Patrick FoleyU.S. EPA - OECATheBasics•Inspections–ProblemsExist•Oversteaming•Overaeration•LowBTU/scf–Upto100s‐1000stonsexcessemissionsperflareExcessSteam/Air:DilutionandCoolingofFlameInsufficientSteam/Air:Smokeduetopoormixing‐NotenoughoxygenGoodCombustion:Turbulent,HotFlame3•Problem:–Wastesmoney•Wastesproductandfuel–IncreasesEmissions•TheSolution–ReduceFlaring•FGRS•SourceReduction–NewFlareEfficiencyMetricswithMonitoring•NetHeatingValue(BTU/scf)ofthegasinthecombustionzone(NHVCZ)•LowerFlammabilityLimitintheCombustionZone(LFLczg)FlaringandOversteamingElevatedFlareVentStreamGasCollectionHeaderKnockoutDrumDrainPurgeGasLiquidSealPilotGasFlareTipPilotBurnerStackSealFlareStack5ToFuelGasSystemorProductRecoveryFlareGasRecoveryCompressorSteamLineSteamFlowMeterGCVentGasFlowMeterSweepGasPFTIRFlareTesting•Flareradianceisthespectralsignal•IRcamerausedtopointthePFTIRjustoutsidetheflarecombustionzone.•IRspectrometermeasurescompounds.678 CZNHVβα1CZNHVβαCEwhereα=0.12,β=‐95EnforcementAlert10LegalBasesforInjunctiveReliefforFlaringViolations•NewSourceReviewviolation:EitherPSDorNonattainmentNSR–ConstructionofnewflaresornewunitstiedintoflaresresultinginasignificantemissionsincreaseofVOCandSO2–BACT/LAERcouldincludeflaregasrecovery,volumetriccaps,LFL/CZNHV,and98%combustionefficiency•FailuretocomplywithSubpartsJandJa andConsentDecrees–ViolationoflimitationonH2Sconcentration–OftenrequiresFGRSandotherflareminimizationsteps•Failuretocomplywithanemissionlimitand/ordestructionorcombustionefficiencythatisapplicabletotheFlare–Permits(eg,INEOS/Addystoncase)andSIPs11LegalBasesforFlaringViolations(cont.)•FailuretoOperatetheFlareinamannerconsistentwithGoodAirPollutionControlPracticesforMinimizingEmissions–NSPS60.11(d)–NESHAP61.12(c)–MACT63.6(e)(1)(i)–Permits–SIPs•FailuretoOperatetheFlareinConformancewithDesign–Permits,SIPs•FailuretoMonitortheFlaretoAssureOperationinAccordancewithDesign–NSPS60.18(d)–MACT63.11(b)(1)–IndividualstandardsintheNSPSandMACTs(eg.,HONLDARClosedVentSystemstandardat63.172(e)(mustmonitorthese“controldevicestoensurethattheyareoperatedandmaintainedinconformancewiththeirdesign”)–Permits–SIPsMarathonandBPSettlements•InjunctiveRelief–FlareMinimization•FlareGasRecovery•“Cap”onVolumetricflowtotheflare–FlareEfficiency•Steam&VentGasFlowmeters•GasChromatography•NHVcz &S/VGratio•Penalty•MitigationProjects&SEPs–Fenceline Monitoring1314MarathonandBPInjunctiveRelief–EmissionsReductions•ForMarathon,flareefficiencyandcapswillresultin:–VOCemissionreductionsgreaterthan5,000TPY*;and–HAPemissionreductionsgreaterthan135TPY*.•ForBP,flareefficiency,flaregasrecoveryandcapswillresultin:–VOCemissionreductionsgreaterthan3090TPY*;–HAPemissionreductionsgreaterthan83TPY*.*Allvaluesestimated.Volumeandcompositionofwastegasnotmonitoredpreviously.15PotentialU.S.RefineryFlareVOCEmissionsifMarathonandBPFlareGasVolume, Composition andCEareTypicalSensitivityAnalysis CrudeCapacity(bpd)TotalVOCEmissionsfromFlares(ton/year)U.S.FullCapacityWithCEProblems17,787,71498,00050%U.S.CapacityWithCEProblems8,893,85749,00025%U.S.CapacityWithCEProblems4,446,92924,00010%U.S.CapacityWithCEProblems1,778,77110,000161.U.S.crudecapacityasofJanuary1,2012,perOil&GasJournal.99%oftheseemissionscanbecontrolledthroughaflareefficiencyprogram.HAPcontentofflaregasishighlyvariable,butcantypicallyrangefrom0.5to3.0%.FlaringSettlementsEmissionsReductionsandCostSavings•EPAisnegotiatingsettlementswithseveralcompaniesthatwillresultinVOC,HAP,andGHGemissionsreductionsaswellascostsavingstothecompaniesfromrecoveredgasandreducedsteamdemand.•Emissionsreductionsandcostsavingsareprovided:–Per1,000barrelsofcrudefeed;–Per1,000poundsofcrudefeed;–Annuallyforamodelrefinerywith140,000barrelsperday(BPD)ofcrudecapacity.•Estimatedcontrolcostsandpaybackperiodareprovidedforamodelfacility.Per1,000BarrelsCrudeFeedBaselinePost‐Implementation ReductionFlareVentGas FlowRate(SCF/MBBL)12,7565,175 7,582VOCEmissions(LB/MBBL)301.429HAPEmissions(LB/MBBL)0.810.07 0.74GHGEmissions(LBCO2e/MBBL)1,743 655 1,088VentGasLostProduct Value($/MBBL)119 41 78VentGasLostFuelValue($/MBBL)42 18 24AssistSteamCost ($/MBBL)16 3 1218Per1,000PoundsFeedBaselinePost‐Implementation ReductionFlareVentGas FlowRate(SCF/MLB)421725VOCEmissions(LB/MLB)0.0990.004 0.094HAPEmissions(LB/MLB)0.00270.0002 0.0024GHGEmissions(LBCO2e/MLB)5.7 2.1 3.6VentGasLostProduct Value($/MLB)0.39 0.14 0.26VentGasLostFuelValue($/MLB)0.14 0.06 0.08AssistSteamCost ($/MLB)0.051 0.011 0.04019140,000BPDRefinery42.8mmlb/dayFeedPlantBaselinePost‐Implementation ReductionFlareVentGas FlowRate(MMSCF/YR)660270390VOCEmissions(TON/YR)78040740HAPEmissions(TON/YR)21219GHGEmissions(TONCO2e/YR)44,600 16,800 27,900VentGasLostProduct Value($/YR)6,105,000 2,111,000 3,994,000VentGasLostFuelValue($/YR)2,124,000 909,000 1,216,000AssistSteamCost ($/YR)795,000175,000 620,0001.42.8mmlb/dayfeed.ControlCostsandPaybackPeriod•Forthe140,000BPDmodelrefinery,totalinstalledcostsof–Flaremonitoringandcontrols:$6,040,000;–Flaregasrecoverycompressors(2× 62.5MSCFH):$20,000,000.•Ifventgasisrecoveredasproducts,thesavingsfromrecoveredgasandreducedsteamdemandare:–AnnualSavings:$4,614,000;–PaybackPeriod:5.6years.•Ifventgasisrecoveredasrefineryfuelgas,thesavingsfromrecoveredgasandreducedsteamdemandare:–AnnualSavings:$1,836,000;–PaybackPeriod:14.2years.AnOunceofPreventionisWorthaPoundofCure•Moremoneycanbemadefrompreventingthegasfromenteringtheheaderinthefirstplace.•Flaregasmappingcombinedwithsourcereductionoftenpaysforitself.AssumedVentGasCompositionComponentConcentration(vol%)Hydrogen26.4Nitrogen25.7Methane25.3Ethane3.7Ethylene1.0Propane &Propylene8.0Butane&Butenes5.7Pentane&Heavier2.7AssumedProductValuesComponentValueHydrogen($/MSCF)3.33Nitrogen($/MSCF)3.25FuelGas($/MMBTU)14.40Propane &Propylene($/GAL) 1.28Butane &Butenes ($/GAL) 1.89Pentane &Heavier($/GAL) 2.91Steam($/MLB) 6.661Methane,ethane,andethyleneassumedtoberecoveredasfuelgas.AFPMandACC•AFPMandACCmetwithEPAstaffandOECA(Enforcement)managementinrecentmonths.•AFPMandACCsuggestedthatanalternativepathtotraditionalEPAenforcementwouldbepreferredbytheirmembership.•EPAisconsideringaprogramtorapidlyaddressnoncomplianceinamorecooperativeandexpeditedmannerthantraditionalenforcementforalargepartoftherefiningandpetrochemicalsectors.•TimeneededtodevelopandvetwithinEPAbeforethedetailsoftheprogramareprovided.AlternativeProgramIssues•RefineriesandOlefins–Easiertodetermineexpectations–Settlementscompletedornearcompletionthatsetexpectationsforfuturesettlements–ExtensiveongoingandhistoricalsubpartJ/Ja noncomplianceatrefineriesisacomplicationforalternativeprogramentry•OtherChemicalPlants–Batchandcontinuous–Specialtyproducts–Highnitrogenpurges,loweringvalueasafuel–HigherratioofflaredgasBTUtopotentialfuelsinkBTU–Highpurityconcernsforproductrecovery–Searchingforcommonalityinflaregasflows,butmaybecasebycaseorsubsectorbysubsectordeterminationofFGRSexpectationsNextSteps•Developentryqualificationsforalternativeprogram.•Developrequirementsandtimelineforalternativeprogram.•SeekapprovalofEPAmanagementforalternativeprogram.PatrickFoleyU.S.EPAFoley.Patrick@epa.gov