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# OAR Box 1124 Prepped byOllie Stewart



## Document

Number: 

# 64 ) ll-D- 5 Docket Number: 

# A-84-4 4

Printed 4/16/20088:13:22 AM

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Nort hAmerica nRefining Conoc oInc . P.O. Bo x3 7 Westlake. L

A 70669 (318 ) 491-521 1
Apri l 1 , 198 5

CERTIFIE D MAI L - RETUR NRECEIP T REQUESTE D ( P 24 3 17 7 372 ) 

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# A-84-4 4

Mr . John R . Farme r Directo r Enissio n Standard s an d Engineerin g Divisio n U . S . Environmenta l Protectio n Agenc y Offic e o f Ai r Qualit yPlannin g an d Standard s Researc hTriangl e Park , Nort hCarolin a 2771 1 Dea r Mr . Farmer : Attache d i s Conoco' s respons e t o th e Fue l Ga s KSP S Questionnaire . W e wer e gla d t o b e o f assistanc e i n thi s natter . I f yo u hav e an yquestion s o r conments , pleas e contac t Mr . Ric k McCali p a t th e refinerya t (318 ) 491-5599 . Sincerely ,

Manage r Lak e Charle s Refinery MES/sww Att .P. 3
INFORMATIONNEED S FORREVIEWIN G' TH E REFINERYFUE L GA S KSP S Liste d belo wi s the informatio n w e ar e seeking fo r the facilitie s subjec t t o th e ne wsourc e performanc e standard (NSPS ) fo r refineryfue l gas . I . INTRODUCTION Th e affecte d facilit yfo r the NSP S i s an ynew , modified , o r recon structe d refinerycombustio n devic e tha t burn s fue l gas , suc ha s flares , boilers , an

d proces s heaters . Th e primarycontro l devic e i s a preprocessing uni t (usuall ya n amin e treater ) tha t remove s th e H^ S fromth e fue l ga s befor e i t i s combusted . Secondarycontrol s ar e the n neede d t o proces s the mor e concentrate d H_S streamtha t exit s fromthe amin e treater ; thes e secondarycontrol s mayb e sulfuri c aci d plants , thiosulfat e plants , Clau s sulfu r plants , etc . Thes e secondarycontrols , i n turn , hav e emission s tha t requir e treatment , suc ha s tail-ga s units . Les s conventiona l one-step system s (sucha s LO-CAT , Stretford , Stauffer , etc. ) mayals o b e used , an d ma yb e preferre d b ysmalle r refineries . A s a n alternative , refinerie s ar e allowe d t o blend the refineryfue l ga s wit hnatura l ga s t o dilut e the H„ S concentratio n o r us e add-o n control s suc ha s flu e ga s desulfurizatio n (FGD ) units . I n orde r t o conduc t a comprehensiv e reviewo f th e NSP S an d t o under

stan d th e effect s o f th e curren t regulation , w e nee d t o investigat e the entir e systemtha t deal s wit hfue l ga s (combustion devices , primarycon trols , an

d secondarycontrols) , an d the costs , credits , an d emissio n re duction s o f eac hpart . Althoughthe affecte d facilit yi s a combustio n device,.ou r mai n focu s wil l b e o n th e primarycontro l devic e (amin e treater s o r others) , particularl ycurren t designs , chemicals , technica l capabilities , an d costs . W e ar e als o focusing o n alternative monitorin g approache s fo r emissio n complianc e determinations . II . FACILITYDESCRIPTION Pleas e provid e a genera l descriptio n an d schemati c o f the refineryfue l ga s system , combustio n devices , an d sulfur treatmen t processes , (sucha s amin e treaters , sulfur plants , tai l ga s units) . Includ e ga s flowrate s (untreated fue l gas , treate d fue l gas , an d natura l gas) , K_ S concentrations , an d sulfu r mas s balances . Not e o n the diagra mwher e ga s blending i s don e an d wher e proces s monitorin g an d emissio n monitoring samples.ar e taken . Drawin g No . LC-55-00-8A-42.2T- B i s a schemati c o f the refinery' s fue l ga s system . Fue l ga s produce d i n variou s refineryprocesse s i s collecte d in-on e o f tw o fue l ga s knock-ou t drums . Th e fue l ga s sen t t o thes e drums.i s eithe r fre e o f hydroge n sulfid e (H-S ) b ynatur e o f the proces s i t i s coming from , o r ha s had th e H- S remove d i n on e o f the refinery' s fue l gas/amin e ab

sorbers . Th e lowpressur e systemreceive s off-ga s fro n the refinery' s hydroge n purificatio n plant . I t supplie s fue l ga s onl yt o th e Kc. 2 Coke r heaters , H-300 1 and . H-3002 , the pilo t fo r the nort hflare , an d the si xheater s i n the No. 3 Reformer/Hydrodesulfurize r Units . I f mor e fue l ga s i s require d b y thes e heater s than can b e supplie d b ythe purificatio n plant , ga s fro mthe highpressur e systemmake s up the difference .P. 4

Th e hig hpressur e systemreceive s fue l gase s fro mal l othe r producer s i n th e refinery . I t supplie s fue l ga s t o al l heater s i n th e plan t no t serve d b y th e lo wpressur e systemincluding th e Nos . 6 an d 7 Hydrodesulfurize r heat

ers , H-310 1 an

d H-3201 , an

d th e Therma l Cracke r heater , H-14 . Whe n demand exceed s supply , the differenc e i s mad e u p wit hpurchase d natura l gas . Th e refineryha s bot hmodifie d an d ne wcombustio n device s i n operatio n whic h mus t mee t the NSPS . Tabl e I list s thes e device s an d proces s flo wdiagram s ar e include d detailing each . Th e refinery' s sulfu r treatmen t include s primaryamin e treating , two sulfu r recoveryuni t train s wit htai l ga s units , an d a sulfuri c aci d plant . Proces s flowdiagram s ar e include d fo r each . Composition s fo r some stream s i n the Sulfu r RecoveryUni t ar e give n i n Tabl e X , following the drawings . III . COST S 1 . W e woul d lik e separat e capita l an d operating cost s o f you r primary emissio n contro l system s (amin e treater , FGD , o r othe r processing unit) . Th e cost s requeste d ar e fo r th e entir e contro l systen , bu t w e ar e als o intereste d i n th e cost s associate d wit hthe additiona l absorptio n capacit y require d fo r treating th e fue l ga s tha t i s route d t o ne wcombustio n sources . Pleas e provid e a breakdow n (or factor ) fo r jus t the fue l ga s treatment , i f possible . Th e tota l capita l investmen t fo r the primaryamin e treatmen t systemthrough Decembe r 31 , 1984 , wa s $14238798.12 . 2 . Pleas e provid e the following cos t information . Inde xcost s t o yea r an d month . a . Purchas e cos t (explai n wha t i s included) . 1 . Breakdow

n b ymajo r equipmen t item(i.e. , vessel ) 2 . Cos t o f initia l chemica l inventory . Th e capita l investmen t fo r majo r equipmen t item s i s show n i n Tabl e I . The cos t o f the initia l chemica l inventorywa s no t available . b . Installatio n cos t (explai n wha t i s included ) 1 . Breakdow

n b ydirec t and indirec t costs . 2 . Not e specifi c cost s attributabl e t o retrofitting a ne wo r expande d amin e treate r int o an existing system . Th e installatio n cost s wer e no t available . c . Annua l operating costs . 1 . Labo r cost s (Doe s thi s includ e overhead? ) Not e labo r hours , an d $/hour rate" . 2 . Material s a . Replacemen t part s b . Chemical s ( # o f gallons ; $/gallon ) 3 . Stea

m(cost , amount , pressure , an d temperature ) 4 . Electricit y' 5 . Wate r 6 . Othe r utilitie s an d fue l cost s 7. . Credit s fo r valu e o f sulfu r i n the off-ga s t o th e sulfur plant .P. 5

SE E TABLE S I I AND III , IV . REFINERYCOMBUSTIONDEVICE S 1 . Ho wman

ycombustio n source s tha t bur n refineryfue l ga s ar e ther e a t you r refinery(flares , boilers , proces s heaters , incinerators , others )

Flare s - 2 Boiler s - 5 Proces s Heater s - 2 5 2 . Fo r eac hgenera l typ e o f combustio n devic e tha t burn s refinery fue l gas , pleas e provid e the following informatio n (for a typica l exampl e an d ranges) :

a . Siz e - capacity , BT Urating , fue l consumptio n b . Cost s - capita l an d operating c . Hour s o f operation , day s pe r year , (continuou s o r periodi c operation ) d . Othe r fuel s used , an d i n wha t proportio n A . B .


### C . Se e Table s IV

& V Se e Tabl e V I fo r Capita l Costs . Se e Tabl e VI I fo r Operating Cost s o f Unit s including the specifie d combustio n devices . Operating cost s fo r eac h combustio n devic e alon e ar e no t available . Th e refineryoperate s 2 4 hours/day , 7 days/week , 5 2 weeks/year . Norma l operatio n fo r combustio n device s i s o n thi s same continuou s schedul e unles s otherwis e specified . D . Othe r fuel s i n additio n t o refineryfue l ga s ar e use d b yB-5 , B-6 , an

d B-7 . I n 1984 , B- 5 an d B- 6 use d 27 % purchase d natura l gas . B- 7 use d 158. 4 MTo n o f gree n coke . 3 . Pleas e lis t an d describ e an

ynew , modified , reconstructe d com bustio n device s yo u hav e tha t ar e subjec t t o the NSPS , an d th e date s o f installation . Fo r thes e affecte d combustio n devices , describ e ho wyo u complie d wit hthe NSP S an d th e resulting decreas e i n H„ S concentration . Estimate , i f possible , the incrementa l cos t o f complianc e an d the resulting S0 2 emissio n reduction . SE E TABL E V I

a . Existing H_S leve l wa s acceptabl e (e.g. , use d existing amin e treate r o r swee t crude) . 

### N O Adde d ne wamin e treate r o r othe r preprocessing unit , YES , adde d ne wamin e treater . c . Upgrade d an existing amin e treater . Describ e ho w(increase d capacity , increase d flowrate , adde d trays , change d chemi

cals ) . YES , upgrade d an existing amin e treater .P. 6

Change s t o increas e amin e treate r capacit ywer e no t jus t du e t o NSPS . Bu t rather , theywer e necessarywhe n th e refinerychange d t o a sour crud e feed stream . Wit hthi s proces s chang e mad e i t woul d b e difficult , i f possible , t o estimat e the incrementa l cos t o f complianc e an d th e resulting S0

_emis

sio n reductio n du e t o NSPS .

d . Adde d a flu e ga s desulfurizatio n (FGD ) uni t a t outle t o f the combustio n source . NO e* . Replumbe d an

d reroute d variou s fue l ga s line s s o cleane r ga s wa s route d t o NSP S combustio n sources . 

### N O f . Blende d wit hnatura l gas . NO , thi s wa s no t a chang e made . Th e refineryalon e purchase s natura l ga s fo r th e purpos e o f meetin g refinery fue l deman

d whe n i t i s no t me t b yrefineryfue l gas . 4 . Withou t the NSPS , wha t leve l o f H„ S an d othe r sulfu r compound s i n fue l ga s woul d be acceptabl e befor e ther e woul d b e significan t advers e corrosio n p f combustio n equipment ? Th e leve l o f sulfur compound s acceptabl e depend s o n the metallurgyan d flu e ga s temperature . Acceptabl e loading o f the refinerysystemwoul d b e betwee n 0.5 % an d 1.0% . 5 . Wha t othe r Federal , State , an d loca l environmenta l regulation s appl yt o thes e combustio n devices , an d ho wdi d tha t affec t you r design consideration s an

d decision s t o replac e o r upgrad e existing devices ? H-3001 , H0-3002 , H-3101 , H-3201 , an d H-380 4 ar e PS D fo r NO , requiring lowNO burner s an d 0 . control . Othe r design parameter s wer e 2$ % opacity , 200 0 ppmS O i n stac k gas , an d 0. 6 l bPM/1 0 BT Uhea t input . Whe n design s ar e specifie d t o mee t NSPS , ther e i s n o problemmeetin g an yothe r requirements . Ther e ar e problem s meetin g NO limit s o n coke r furnace s du e t o thei r cyclica l duty . ~
V . PRIMARYCONTRO L (AMIN E TREATERS ) 1 . Wha t ar e the characteristic s an d compositio n o f th e fue l ga s tha t i s expecte d a t the inle t t o the amin e treate r an d tha t i s desire d a t the outle t prio r t o combustio n (typica l an d range) ?
a . Flo wrat e



### b . SE E TABL E VII I Heating valu e Curren t Typica l Valu e 99 0 3TU/f t , Afte r cyrogen'i c uni t o n strea m88 0 BTU/f tP. 7

c . Temperatur e an d pressur e SE E TABL E I X d . Aci d ga s compositio n (H-S , CO. , othe r sulfur compounds ) Aci d Ga s t o Sulfur RecoveryUni t Componen t Percen t byVol . H, S 92.8 1 CO
- 1.6 5 HC ^ .9 5 H 2 0 4.5 8P. 8

2 . Amin e treate r descriptio n (I f th e refineryha s mor e tha n on e amin e treate r system , describ e onl ythe system s tha t provid e fue l ga s t o com bustio n source s subjec t t o the NSPS. )

a . Genera l schematic , including flowrate s an d sulfu r materia l balance . SE E DRAWIN

GSD-2720-42-98- L Manufacture r o r vendo r (includ e licenso r an d engineering firm ) SE E TABL E I X Start-u p dat e SE E TABL E I X Desig n capacit yan

d rang e SE E TABL E VII I Hour s o f operation , hours/yea r 2 4 hours/day , 7 days/week , 5 2 weeks/yea r f . Numbe r o f vessel s i n system(stripper s an d absorbers ) Not e the relativ e ga s flowrate s an d amin e circulatio n rate s fo r fue l ga s treatmen t vs . othe r ga s treatment . 8 absorber s ( 5 fue l gas , 3 propane-butane ) 2 stripper s SE E TABL E VII I fo r ga s flowrate s an d amin e circulatio n rates . g . Tota l amin e inventoryi n system 2000 0 gal . Estimate d fromvolume o f D-3502 , Amin e Surg e . - Fo r eac habsorber , design an d actua l operating level s 1 . Ga s flowrat e 2 . Ga s pressur e an d temperatur e 3 . Amin e circulatio n rat e an d temperatur e
SE E TABL E VII I Desig n rat e i s give n a s maximu man d actua l operating rat e i s give n a s normal . SE E TABL E I Xfo r temperature s an d pressures . Als o se e Drawing No . SD-2720-42-98-L . i . Fo r eac hstripper , design an d actua l operating levels . 1 . Amin e circulatio n rat e an d temperatur e 2 . Stea

musag eP. 9

W-3501 , W-355 1 Desig n Amin e Circulatio n Rat e 50 0 gpm Temperatur e (Top ) 110° F Dut y36.8 8 MMBTU/hr . 5 0 psi g Stea

m Als o se e Drawin g Nos . SD-2720-42-98- L an d LC-91-00-82-42.1A-D . j . Typ e o f amin e used . UCARSO L MDE A k . Othe r importan t design o r operationa l criteria . No t available . 3 . Wha t typ e o f systemwoul d hav e bee n installe d i f the NSP S had no t bee n i n effect ? Lis t th e difference s fromth e presen t system .

Th e systemwoul d hav e bee n verysimilar . Th e Tai l Ga s Uni t may no t hav e bee n economicall yjustifiable . 4 . Acomplet e maintenanc e historyo f the amin e treating systemi s requested , o r a t a minimum , a narrativ e o f th e majo r outage s an d mos t frequen t maintenanc e item s tha t hav e occurre d sinc e start-up . I n discussing thes e problem s o r outages , pleas e indicat e the exces s emission s tha t oc curre d an

d th e correctiv e actio n taken . a . Degradatio n o r los s o f amine , (provid e los s rat e vs . baselin e inventory ) . v b . Foaming c . Contaminatio n o f amin e d . Corrosio n o f vessel s and pipin g e . Othe r Th e los s rat e o f amin e i s 200,00 0 lb/month . Foaming a t th e contactor s i s a problem . Some o f the cause s o f foaming ar e known , heav

yhydrocarbo n fromGRP , solid s (Fe SO,) . However , th e tota l caus e i s ye t t o b e identified . Contaminatio n o f amin e i s no t a bi g problembecaus e a significan t amoun t o f amin e i s los t an

d replace d b

yfres hamin e eac hmonth . Corrosio n occur s i n a n amin e systemwhe n the maximun allowabl e concen tration s o f MDE Aan d sulfide s ar e exceeded . I n general , Conoco' s systemha s highloadings . However , thes e ar e no t hig henought o accoun t fo r the corrosio n rate s seen . Atesting programi s bein g run t o analyz e fo r impu

ritie s i n the systemwhic hmayb e a sourc e o f th e corrosion . Whe n the corrosio n proble n i s solved , foaning shoul d decreas e i n al l contactor s an d th e us e o f antifoam wil l b e minimal . Th e mos t frequen t maintenanc e ite mi s changing filters . Th e carbo n filter s ar e change d everysi xmonth s du e t o iro n sulfid e plugging fro mcorrosion . Cartridg e filter s ar e change d ou t abou t 3 time s a month .P.1 0

Severa l refiner s hav e experience d increase d filte r problem s (solid s i n amin e system) , extreme carryove r o r bot hwhe n Ucarso l wa s introduce d int o thei r amin e systems . W e hav e no t determine d whethe r o r no t Ucarso l i s a majo r sourc e o f ou r problems . Installatio n o f large r knock-ou t drum s i s planne d becaus e o f amin e carryove r fro mthe contactors . 5 . Ar e the maintenanc e requirement s an d amin e replacemen t rate s mor e excessiv e tha n tha t indicate d b yth e vendor ? YES , the bigges t maintenanc e itemi s changing filters . 6 . Wha t wa s the reliabilit yo f the amin e treate r systemo n an annua l basi s fo r eac hyea r sinc e start-up , (amoun t o f schedule d an d unschedule d downtime) ? Ther e hav e bee n n o unschedule d downtime s sinc e modificatio n o f the

systemi n 1983 . W-1 3 wa s chemicall ycleane d during a schedule d downtime . 7 . Wha t ar e the inspectio n practice s an d schedule s fo r the amin e treate r system , an

d wha t type s o f personne l performthes e inspections ? Inspection s ar e conducte d b yrefinerypersonne l o r b yConoc o Engineering Departmen t personnel . Th e amin e treater s ar e inspect

ed wit hthei r respective unit s ever y2- 3 years . Th e amin e regen erator s ar e inspecte d annually . Corrosio n probe s ar e read month

ly . 8 . Wha t ar e the proces s operating parameter s tha t ar e monitore d o r teste d t o determin e i f th e amin e treate r i s performing properly , (fo r example : amin e samples , outle t concentration) ?

Sample s ar e taken . Sulfid e concentratio n i n lea n and ric hi s measure d daily . Foaming i s monitored . 9 . Wha t amin e treate r operating parameter s ar e se t b yoperator s t o adjus t fo r varyin g condition s an d inle t loading s s o tha t a "lowH_S concen tratio n can b e maintaine d a t the outlet ?

Th e circulatio n rat e i s kep t a t a maximum , a s i s the ric hamin e strength , t o keep loading s a t a n acceptabl e level . B yrunning al l th e lea n amin e through , th e sulfide' s i n lean amin e are"^kept a t 50 0 ppm . VI . SECONDARYCONTRO L (SULFU RPLANT , ETC. ) 1 . Ho wi s the mor e concentrate d H- S strea mexiting the amin e treate r handle d (sulfuri c aci d plant , Clau s Sulfu r plan t wit htai l ga s treater , thiosulfat e plant , sol d t o anothe r firm) ? Briefl ydescrib e thi s secondary contro l system , including design size , vendor , yea r installed , an d sulfu r mas s balances . Wa s thi s secondarycontro l systeminstalle d separatel yo r a s par t o f a packag e wit hthe amin e treater ?P.1 1
Th e refinery' s secondar ycontro l include s two,Clau s sulfur plan t train s wit htai l ga s treatmen t an d a sulfuri c aci d plant . Clau s Sulfu r Plan t Trai n 1 - 10 8 LTP D (expansio n t o 19 0 planned ) Trai n 2 - 10 8 LTP D (expansio n t o 19 0 nea r completion ) Vendo r - Ralp hM . Parson s Installe d I n 198 3 Par t o f Amin e Treate r packag e Se e Drawing s LC-91-00-82-42.1A- D an d LC-91-00-82-42.2A-D . 2 . I f the tai l ga s uni t use s amin e scrubbing , doe s i t no w(or ar e yo u considering ) combining th e tai l ga s an d fue l ga s amin e stripping ? Wha t ar e th e advantage s an

d disadvantage s o f thi s approach ? Th e refineryi s no t considering combining the tai l ga s an d fue l ga s amin e stripping . The fue l ga s i s presentl yscrubbe d a t 18 0 psi , wherea s the tai l ga s i s scrubbe d a t 2 psi . I t woul d no t b e practica l t o combin e operation s presentl ya t suc hdifferen t pressures . Eac huni t ha s advantage s and disadvantages . Tai l ga s treating ha s the potentia l o f hea t stabl e salt s whic har e les s probabl e i n fue l ga s treating . O n the othe r hand , chloride s and ammoni a caus e problem s wit hfue l ga s treating . VII . EMISSIONTESTIN G 1 . . Pleas e provid e a ful l cop yo f al l emissio n test s performe d o n fue l ga s fromyou r amin e treaters .

N o emissio n test s hav e bee n performe d a t th e amin e treaters . 2 . Pleas e provid e a brie f summaryo f an yemissio n test s tha t hav e bee n performe d a t the outle t o f combustio n device s whic hbur n fue l gas . Describ e the combustio n device s tested . I n additio n t p th e type s o f infor

matio n liste d above , w e ar e intereste d i n a summaryo f the emissio n dat a fo r an yothe r pollutants/compound s (SO- , tota l sulfur , 

### N O CO , hydrocarbons , etc. ) O n May14 , 1981 , Conoc o Inc . performe d th e require d EP Atesting o f

the fue l ga s use d i n furnace s H-1101 , H-1102 , H-l20'l , an d H-1301 . Th e sampling poin t i s show n i n th e attache d Drawin g No . LC-55-00-81-42.1F-A . Th e resul t o f thi s investigatio n wa s tha t th e leve l o f H- S i n the fue l gas , 55. 2 mg/ m, wa s wel l withi n th e maximu mallowabl e leve l o f 23 0 mg/ m. Thi s resul t wa s base d o n a tes t serie s o f 3 set s wit h2 run s pe r set . Isokineti c sampling rate s wer e no t applicabl e becaus e the fue l ga s containe d n o liqui d o r soli d particles . Th e designe d firing dutyo f furnace s H-110 1 an d H-110 2 wer e 265. 4 MMBTU/HR . During the testing , 71 % o f the designe d dutywa s used . Furnace s H-120 1 an

d H-130 1 wer e designe d fo r a firing dut yo f 28. 5 an d 29. 4 MMBTU/HRrespectively . Th e operating rate s the da yo fP.1 2



### ii . the test s wer e 3 % an d 4 % o f the designe d duty , n o wayaffecte d the H- S leve l I n th e fue l gas . Thes e lowrate s i n
O n May11 , 1983 , Conoc o Inc . conducte d a H- S Fue l Ga s Tes t t o determin e complianc e o f th e fue l ga s t o th e ne wheater s H-26 , H-46 , an

d H-1201 . Th e sampling poin t i s show n i n th e attache d Drawing No . LC-55-00-83-42.1B-A . Th e averag e concentratio n o f H^ S foun d i n the test , a serie s o f thre e set s o f two run s each , wa s 4 0 mg H-S/ mo f fue l gas . Thi s i s wel l withi n the maximu mallowabl e concentratio n o f 23 0 mg/ m. Th e design dutie s o f H-26 , H-46 , an d H-120 1 wer e 60.0 , 117.0 , an d 33. 0 MMBTU/HRrespectively . TH e corresponding operating rate s the da yo f the tes t wer e 74.5 , 97.6 , an d 16. 6 % o f capacity . conducte d a H- S i n Fue l Ga s Tes t t o determin e complianc e o f the lo wpressur e fue l ga s system . Th e iii . O n Novembe r 2 , 1983 , Conoc o In c t o determin e complianc e o f averag e concentratio n o f H foun d i n the tes t serie s o f 3 set s o f 2 run s eac hwa s 2 7 m g H-S/ mo f fue l gas . O n Novembe r 3 , 1983 , Conoc o Inc . conducte d a H- S i n Fue l ga s Tes t t o determin e complianc e o f the hig hpressur e fue l ga s system . Th e averag e concentratio n o f H„ S foun d i n the tes t serie s o f 3 set s o f 2 run s eac hwa s 2 9 mg H-S/ mo f fue l gas . Drawing No . LC-55-00-84-42.2T- B i s a schemati c o f the refinery' s fue l ga s system . Th e sampling point s fo r Novembe r 2 an d 3 ar e indicated . 3 . Ar e ther e an

yStat e o r loca l regulation s tha t requir e testing o f fue l ga s fo r existing sources , o r tha t requir e additiona l testing fo r ne w source s beyond tha t require d byth e NSPS ?

VIII . Yes , bu t the Stat e mus t reques t the testing an d ha s not . MONITORINGO F EMISSION S AND PROCES S OPERATION 

### 1 , Discussion : Th e presen t regulatio n require s a continuou s H_S monito r o n the fue l ga s lin e a t th e inle t t o a combustio n devic e affecte d b ythe NSPS . Com
bustio n device s having a commo n sourc e o f fue l ga s mayb e monitore d a t one locatio n instead o f eac hcombustio n devic e having a separat e monitor . Exces s emissio n report s ar e require d wheneve r the averag e H- S concentratio n fo r 3 hour s exceed s the standard . However, , continuou s H- S monitor s ar e no t ye t require d becaus e EPAha s no t promulgate d performanc e specifications . A s par t o f thi s revie wproject , EPAi s investigating alternativ e monitoring approache s whic hmayb e reliabl e indicator s o f performanc e bu t no t a s costl y a s continuou s H- S monitors . W e ar e seeking informatio n abou t th e typ e o f monitoring yo u conduc t (i f any ) an d the usefulnes s o f the monitoring re sults , costs , an

d problems . Monitorin g can b e divide d int o tw o categories : direc t emissio n monitoring o f H- S concentration ; an d indirec t emissio n monitoring b

ymonitoring o f proces s parameters . Pleas e describ e an

yStat e o r loca l regulation s tha t requir e yo u t o monitor .
Non e 

### 1 0P.1 3

3 . Emissio n monitorin g o f H- S concentratio n i n the fue l gas :
a . Ho wd o yo u monito r th e H- S concentratio n o f the fue l gas , (continuou s instruments , periodi c grabsamples) ? D o yo u monito r mor e than on e location , (immediatel yafte r treating , afte r blending , o r befor e com bustion) ? D o yo u monito r primaril yt o demonstrat e complianc e wit hth e NSPS , o r fo r you r ow

n purpose s t o ensur e tha t the amin e treate r i s operating properly ? H- S concentratio n i s monitore d b yperiodi c grabsamples . Sample s ar e take n afte r treating a t W-1 3 an d W-6 7 an

d afte r blending i n th e fue l ga s system . Ther e ar e plan s t o instal l a continuou s monito r fo r the fue l a s systemsample . Th e monitoring i s don e primaril yt o ensur e saf e operation . **
- b . I f manua l sampling i s done , describ e the procedur e an d costs . Wha t i s th e schedule d frequenc yo f sampling ? Describ e problem s tha t yo u hav e ha d wit hthi s procedur e an d the accuracyo f the measurements . Drage r tube s ar e use d t o sampl e W-1 3 an d W-6 7 onc e pe r da

yan d the fue l ga s systemonc e pe r shift . Drage r tube s ar e accurat e t o ±20% . Sampling i s don e b yrefinerypersonne l a s a par t o f th e uni t operating cost . Thi s sampling can b e a safet yproble mwhe n H- S i n fue l ga s i s high . c . I f instrumen t emissio n monitor s ar e used , provid e the follow

ing : Instrumen t monitor s ar e no t presentl yused . 4 . Monitoring o f proces s parameters :
a . Wha t proces s parameter s ar e monitored ? Ho wi s th e monitoring done(instrument s o r manua l sampling) ? Wha t i s th e schedule d sampling frequency ? Ho wmuc hdoe s i t cos t t o conduc t thi s monitoring ?

Level , Flow , Temperature , an d Pressur e ar e monitore d continuousl y b yinstruments . Amin e strengt hi s monitore d dail yb ygrabsample . Monitorin g i s don e b yrefinerypersonne l a s a par t o f the uni t operating cost . b . Whic hproces s parameter s ar e goo d indicator s o f the prope r performanc e o f th e amin e treate r an d o f lowH- S concentration s a t "th e outlet ? Ho wwell . d o the proces s parameter s correlat e wit h--H-S concen trations ? Th e amine-hydroge n sulfid e rati o i s monitore d an d controlled . 5 . Ar e ther e plan s t o replac e o r purchas e ne wmonitors , an d i f so , vh yand wit hwha t type ?

N o



### 1 16 . Ar e an yo f the instrumen t monitor s integrate d int o the proces s a s a contro l system ?

Ye s IX . GENERAL REFINER YINFORMATION(RELATE D T O AMINE TREATER S AN D FUE L GAS ) 1 . Wha t i s the nomina l siz e o f you r refineryan d curren t operating leve l (barrel s o f crude/day) ? Wha t i s the operating schedule ? Wha t refin

er yoperating parameter s affec t th e sizing an d operatio n o f you r amin e treaters ? The nomina l siz e o f the refineryi s 16 4 MBPS D o r 15 6 MBPCD .

I n 1984 , the refineryoperate d a t 11740 0 BBLS/day . Th e refinery operate s 2 4 hr/day , 7 days/week , 5 2 weeks/year . Crud e feed rat e an d sulfur conten t affec t the sizing an d operatio n o f the amin e treaters . 2 . Wha t I s the sulfu r conten t o f the crud e oi l (typica l an d range) ? Ho wdoe s the crud e oi l sulfur conten t affec t the operatio n o f amin e treater s and th e leve l o f H- S an d othe r sulfu r compound s i n the fue l gas ?

No. 2 Crud e Uni t - Swee t Crud e No. 3 Crud e Uni t - Sou r Crud e Sulfur Typica l .35 % 2.5 % Conten t

Rang e .15

- 

### 2

- 

### .7 % 3 % Thirt ypercen t o f al l sulfu r recovere d come s fromth e fue l ga s contactors . A s the crud e sulfur increases , loading i n the fue l ga s increases . 3 . Ho wd o othe r refineryoperating factor s (sucha s desulfurizatio n o f products ) affec t the sizing , operation , an d cos t o f you r amin e treating system ? Increase d desulfurizatio n demand s increase d circulatio n fro mthe amin e treaters , thu s increasing pumping costs . Mor e stea mi s neede d fo r regeneration . Ther e ar e mor e problem s I n genera l becaus e o f the stres s on th e system . 4 . Ho wmuc hnatura l ga s (i f any ) i s blende d wit hth'e , refineryfue l ga s prio r t o combustio n (typica l an d range) ? I s thi s blending don e primari

l yt o kee p a constan t flowo f ga s t o proces s unit s or t o dilut e the H 2 S concentratio n t o an acceptabl e level ?

X . Natura l ga s i s blende d wit hrefineryfue l ga s whe n necessary , t o

keep a constan t flowo f ga s t o proces s units . Natura l ga s i s sen t t o the stea

mplan t firs t an

d the n an

yadditiona l neede d i s blende d wit hthe refineryfue l gas . GENERAL REGULATORYINFORMATIO N 1 . Wha t problem s hav e yo u experience d i n interpreting the NSPS , achieving the NSPS , an d operating the contro l system s t o compl ywit hth e NSPS ? N o problem s hav e bee n identifie d i n interpreting an d achieving the NSPS . 1 2P.1 5
2 . Wha t problem s o r difficulties , i f any , have 'yo u experience d i n performing testing , monitoring , an d recordkeeping fo r the NSPS ? D o yo u hav e an ysuggestion s (pleas e provid e rationale ) fo r alleviating thes e problems , including alternativ e approache s o f achieving the same objective ?

Du e t o th e complexit yo f the refinery' s fue l ga s system , opening fue l ga s line s fo r grabsample s can presen t a safetyproblem . Ther e ar e plan s t o instal l a continuou s monito r fo r the fue l ga s systemsample . 3 . Ho wmuc hdoe s i t cos t yo u t o compl ywit hthe NSP S regulatio n fo r recordkeeping and reporting ? Pleas e provid e a cop yo f th e form s yo u rou tinel yhav e t o fil l ou t an d a sampl e o f a report . Thi s cos t i s a par t o f th e operating overhead an d i s no t recorde d separately . Form s an

d a sampl e o f a repor t ar e attached . XI . CONTACT S FO RFURTHE RINFORMATION

Ric k McCali p - Senio r Technologis t Mar k Sternber g - Proces s Enginee r Melod yYozz o - Environmenta l Technologis t (318)491-559 9 (318 ) 491-520 8 (405 ) 767-523 4



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## I AMINE UNI T CAPITAL INVESTMEN T MAJO REQUIPMENT PURCHAS E DAT E 7/5 3 7/5 3 7/8 4 12/8 0 8/8 1 8/8 1 8/8 1 8/8 1 12/8 0 8/8 1 8/8 1 8/8 1 12/8 0 12/8 0 12/8 0 8/8 1 5/8 3 5/8 3 5/8 3 5/8 3 2/8 4 5/8 3 5/8 3 5/8 3 12/8 0 8/8 1 5/8 3 6/4 1 12/8 0 9/8 3 12/8 0 9/5 6 3/8 0 12/7 3 DESCRIPTION

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TABL E II I AMIN E UNI T OPERATIN GCOST S 198 4 No . Amin e Labo r Cost s Contrac t Cost s Op . Material s Maint . Material s Proces s Supplie s Tota l 5389 7 2798 4 14 0 368 7 1343 0 $9913 7 Proces s Supplie s Nitroge n $13430/1309 6 cu . ft .

No. 2 Amin e Labo r Cost s Contrac t Cost s Op . Materia l Maint . Material s Proces s Supplie s Tot a 8801 5 2528 5 1073 7 834 5 1343 0 $24581 2 Proces s Supplie s Diethanolamin e 0 thi s yea r Nitroge n $13430/1309 6 cu . ft .

No. 3 Amin e Labo r Cost s Contrac t Cost s Op . Material s Maint . Material s Proces s Supplie s Electricity-Clearanc e Stea m Wate r Tota l 13697 0 2700 8 10218 4 2131 1 224917 3 19484/56400 0 KWH 1387883/30736 1 MMBT U 55108/2771 0 GAL . $399912 0 Proces s Supplie s NITROGE N$13430/1309 6 cu . ft . CHEMLIN K IP C 512 0 $1275/92 0 cu.ft . Activate d Carbo n $2162/180 0 lb . Cerami c Ball s $1411/207 0 lb . UCARSO L MDE A$2211154/147230 0 lb. ) TRET T 0-LIT E K43 7 $19741/255 9 GA LTABL E IV P.2 0

COMBUSTIONDEVIC E H-6 , FC C H-9 , Heating Oi l Belt(H-1 0 Spare ) H-ll , No. l Reforme r H-l2 , No. l Reforme r H-13 , No. l Reforme r H-18 , Premiu

mCoke r H-21 , No. 2 Reforme r H-22 , No. 2 Reforme r H-23 , No. 2 Reforme r H-24 , Naphtha Desulfurize r B-5 , HighPressur e Boile r B-6 , HighPressur e Boile r B-7 , Calcine r Wast e Hea t Boile r ST-4 , Flar e an

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H-14 , Therma l Cracke r H-46 , (H-4&H-5) , No. 2 Crud e Topping Uni t H-1201 , Distillat e Desulfurize r Heate r St-3 , Flar e H-3951 , No. 8 HD S BTURATING MMBTU/HR . 67. 0 55. 0 29. 0 29. 0 17. 0 96. 0

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### r Li-3101 , tl-3201 , '1-3001 , -1-3002 , 1-3801 , C D HD S Heate r 1506 8 HVG O HD S Heater1003 5 Coke r Heate r Coke r Heate r 2,3,4ABC , No. 3 Reforme r [-14 , Therma l Cracke r [-46 , (H-4&H-5) , No. 2 Crud e 1-1201 , Toppin g Uni t Distillat e Desulfurize r Heate r IT-3 , Flar e s 1-3951 , No. 8 HD S 8721 4 7869 6 14318 3 

### 0 10485 7 1769 3 1800 0

1483 9 9433 5 8962 4 16312 7 

### 0 12016 0 2373 1 3284 2

1735 2 8447 2 7586 5 13712 2 

### 0 10650 5 2223 0 3584 0

1514 3 6763 4 6218 0 8685 9 

### 0 6864 2 1814 7 4226 5

1732 7 9643 7 9146 0 12854 5 

### 0 11713 1 2458 2 4085 3

2400 4 8187 5 7697 2 12918 9 

### 0 99553 . 2278 3 2759 7

1287 9 4585 0 4206 9 5057 8 47206 8 7361 0 1308 3 1710 4

984 8 2759 6 2642 3 5349 4 68118 8 4751 6 1055 2 1679 4

1212 8 5037 2 5115 0

'•:•'. '8033 1 34778 9 9343 7 1262 6 Surg e Dru m 213 6 575 0 3344 5 2715 4 5890 8 48202 7 6065 1 1145 4 / 

### 52 2

343 4 2291 0 2420 0 5318 4 2063 2 57927 8 711 7 

### 8 5

119 6 1324 8 1266 5 7160 6 

### 0 34243 8 1135 9 PILO T 24910 6

14393 5 70538 8 65845 8 115612 6 200370 4 181377 8 19535 7 100SCF HP.2 3

Combustio n Devic e H-6 , FC C H-10 , Heatin g Oi l Bel t (Spare ) H-ll , No. l Reforme r H-l2 , No. l Reforme r H-13 , No. l Rforme r H-18 , Premiu

mCoke r H-21 , No. 2 Reforme r H-22 , No. 2 Reforme r H-23 , No. 2 Reforme r H-24 , Naphth a Desulfurize r ST-4 , Flar e an

d Blowdow

n H-1101 , Crud e Uni t Heate r H-1102 , Vacuu

mUni t Heate r H r 1301 , Ga s Oi l Desulfurize r Heate r H-26 , Coke r Heate r H-2801 , ST-2801 , Sulfuri c Aci d

Ai r Heate r an

d Stac k H-3101 , CD HD S Heate r H-3201 , HVGO.HD S Heate r H-3001 , Coke r Heate r H-3002 , Coke r Heate r H-3801,2,3,4ABC , No. 3 Reforme r H-14 , Therma l Cracke r H-46 , No. 2 Crud e Topping Uni t H-1201 , Distillat e Desulfurize r Heate r ST-3 , Flar e H-3951 , No. 8 HD S TABL E V I
Installatio n Dat e 195 3 195 3 195 3 195 3 195 3 195 7 195 9 195 9 195 9 197 1 198 1 198 0 198 0 198 0 198 2 198 0 198 3 198 3 198 3 198 3 198 3 198 2 198 3 : 198 3

198 1 198 5 Tota l Capita l Investe d

(throug hDecembe r 31 , 1984 ) 189750.1 4 185798.3 8 69913.0 0 89876.2 3 104608.9 2 505329.8 1 139459.8 6 105011.0 0 58240.0 0 159579.5 9 845178.2 4 6990096.0 7 1476970.2 8 1341280.4 9 3058971.4 7 830841.0 1 750519.9 3 480621.5 4 5072213.4 8 5072213.4 8 5658043.1 4 1884135.7 4 674689.3 4 696497.4 8P.2 4

TABL E VI I

Uni t No. 2 Crud e Topping therma l Cracking No. l Flui d Catalyti c Cracking No. l Coke r Ga s Oi l Heating Bel t No. l Calcine r & Cok e Loading No. l HD S Naphtha No. 2 HD S Naphtha No. 2 Reforme r No. 3 Crud e Topping No. 4 HD S Distillat e No. 5 HDS-Ga s Oi l No. 3 Vaccu

mUni t Stea mPlan t No. 3 HD S Naphtha No. 3 Ca t Reforme r No. 6 HD S Cracke d Distillat e No. 2 Coke r No. 7 HDS-Hv

yVacuu mGa s Oi l 198 4 Operating Cos t Combustio n Device s X1 0 $ i n Uni t 9.8 7 

### 9. 6 5. 7 9. 2 1. 4 2.2

- 1.4 1 

### .9 0 3.5 5 9.9 5 2.0 3 1.5 6 2.7 7 44.8 2 2.1 6 , 1.8 4 J 2.8 5 9.2 6 

### 1. 7 H

H


### H -4 6 (H- 4 & H-S ) H-1 4 

### H- 6 H-18 , H-2 6 H-9 , H-1 0 

### B- 7 H-2 4 -21 , H-22 , H-2 3 H-110 1 H-120 1 H-130 1 H-110 2 B-5 , B- 6 -3801 , 2,3, 4 A

B H-310 1 H-3001 , H-300 2 H-320 1Typ e Internals * Ca s Contactor s W-1 3 W-6 7 W-120 2 W-370 1 W-370 2 P- B Contactors(lO ) W-1 4 W-6 3 W-330 4 VT

VT VT VT VT

P S T P Maximu

m Amin e Rat e GPM(l ) 39 0 15 0 26 0 

# 0 12 0
GP M 7 0

' 30 0 Minimu

m Amin e Rat e GPM(2 ) 2 0 3 0 2 0 2 0 2 0


### GP M TABL E VII I

Amin e Contactor s Lak e Charle s Re Maximu m Proces s Flui d Lb/Hr(4 ) 163,00 0 38,00 0 56,00 0 75,00 0 27,00 0
GP M 250(11 ) 300(12 ) 25 0 finery

Minimu m Proces s Flui d Lb/Hr(5 ) 20,00 0 9,00 0 13,00 0 19,00 0 3,50 0
GP M 30(13 ) 5 0 3 0 Normal(7 )

Amin e Rat e Require d


### GP M 26 5 3 0 18 0 15 0 2 0
GP M 1 0 1 0 4 5 Normal(8 )

Proces s Rat e Lb/Hr 92,98 6 31,49 0 40,37 2 35,77 9 10,25 8
GP M 3 5 22 3 20 0 RichAmine (9 )

Loadin g
Mo l H.S/Mo l MDE A

i i 0.5 6 0.1 6 0.6 0 0.4 4 0.2 4

0.4 5 0.4 5 0.4 5

* V T = Valv e Trays , S T = SieveTrays , P = Packin g (No . 2 HY-PAK )P.2 6



## wW


## wwwwwwww - •63 -67 •13 -14 -330 4 -120 2 -370 1 -370 2 -350 1 -355 1 Inle t

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### 11 0 11 5 11 5

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### 11 0 11 0 11 0 11 0 Colum

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### 29 0 19 5 19 5 12 5 30 0 50 0 75 0 29 5 TABL E 

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X

C . C . C . C . Parson s Parson s Vendo r

Wyat t Wyat t
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, Delt a Southern

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Installatio n Dat e 195 6 194 1 Modifie d 198 0 198 3 198 3 198 3 198 3 198 3 198 3 198 3P.2 7



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_24.2 3 0.1 1 26.8 4 38.5 4 0.0 3 11.7 0 C O 2.5 1 CO S 0.0 1 H O 64.8 6 61.4 0 2.1 7 S0

_6.9 5 N/ 653.9 7 0.04 5 0.3 1 S, 0.0 4 SZ 0.0 9 C , 10.92 5 12.2 3 

### c i 

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732.5 8 21.8 0 38.5 4 0.0 2 0.0 1 61.4 0PROCES S FLOWDIAGRAM S

Drawing No . LC-55-00-84-42.2T- B
SD-2720-42-98- L LC-91-00-82.42.1A- D LC-91-00-82-42.2A- D LC-23-00-84-42.1A- D LC-91-00-84-42.1E- D LC-92-06-84-42.1C- B LC-83-00-84.42.1A- D
SRE-029-8205-PI-04- L LC-53-00-84-42.1B- D LC-57-00-84-42.1A- D LC-39-00-84-42.1A- D LC-52-00-84-42.1A- D LC-58-00-84-42.1A- D LC-37-00-81-42.1B- D LC-56-00-84-42.1A- D LC-03-00-83-42.1C- D LC-25-00-84.42.1A- D LC-14-00-84-42.1A- D SD-2720-42-45- L SD-2720-42-188- L LC-79-00-84-42.1A- D LC-81-00-84-42.1A- D LC-82-00-84-42.1A- D Proces s Flo wDiagram s Descriptio n Schemati c FlowDiagram Fue l Ga s System Amin e System Sulfu r RecoveryUni t (Sht . lof2 ) Sulfur RecoveryUni t (Sht . 2of2 ) Sulfuri c Aci d Plan t MDE ATai l Ga s Uni t Sulfur Pits , Sulfu r Degassing Fue l Ga s Cryogeni c Plan t (Pending ) FC C Heating Oi l Bel t t . No. l HD S Premiu mCoke r No. 2 Reforme r Naphtha HD S 60 0 PSI GStea

mSystem Calcine r No. 3 CT U No. 3 Vacuu

mUni t No. 5 Ga s Oi l HD S No. 6 HD S Uni t No. 7 HD S Uni t Regula r Coke r No. 3 NHD S Uni t No. 3 Reforme r Equipmen t Include d

Trai n No . 1

H- 6 H-9 , H-1 0 H-ll , H-12 , H-1 3 H-18 , H-2 6 H-21 , H-22 , H-2 3 H-2 4

-- ' B-5 , B- 6 B- 7 H-110 1 H-110 2 H-130 1 H-310 1 H-320 1 H-3001 , H-300 2 H-3801 , H-380 2 H-3803 , H-3804 , A,B, CC-15-00-84-42.1A- DTherma l Crackin gUni t H-1 4 LC-02-00-79-42.1B- C No. 2 Crude Toppin gUni t H-4& 5 (H-46 ) LC-10-00-84-42.1A- DDistillat e HD S Uni t H-120 1 LC-84-00-84-42.1A- DNo. 8 Ga s Oi l HD S H-395 1 LC-55-00-81-42.1F- A Fue l Syste

m NSPS'fes t " H^l101 , B=fib2 , H-1201 , H-130 1 LC-55-00-83-42.1B- A Fue l Syste

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### Vfc^e - yT"l ! / ^ ^ Nort h Amorico n Refinin g Conoc o Inc . P.O . Bo x37 Westlake . L

A70S69 (318 ) 431-521 1 Octobe r 15 , 198 4 

### CEgnrn p MI L- RETUR NRECEIP

TREQUESTE

D ( #P24 3 17 7 324 ) Mr . Gu s Va n Bodunge n Louisian a Departmen t o f Environmenta l Qualit y P . 0 . Bo x4406 6 Bato n Rouge , I A7080 4 Dea r Mr . Va n Bodungen : . ' Attache d i s th e thir d quarterl yrepor t fo r -Conoco° s Lak e Charle s Refinery , a s require d bytt e Ne wSourc e Performanc e Standard s (NSPS ) [4 0 CF R60.7(c)] . Th e perio d covere d i s fo r Jul ythroug hSeptember , 1984 . di s repor t include s th e performanc e o f th e tw o Sulfu r RecoveryUnit s (SRUs ) [required by4 0 CF R 60.104(a).2.i] , an d th e performanc e o f th e fue l ga s system[required by4 0 CF R60.104(a).1] . Acontinuou s nonito r record s th e sulfu r -dioxid e (SO J concentratio n i n th e tai l ga s frc meac ho f th e refinery' s SRUs . Th e standar d require s tha t th e hourl yaverag e concentratio n no t excee d 0.025 % (25 0 ppn ) SO

_o n a dr ybasi s correcte d t o zer o oxyge n fo r twelv e consecutiv e hours . Hie monitor s installe d a t th e plan t recor d th e actua l part s pe r millio n S0 2 concentratio n i n th e tota l stream , including moistur e an d oxygen . Di e permitte d leve l o f 25 0 pp mSO

_wa s adjuste d t o a comparabl e basi s o f 21 0 ppra , assumin g concentration s o f 10 % moistur e an d 5 % oxygen . ih e correcte d 21 0 ppr . specificatio n wa s the n compare d t o actua l readings . Table s I an d I I sho wth e instance s whe n th e tai l ga s SO

_level s exceede d th e correcte d allowabl e 21 0 pp mreadin g fo r twelv e consecutiv e hour s i n th e No . 1 an d No . 2 SRUs , respectively . Th e followin g ar e majo r reason s fo r no n compliance : (1 ) Tai l ga s uni t problem s du e t o corrosio n caus e mos t o f th e exceedances . Ih e corrosio n cause s exchange r leaks , pluggin g o f th e amin e contacto r towe r an d foaming . Ihes e problem s preven t adequat e amin e contac t wit h th e gas , and i n some instance s caus e uni t shutdown . Th e refiner yi s doin g everythin g possibl e t o pinpoin t „th e cause s o f corrosio n an d eliminat e them . Corrosio n inhibito r wil l als o b e injecte d i n th e future . (2 ) Amin e solutio n i n th e tai l ga s unit s ha s degrade d t o hea t stabl e salt s du e t o S0 2 breakthroughfromth e Beavo n Sulfu r Recoverysectio n o f th e sulfu r train . A s a preventativ e Treasure , th e tailga s uni t i s bypasse d durin g majo r upset s s o tha t SO

_doesn' t contac t th e amin e solutio n fo r furthe r degradation .P.4 2

Mr . Gu s Vo n Bodunge n Pag e 2 Octobe r 15 , 198 4

(3 ) Fee d fluctuation s an d upset s cause d byupstreamhydrocarbo n processin g unit s ar e problem s whic hth e sulfu r plan t mus t liv e with . Thi s quarte r wa s particularl ydifficul t a s th e hydroge n compresso r i n th e sou r crud e are a ha d vibratio n problem s an d shutdowns . Consequently , swing s i n th e primar yamin e hydroge n contactor s wer e fel t al l th e wa ythroug hth e Sulfu r Plant . The refineryi s installing a projec t t o continuousl yad d hydroge n t o hel p hydrogenat e th e tai l ga s S0 2 t o H_S . Thi s prevent s S0
_ breakthroug ht o th e amin e uni t and permit s th e H 2 S t o b e recovere d an a recycle d fo r optimum uni t performance . (4 ) Th e combustio n ai r t o th e B Xi s o n rati o contro l fro n a n H 2 S/S0 2 analyze r o n th e Clau s tai l gas . Conversio n t o sulfu r i s ver ysensitiv e t o th e prope r H-S/SO

- ratio . Fee d compositio n change s o r drift s i n analyze r ca l ibratio n sometime s resul t i n rati o contro l problems . Th e analyze r i s calibrate d dail yt o minimiz e thi s problem . Tabl e II I show s period s o f tim e whe n th e concentratio n o f hydroge n sulfid e (H 2 S ) i n fue l ga s t o ne wheater s exceede d th e standar d 0. 1 g r pe r dr y standar d cubi c foo t fo r thre e consecutiv e hours . Whil e ther e i s n o continuou s monitorin g i n th e fue l ga s system , operator s tes t fo r H_ S dail y usin g sanpling tubes . I f yo u hav e anyquestions , pleas e cal l Mr . Ric k McCali p a t (318 ) 491-5599 . 

### Sincerely ,
P
. W
. Hashbroc^ e Manage r lak e Charle s Refinery VRD/sww att : cc/att : Mr . Jo e Wither s

Departmen t o f Environmenta l Qualit y Ai r Qualit yDivisio n P . O . Bo x304 7 Lak e Charles , I A7060 2 Mr . Bo bClar k EP ARegio n V I 120 1 El mStree t Dallas , Texa s 7527 0 bcc : pWL/PFMJW

L O MHG GRLMME S VR D File : 091.1 4SO
- Exceedance s TABL E I NO . 1 SULFURRECOVERYUNI T THIR D QUARTE R198 4 P.4 3

Star t Dat e Tim e Bi d Duratio n Averag e SO .

Dat e 'Tim

e Hour s •

» PP M Caus e 

### 7- 7 7- 8
7-1 7 7-2 9

8-1 1 8-1 8 8-2 2 8-3 0


### 9- 5 9- 6 9- 9 9-1 2 9-1 6 9-1 7 9-1 8 9-2 2 9-2 6 7:0 0 19:0 0
5:0 0 4:0 0

5:0 0 16:0 0 13:0 0 8:0 0

1:0 0 16:0 0 22:0 0 10:0 0 18:0 0 12:0 0 9:0 0 12:0 0 10:0 0 

### 7- 8

7-1 1
7-1 7 7-2 9

8-1 8 8-2 1 8-2 3 

### 9-4

'9- 6 

### 9- 9 9-1 1 9-1 5 9-1 7 9-1 8 9-1 9 9-2 3 9-2 7 17:0 0 16:0 0
18:0 0 23:0 0

14:0 0 4:0 0 20:0 0 22:0 0

5:0 0 3:0 0 13:0 0

. 9:0 0 6:0 0 24:0 0 17:0 0 8:0 0 5:0 0 

### 3 4

6 4 1 3 1 9


### 17 7 5 7 3 1 

### 11 0

2 8 5 9 3 9 7 1 1 2 1 2 3 1 1 9 1 9
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### 44 7

69 9
1000 + 1000 +


### 40 5 23 8 23 0 65 6
28 4 47 2 45 0 1000 + 

### 26 0 23 0 25 0 61 5 49 0 Bypas s t o was htailga s uni t

Bypas s t o repai r leaking exchanger s Washin g unit/bypas s Bypasse d t o tighte n hea d o n exchanger s Washin g uni t Washin g uni t Rati o contro l problem s Circulatio n problem s du e t o pluggin g Foamin g i n tai l ga s contacto r Ai r denend analyze r ba d orde r Washin g exchanger s Bypasse d fo r washin g Foamin g i n contacto r Foamin g i n contacto r Foamin g i n contacto r

i Powe r f-feilur

e Tai l ga s upset sP.4 4

. TABI E I I NO . 2 SUIFUR RECOVERYUNI T THIR D QUARTE R198 4
SO ? ExQepd-anoe s
1 Star t Bi d Duratio n Averag e S0 2 Dat e Tim e Dat e Tim e Hour s PP MCaus e 6-3 0 1:0 0 7- 2 16:0 0 6 3 92 4 Starting uni t u p
7- 2 18:0 0 7- 3 10:0 0 1 6 58 0 Starting uni t u p 7- 3 18:0 0 7-1 0 19:0 0 16 9 1000 + Bypas s MDE At o repai r leakin g exchange r 7-1 9 20:0 0 7-2 0 8:0 0 1 2 52 6 Ai r demand analyze r calibratio n of f
8-1 5 5:0 0 8-1 6 22:0 0 4 1 39 6 Leaking discharg e valv e o n ai r j blowe r j i 8-3 0 3:0 0 9- 6 2:0 0 19 1 84 8 Circulatio n problem s i n tai l I gi s du e t o pluggin g ! 

# j 9-1 0 24:0 0 9-1 2 12:0 0 3 6 50 9 Fee d surge s 9-1 3 17:0 0 9-1 4 5:0 0 1 2 25 0 Foamin g i n tai l ga s contacto r 9-2 6 15:0 0 9-2 7 5:0 0 1 4 80 0 Tai l ga s upset s<*t



### TABL E II I FUE L GA S SYSTE M P.4 5



### Star t Dat e Time 7- 9 9:0 0 7-1 0 '13:0 0 7-1 8 14:0 0 7-2 0 21:0 0

Eh d Duration Averag e H_ S Dat e Time Hour s PP M

2 8 5 6 22 0

35 0 Caus e

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