

changes were also agreed to by all attendees: 

(1) Evaluate the model plants at only one control level instead of 

three different levels. The control level to be used is equivalent to the 

existing NSPS level of 162 ppmv. This decision significantly reduced the 

number of model plants. Also, a 50 percent reduction 1n the emission 

standard for combustion devices results in only 6 percent reduction in 

overall emissions from the total sulfur treatment system. Also, the primary 

purpose of a review study is to evaluate the current NSPS. 

(2) 'We will redesign the model plant for a small new source in a 

small refinery to match the Quaker State refinery in West Virginia. This 

refinery is the only real-life case that we-are aware of that falls into 

this category. Determining the C/E for the Quaker State situation rather 

than a hypothetical situation would be a stronger case if questions later 

arise concerning the C/E of controlling small sources. (However, that 

Quaker State refinery has been temporarily closed.) 

So far industry has not raised the issue of the need for a lower 

size cutoff, and we are therefore investigating this issue primarily for 

our own background information. 

V. Conclusion: 

Except for the two changes discussed above, all attendees concurred 

in the design of the model plants which had been presented in the background 

materials. 

Attachment 

cc: Attendees 

ESED/ISB/SDS/NDMcLaughling/cbaker 6/3/85 x5596 Rm. 755 MU (MD-13) 

File: AIP 8.1.15.5 ESED 83/03 
P.5 

1

 ?.--.\ UNITED STATES ENVIRONMENTAL PROTECTION AGENCY 

i 23 K 5 Office of Air Quality Planning and Standards 

V** 7 Research Triangle Park, North Carolina 27711 

'

M y ? 1985 

MEMORANDUM. 

SUBJECT: Refinery Fuel Gas NSPS Review (ESED Project No. 83/03) 

FROM: Stanley T. Cuffe, Chief.jfc C 

Industrial Studies Branch, ESED (MD-13) 

TO: See Below 

There wil l be a meeting for the refiner y fuel gas NSPS review projec t 

on Thursday, May 9, 1985, from 12:30 - 2:00 i n the 7th Floor Conference 

Room. The purpose of the meeting i s t o discuss the model plants and the 

approach toward selectin g a small size cutoff . Background materials on 

the issues involved and the model plant parameters are attached. 

Addressees: *"f~ " 

Bob Ajax, SDB '-"_ 

Ken Durkee, ISB 

Gail Lacy, SDB -

/^Nancy McLaughlin, ISB 

Bil l Vatavuk, EAB 

Al Wehe, EAB -

• Gil Wood, SDB 

2 Attachments 
u >«. 

P.6 

REFINERY FUEL GAS NSPS REVIEW 

MODEL PLANT ISSUES 

Background 

As part of the review of the current NSPS for refinery fuel gas, we 

are conducting a cost-analysis to determine the cost-effectiveness of the 

regulation. Also, results from this analysis wil l he!p us determine i f a 

lower-size cutoff i s warranted. 

There are several issues involved in selecting the appropriate model 

plant parameters, particularly in the lowest size range. Plant visit s 

were made and industry and vendor representatives were contacted to gather 

further information. Based on these findings, model plants have been 

developed. 

Under thi s standard, the affected facilit y is each individual combustion 

device. However, the control device is usually selected and sized based 

on the total sulfur loading to al l new combustion sources in the refinery. 

Thus, the model plant sizes are based on the total sulfur loading (in 

long tons per day) to al l NSPS combustion sources in a refinery. Larger 

model plants represent the situation of several new combustion sources 

in a refinery; the small model plants represent the situation of only one 

(or a few) new combustion sources. 

The recommended final model plant sizes and their associated control 

techniques are liste d in Table 1. The handwritten attachment presents 

the preliminary model plants and gives detailed information on the model 

plants and control devices. 
P.7 

Large and Medium Size Model Plants 

The approach toward large and medium sized systems has remained the 

same as in the preliminary model plants except that the number of model 

plants and control options has been pared down. One major change i s that 

the largest model plant sizes (200 and 500 LT/D) have been eliminated 

because their cost effectiveness would be the same or better than the 

next size plant (100 LT/D). Also, the number of control options has been 

reduced from 3 to 2 levels, (NSPS level and 1/2 NSPS level). 

Small Size Model Plants 

Issues have arisen in the approach toward modeling small plants (less 

than 2 LT/D). This represents the situation of one (or a few) new combustion 

sources in a refinery. The control technology approach wil l be different 

for small model plants in large refineries vs. small refineries. 

Small Size Model Plants - Medium and Large Refineries 

In a medium or large refinery, the H£S in the fuel gas is controlled 

in a central amine treater/ sulfur processing system which cleans the gas 

entering several combustion devices. Thus, one NSPS combustion device in 

a large refinery is not controlled individually. A large refinery with one 

new device has the flexibilit y to meet the standard in several ways: 

1 . Use an existing control system which has excess capacity 

2. Expand an existing control system 

3. Build a new control system which wil l control other sources in 

addition to the NSPS source 

4. Repipe, so that a low H2S stream is sent to the NSPS source 

5. Buy natural gas for the NSPS source 

6. Design the NSPS source to use fuel oi l 
P.8 

All of these options have been used by industry since the standard 

took effect. Option 1 is clearly cost-effective.;Option 2 is probably 

also cost-effective and we plan to use 114 responses to get cost estimates. : 

Option 3 may not be cost-effective if all the costs are related to the 

emission reduction from only the one NSPS source; however, i f we can use 

the total emission reduction for all the cleanedigas going to all combustion 

devices (NSPS and non-NSPS), then thi s case would fal l into a higher model 

plant size (>2 LT/D) and would be cost-effective.: Options 4, 5, and 6 

wil l cost a refinery a small amount to attain the standard but no emission 

reduction wil l occur since the H2S wil l be rerouted to another existing 

combustion device. However, this is essentially a delaying tactic ; when 

more NSPS sources come on-line, the refinery wil l eventually have to 

construct a treatment system for several new sources. Then, this case 

would fal l into a higher model plant size (>2 LT/D). 

The issue here is how to design model plants for small new sources 

in larger refineries. Because of the variety of configurations and options, 

several model plants would be needed and a large amount of time and money 

expended. Also, there have not been significant complaints by industry 

concerning this situation. Thus, the recommended approach for this case 

is not to develop rigorous models, with rigorous cost/effectiveness 

analyses. Only Option 2 wil l be formally addressed, (i.e. , a small expansion of . 

less than 2 LT/D which is needed for an existing amine treater/Cl aus plant 

control system). This is a difficul t situation to model because there are 

many ways to expand capacity, (operational changes, chemical changes, and 

physical capital changes). We wil l use results from 114 responses to 

develop rough cost/effectiveness estimates. Also, i f needed, we wil l 
P.9 

4 

model a 0.5 LT/D expansion to an existing 10 LT/D plant. This is a worse-case 

situation, because small increases to capacity for relatively large systems 

can probably be handled without physical changes and capital expenditures. 

Small Size Model Plants - Small Refineries ' 

For very small refineries the situation is different. If one new 

combustion device is built , a small refinery does not have the flexibilit y 

and variety of options that are available to a larger refinery. Also, 

the entire small refinery may have less than 2 LT/D of sulfur in its' fuel 

gas system. These small refineries would probably process less than 

20,000 barrels of sweet crude per day, and the H2S level in the fuel gas 

may be only slightl y above the NSPS limit. : Due to costs and technical 

limitations , conventional sulfur control systems (amine treater/Cl aus 

plant, or L0CAT plant) are not appropriate for this situation, and there 

are no other traditionall y accepted sulfur treatment processes that have 

been demonstrated for such a situation. So far in the review, we have 

identified only a couple of instances that fal l into this category of a 

small NSPS source in a small refinery that wil l need to treat the H2S in 

the fuel gas. Essentially, model plants less than 2 LT/D in this situation 

are hypothetical situations, that have no conventional, demonstrated 

control approach, and would have to be dealt with on a case-by-case basis. 

Designing model plants and evaluating the cost/effectiveness for the 

variety of possible situations could become a time-consuming, tedious 

exercise that may yield littl e useful real-world information. The recommended 

approach is to investigate only two model plants that would represent the 

end points of the range of possibilities . The worst case, (i.e. , the 

highest cost-effectiveness), would be for a model plant at the smallest 
P.10 

size considered by NSPS studies (0.13 LT/D of sulfur results in 100 tons 

of SO2 per year) and with a relatively low.concentration of H2S in the fuel ; 

gas. The upper end of the range wil l be represented by a 2 LT/D model 

plant. The control technique wil l probably be caustic scrubbing, but 

because thi s is a hypothetical case, we wil l rely heavily on the suggestions 

by vendors about the selection and design of the best control system. 

The results from this analysis wil l show us i f the smallest, worse-case 

situation could be controlled cost-effectively. Based on the outcome, we 

could then decide whether to set a lower-size cutoff, pursue the study 

in more detail , or drop the issue, leaving the standard unchanged with 

no lower-size cut-off. 

Details on Model Plants 

Details on the process being modeled, the model plant parameters, and 

the selected contol techniques are given in Table 1 and in the handwritten 

attachment. 
P.11 

Size 

LT/D* 

TABLE 1 

SUMMARY OF RECOMMENDED MODEL PLANTS 

Design Parameters, Control Techniques, and Control Levels 

500 Modeled using multiples of 100 LT/D plants 

200 Same as above 

100 

50 

10 

5** 

Modeled using: 

Control techniques: 

Inlet conditions: 

Outlet to Claus: 

Outlet from Claus 

to atmosphere; 

Control levels: 

Amine treater and Claus sulfur recovery plant 

1, 5, and 10% H2S 

80% H2S and 20% C02 

96.6% control by Claus plant 

NSPS and 1/2 NSPS, (162 and 81 ppmv H2S in fuel gas) 

10 

5 

2 

1** 

Modeled using: 

Control techniques: 

Inlet conditions: 

Outlet from LOCAT 

to atmosphere: 

Control levels: 

LOCAT 

Same as above 

Unregulated by NSPS, use vendor's recommendations 

Same as above 

< 2 Modeled for large refineries, for case of an expansion to an existing amine 

treater/Claus system (Option 2): 

Use 114 responses for estimates 

Model a 0.5 LT/D expansion to a 10 LT/D plant 

2.0 Modeled for small refineries 

0.13 Control technique: Caustic scrubbing 

Inlet conditions: 

Outlet from scrubber 

to atmosphere: 

Control levels: 

About 0.1% H2S (1000 ppr.v) 

Unregulated by NSPS, use vendor's recommendations 

Same as above 

* LT/D i s long tons of sulfur per day. If combusted with no prior control, 

1 LT/D wil l result in about 785 tons per year of SO2 emissions, assuming 

350 operating days per year. 

** A 5 LT/D plant may be analyzed for amine treater/Cl eus plant control, and 

a 1 LT/D plant for LOCAT control, only i f i t can be done easily without 

significant extra expenses. 
P.12 

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