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# OAR Box 1784 Prepped by Ollie Stewart



### Document

Number: 

# 48 ) II-B-7 Docket Number: 

# A-84-4 4

Printed 10/31/2008 8:05:40 AM Sheet 48 of 143

# I P. 2 UNITE D STATE S ENVIRONMENTA LPROTECTIONAGINC Y



### M 198 5

MEMORANDU M SUBJECT : Meetin g Note s - Refiner yFue l Ga s NSP S Revie w(83/03 ) FROM : Nanc yD . McLaughlin , Environmenta l Enginee r

Industria l Studie s Branch , ESE D (MD-13 ) TO : KennethR . Durkee , Chie f

Standard s Documentatio n Section , IS B (MD-13 ) I . Purpose : Th e purpos e o fth e meetin g wa s t o discus s th e mode l plant s an d th e approac h towar d selectin g a lower-siz e cutoff . I I . Tim

ean dPlace : Thursday , Ma

y9 , 198 5 12:3 0 - 2:0 0 p.m . 7t hFloo r Conferenc e Roo m III . Attendees : IS B - Nanc yMcLaughli n Ke n Durke e Sta n Cuff e SD R - Gai l Lac y Gi l Woo d EA B - Bil l Va'tavu

k IV . Discussion : Afe wday s prio r t o th e meeting , al l attendee s wer e give n backgroun d • material s (copyattached) . Thes e backgroun d material s include d a n outlin e o f th e desig n o f th e mode l plant s an d a n issu e pape r discussin g problem s an d recommendations . Th e mai n issue s presente d were : (1 ) Determinin g a n approac htowar d selectin g a lowe r siz e cutof f an d designin g appropriat e mode l plant s fo r thi s approach .

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(2 ) Identifyin g th e variou s option s fo r complianc e that are availabl e t o a larg e refiner y whic hha s a new , smal l NSP S source . (3 ) Designin g th

e parameter s an

d contro l technolog y fo r th e hypothetica l cas e o f a smal l source i na very

smal l refinery . A t th e beginning o f th e meeting I discusse d th e background materials , filling in some additiona l technica l information . Th e mai n point s tha t I mad e were : (1 ) Ther e i s n o suchthing a s a "typica l refinery " fo r thi s NSP S becaus e ther e ar e numerou s configuration s o f amin e treaters , sulfu r recover y units , an

d fue l ga s system s a s wel l a s variou s type s o f crude s an d final products . Thi s standar d i s particularl yawkwar d becaus e th e affecte d facilit yi s eac hindividua l combustio n device . Ther e ma yb e 1 5 t o 20 0 combustio n device s in a refiner ydepending on th e siz e o f the refinery . However , th e numbe r o f NSP S sources , and thu s th e amoun t o f sulfur t o b e controlled , canno t b e correlate d t o th e refiner ysize . (2 ) Designin g a mode l plan t fo r a smal l sourc e 1 n a smal l refiner y i s mostl ya hypothetica l exercise . .Small refineries , becaus e o f technica l limitations , usuall ycanno t proces s non-sweet , crudes ; thus , th e generate d fue l ga s i s lo

win H^ S an

d usuall ydoe s no t requir e additiona l control . I f additiona l contro l i s needed , conventiona l contro l approache s (amin e treaters ) are

no t appropriate . S o fa r in th e review , onl ya coupl e case s hav e been identifie d tha t fel l int o thi s categoryan d require d some control . One refiner yreceive d a

n exemption , th e othe r (Quake r State ) ha s no t ye t take n an yaction . W e plan t o us e causti c scrubbing i n mode l plan t desig

n becaus e i t ha s bee n presente d in th e literature ; however , i t ha s no t been applie d t o a n actua l refiner

ysituation . W e als o discusse d tha t th e tren

d i s awa

yfromsmal l refinerie s an d towar d larg e refineries . N o seriou s disagreement s aros e concerning th e propose d mode l plant s an d reconnende o approaches . The importan t issues/approache s tha t wer e concurre d o

n are : ( 1 ) I n calculating a cost/effectivenes s fo r a contro l system , w e can includ e th e entir e emissio n reductio n due t o tha t contro l system , no t jus t th e reduction s fromNSP S affecte d facilities . (2 ) Some large r refinerie s wit ha ne wsmal l sourc e ar e abl e t o compl y •wit hth e NSP S b

yrerouting gases . Th e background pape r describe s thes e "delaying tactics " i n mor e detail . Essentiall ythes e ar e temporarycomplianc e action s whic hhav e a minor , nomina l cos t bu t do no t reduc e emission s a s th e origina l standar d had intended . However , a s a refiner ycontinue s t o expand o r replac e ol d units , i t wil l eventuall yinstal l a larg e contro l system an d probabl ycontro l existing a s wel l a s ne wsources . W e agree d t o accep t thi s trade-of f an

d no t scrutiniz e thi s "delaying tactic " issu e further ; thus , w e do no t inten

d t o alte r the curren t NSP S t o preven t this .P. 4

(3 ) W e wil l desig

nonly on e mode l plan

t t o mode l the situatio nwhen a refiner

y witha ne

w sourc e expand s a

nexistin

g contro l system . Preliminar y informatio

nIndicate s that thi s i s cost/effective , bu t becaus e o f th

e variety o f possibl e configuration s an dsiz e range s w

e didnot want t o mode l al l possibilities . Instead , a worst-cas e (highes t C/E ) situatio nwa s selecte d— a smal l ne

w sourc e an

da relatively

smal l existin

g contro l device . Tw o change s t o th

e recommende

dmode l plant s wer e suggested . Thes e change s wer e als o agree dt o b y al l attendees : (1 ) Evaluat e th

e mode l plant s a

t only on e contro l leve l instea dof thre e different levels . Th e contro l leve l t o b e use di s equivalent t o th e existin g NSP S leve l o f 16 2 ppmv . Thi s decisio nsignificantly

reduce dth e number of mode l plants . Also , a 5 0 percent reductio n1 nth e emissio

n standar dfor combustio

ndevice s result s i nonly 6 percent reductio ni n overal l emission s fro m th e tota l sulfu

r treatment system . Also , th e primar

y purpos e of a revie

w stud y i s t o evaluat e th e current NSPS . (2 ) 'W e wil l redesig nth e mode l plan t fo r a smal l ne

w sourc e i

na smal l refiner

yt o matc hth e Quake r Stat e refiner y i nWes t Virginia . Thi s refiner yi s th e only

real -lif e cas e tha t we -ar e aware o f that fall s int o thi s category . Determining th e C/ E fo r th e Quake r Stat e situatio n rathe r than a hypothetica l situatio n woul d be a stronge r cas e i f question s late r aris e concerning th e C/ E o f controlling smal l sources . (However , tha t Quake r Stat e refiner y ha s bee n temporaril yclosed. ) S o fa r industr

y ha s no t raise d th e issu e of th e nee d fo

r a lower siz e cutoff , an

d w e ar e therefor e investigating thi s issu e primaril yfo r ou r ow n background information . V . Conclusion : Excep t fo r th e tw o change s discusse d above , al l attendee s concurre d i n th e design o f th e mode l plant s whic hhad bee n presente d i n th e background materials . Attachmen t cc : Attendee s ESED/ISB/SDS/NDMcLaughling/cbake r 6/3/8 5 x559 6 Rm . 75 5 M U(MD-13 ) File : AI P 8.1.15. 5 ESE D 83/0 3P. 5
1 ?.--.\

UNITE D STATE S ENVIRONMENTA LPROTECTIO N AGENC Y i 23 K5 Offic e o fAi rQualit

yPlannin g an d Standard s V** 7 Research Triangl e Park , Nort h Carolin a 2771 1

' M y ? 198

5

MEMORANDUM . SUBJECT : Refiner yFue l Gas NSP S Revie w(ESE D Projec tNo . 83/03 ) FROM : Stanle yT . Cuffe , Chief.jfc C

Industria l Studie s Branch , ESE D (MD-13 ) TO : Se e Belo w Ther e wil l b e a meetin g fo rth e refiner yfue l ga s NSPS revie wprojec t o n Thursday , Ma

y9 , 1985 , fro m 12:3 0 - 2:0 0 i n th e 7t h Floo rConferenc e Room . Th e purpos e o fth e meetin g i s t o discus s th e mode l plant s an d th e approac h towar d selectin g a smal l siz e cutoff . Backgroun d material s o n th e issue s involve d an d th e mode l plan tparameter s ar e attached . Addressees : *"f ~ " Bob Ajax , SD

B '-" _ Ken Durkee , IS B Gai l Lacy , SD

B - /^NancyMcLaughlin , IS B Bil l Vatavuk , EA

B A l Wehe , EA

B - •Gi l Wood , SD

B 2 Attachment su >« . P. 6



### REFINERYFUE L GA S NSP S REVIEW MODE L PLAN T ISSUE S Backgroun d A s par t o fth e revie wo fth e curren t NSP S fo rrefiner yfue l gas , w e ar e conductin g a cost-analysi s t o determin e th e cost-effectivenes s o fth e regulation . Also , result s fro m thi s analysi s wil l he! p u s determin e i fa lower-siz e cutof fi s warranted . Ther e ar e severa l issue s involve d i n selectin g th e appropriat e mode l plan t parameters , particularl yi n th e lowes t siz e range . Plan t visit s wer e mad

e an d industr yan d vendo rrepresentative s wer e contacte d t o gathe r furthe rinformation . Base d o n thes e findings , mode l plant s have bee n developed . Unde rthi s standard , th e affecte d facilit yi s eac h individua l combustio n device . However , th e contro l devic e i s usuall yselecte d an d size d base d o n th e tota l sulfu rloadin g t o al l ne wcombustio n source s i n th e refinery . Thus , th e mode l plan t size s ar e base d o n th e tota l sulfu rloadin g (i n lon g ton s pe rday ) t o al l NSP S combustio n source s i n a refinery . Large r mode l plant s represen t th e situatio n o fsevera l ne wcombustio n source s i n a refinery ; th e smal l mode l plant s represen t th e situatio n o fonl yon e (o ra few ) ne

wcombustio n sources . Th e recommende d fina l mode l plan t size s an d thei rassociate d contro l technique s ar e liste d i n Tabl e 1 . Th e handwritte n attachmen t present s th e preliminar ymode l plant s an d give s detaile d informatio n o n th e mode l plant s an d contro l devices .P. 7

Larg e an d Mediu m Siz e Mode l Plant s Th e approach towar d larg e an d mediu m size d system s ha s remaine d th e same as i n th e preliminar ymode l plant s excep t tha t th e numbe ro fmode l plant s an d contro l option s has bee n pare d down . On e majo rchang e i s tha t th e larges t mode l plan t size s (20 0 an d 50 0 LT/D ) hav e bee n eliminate d becaus e thei rcos t effectivenes s woul d be th e sam e o rbette rtha n th e nex t siz e plan t (10 0 LT/D) . Also , th e numbe ro fcontro l option s ha s bee n reduce d fro m 3 t o 2 levels , (NSP S leve l an d 1/2 NSP S level) . Smal l Siz e Mode l Plant s Issue s hav e arise n i n th e approach towar d modelin g smal l plant s (les s tha n 2 LT/D) . Thi s represent s th e situatio n o fon e (o ra few ) ne wcombustio n source s i n a refinery . Th e contro l technolog yapproac h wil l b e differen t fo rsmal l mode l plant s i n larg e refinerie s vs . smal l refineries . Smal l Siz e Mode l Plant s - Mediu m an d Larg e Refinerie s I n a mediu m o rlarg e refinery , th e H£ S i n th e fue l ga s i s controlle d i n a centra l amin e treater / sulfu rprocessin g syste m whic h clean s th e gas enterin g severa l combustio n devices . Thus , on e NSP S combustio n devic e i n a larg e refiner yi s no t controlle d individually . Alarg e refiner ywit h on e ne wdevic e has th e flexibilit yt o mee t th e standar d i n severa l ways : 1 . Us e a n existin g contro l syste m whic h ha s exces s capacit y 2 . Expan d a n existin g contro l syste m 3 . Buil d a ne

wcontro l syste m whic h wil l contro l othe rsource s i n additio n t o th e NSP S sourc e 4 . Repipe , s o tha t a lo wH2 S strea m i s sen t t o th e NSP S sourc e 5 . Bu ynatura l ga s fo rth e NSP S sourc e 6 . Desig n th e NSP

S sourc e t o us e fue l oi lP. 8

Al l o fthes e option s have bee n used b yindustr ysinc e th e standar d too k effect . Optio n 1 i s clearl ycost-effective.;Optio n 2 i s probabl y als o cost-effectiv e an d w e pla n t o us

e 11 4 responses t o ge t cos t estimates . : Optio n 3 ma

yno t b e cost-effectiv e i fal l th e cost s ar e relate d t o th e emissio n reductio n fro m onl yth e on e NSP S source ; however , i fw e ca n us e th e tota l emissio n reductio n fo ral l th e cleanediga s goin g t o al l combustio n device s (NSP

S an d non-NSPS) , the n thi s cas e woul d fal l int o a highe rmode l plan t siz e (>2 LT/D ) an d woul d b e cost-effective. : Option s 4 , 5 , an d 6 wil l cos t a refiner ya smal l amoun t t o attai n th e standar d bu t no emissio n reductio n wil l occu rsinc e th e H2 S wil l be reroute d t o anothe rexistin g combustio n device . However , thi s i s essentiall ya delayin g tactic ; whe n more NSP

S source s come on-line , th e refiner ywil l eventuall yhave t o construc t a treatmen t syste m fo rsevera l ne wsources . Then , thi s cas e woul d fal l int o a highe rmode l plan t siz e (> 2 LT/D) . Th e issu e her e i s ho wt o desig n mode l plant s fo rsmal l ne wsource s i n large rrefineries . Becaus e o fth e variet yo fconfiguration s an d options , severa l mode l plant s woul d be neede d an d a larg e amoun t o ftim e an d mone y expended . Also , ther e have no t bee n significan t complaint s b yindustr y concernin g thi s situation . Thus , th e recommended approac h fo rthi s cas e i s no t t o develo p rigorou s models , wit h rigorou s cost/effectivenes s analyses . Onl yOptio n 2 wil l b e formall yaddressed , (i.e. , a smal l expansio n o f. les s tha n 2 LT/ D whic h i s neede d fo ran existin g amin e treater/C l au s plan t contro l system) . Thi s i s a difficul t situatio n t o mode l becaus e ther e ar e man yway s t o expan d capacity , (operationa l changes , chemica l changes , an d physica l capita l changes) . W e wil l us e result s fro m 11 4 response s t o develo p roug h cost/effectivenes s estimates . Also , i fneeded , w e wil lP. 9
4 mode l a 0. 5 LT/ D expansio n t o a n existin g 1 0 LT/D plant . Thi s i s a worse-cas e situation , becaus e smal l increase s t o capacit yfo rrelativel ylarg e system s ca n probabl yb e handle d withou t physica l change s an d capita l expenditures . Smal l Siz e Mode l Plant s - Smal l Refinerie s ' Fo rver ysmal l refinerie s th e situatio n i s different . I fon e ne w combustio n devic e i s built , a smal l refiner ydoes no t have th e flexibilit y an d variet yo foption s tha t ar e availabl e t o a large rrefinery . Also , th e entir e smal l refiner yma yhave les s tha n 2 LT/D o fsulfu ri n its ' fue l ga s system . Thes e smal l refinerie s woul d probabl yproces s les s tha n 20,00 0 barrel s o fswee t crud e pe rday , an d th e H2 S leve l i n th e fue l gas ma yb e onl yslightl yabove th e NSP S limit. : Du e t o cost s an d technica l limitations , conventiona l sulfu rcontro l system s (amin e treater/C l au s plant , o rL0CA

Tplant ) ar e no t appropriat e fo rthi s situation , an d ther e ar e n o othe rtraditionall yaccepte d sulfu rtreatmen t processe s tha t hav e bee n demonstrate d fo rsuc h a situation . S o fa ri n th e review , w e hav e identifie d onl ya coupl e o finstance s tha t fal l int o thi s categor yo fa smal l NSP

S sourc e i n a smal l refiner ytha t wil l nee d t o trea t th e H2 S i n th e fue l gas . Essentially , mode l plant s les s tha n 2 LT/ D i n thi s situatio n ar e hypothetica l situations , tha t have n o conventional , demonstrate d contro l approach , an d woul d have t o b e deal t wit h o n a case-by-cas e basis . Designin g mode l plant s an d evaluatin g th e cost/effectivenes s fo rth e variet yo fpossibl e situation s coul d becom e a time-consuming , tediou s exercis e tha t ma

yyiel d littl e usefu l real-worl d information . The recommended approac h i s t o investigat e onl ytw o mode l plant s tha t woul d represen t th e en d point s o fth e rang e o fpossibilities . Th e wors t case , (i.e. , th e highes t cost-effectiveness) , woul d be fo ra mode l plan t a t th e smalles tP.1 0

siz e considere d byNSP S studie s (0.1 3 LT/ D o fsulfu rresult s i n 100 ton s o fSO 2 pe ryear ) an d wit h a relativel ylow.concentratio n o fH2 S i n th e fue l ; gas . Th e uppe ren d o fth e rang e wil l b e represente d bya 2 LT/ D mode l plant . Th e contro l techniqu e wil l probabl yb e causti cscrubbing , bu t becaus e thi s i s a hypothetica l case , w e wil l rel yheavil yon th e suggestion s b yvendor s abou t th e selectio n an d desig n o fth e bes t contro l system . Th e result s fro m thi s analysi s wil l sho wu s i fth e smallest , worse-cas e situatio n coul d be controlle d cost-effectively . Base d o n th e outcome , w e coul d the n decid e whethe rt o se t a lower-siz e cutoff , pursu e th e stud y i n mor e detail , o rdro p th e issue , leavin g th e standar d unchange d wit h n o lower-siz e cut-off . Detail s o n Mode l Plant s Detail s o n th e proces s bein g modeled , th e mode l plan t parameters , an d th e selecte d conto l technique s ar e give n i n Tabl e 1 an d i n th e handwritte n attachment .P.1 1

Siz e LT/D * TABL E 1 SUMMAR YOF RECOMMENDE DMODE L PLANT S Desig nParameters , Contro l Techniques , an dContro l Level s
50 0 Modele dusing multiple s o f 10 0 LT/ Dplant s 20 0 Sam

e a s above 

### 100 5 0 1 0 5* * Modele d using : Contro l techniques : Inle t conditions : Outle t t o Claus : Outle t fro m Clau s t o atmosphere ; Contro l levels : Amin e treate ran d Clau s sulfu rrecover yplan t 1 , 5 , an d 10

% H 2S 80 % H2 S an d 20

% C02 96.6 % contro l b

yClau s plan t NSP S an d 1/

2 NSPS , (16 2 an d 8 1 ppm vH2 S i n fue l gas ) 1 0 5 2 1* * Modele d using : Contro l techniques : Inle t conditions : Outle t fro mLOCA T t o atmosphere : Contro l levels : LOCA T Sam e a s abov e Unregulate d byNSPS , us e vendor' s recommendation s Sam e as above
< 2 Modele d fo rlarg e refineries , fo rcas e o fa n expansio n t o a n existin g amin e treater/Clau s syste m (Optio n 2) : Us e 11 4 response s fo restimate s Mode l a 0. 5 LT/ D expansio n t o a 1 0 LT/ D plan t 2. 0 Modele d fo rsmal l refinerie s 0.1 3 Contro l technique : Causti cscrubbin g

Inle t conditions : Outle t fro m scrubbe r t o atmosphere : Contro l levels : Abou t 0.1 % H2 S (100 0 ppr.v ) Unregulate d b

yNSPS , us e vendor' s recommendation s Sam e as above

* LT/ D i s lon g ton s o fsulfu rpe rday . I fcombuste d wit h no prio rcontrol , 1 LT/ D wil l resul t i n abou t 785 ton s pe ryea ro fSO 2 emissions , assumin g 35 0 operatin g days pe ryear . * * A5 LT/ D plan t ma yb e analyze d fo ramin e treater/C l eu s plan t control , an d a 1 LT/ D plan t fo rLOCA Tcontrol , onl yi fi t ca n b e don e easil ywithou t significan t extr a expenses .P.1 2 

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